MAS has expanded its iQ Series portfolio with the introduction of the iQonicTwin HyperPET, a platform for PET recycling that targets food-contact applications and aims to broaden raw material flexibility. The solution combines a pre-extrusion solid-state polycondensation (SSP) system with the company’s co-rotating conical twin-screw extruder in order to stabilise intrinsic viscosity, maintain colour and minimise acetaldehyde formation at lowered specific energy consumption. By eliminating the need for nitrogen in the SSP step and relying solely on electricity, the system is positioned as a compact and comparatively simple option for food-grade PET recyclate production, including applications that go beyond conventional bottle-to-bottle loops.
Integrated SSP concept and process configuration
In the HyperPET configuration, the polycondensation stage is located upstream of the extrusion step. Recycled PET flakes are first pre-heated and dried in a crystalliser. Following this, they enter the Moby reactor, where infrared radiation is applied under vacuum conditions. This combination of heat input and reduced pressure lowers residual moisture content and adjusts the intrinsic viscosity of the material to the target level for bottle-grade applications.
The pre-heated, crystallised material retains stored thermal energy when it reaches the MAS co-rotating conical twin-screw extruder. According to the concept, this reduces the specific energy demand of the extrusion stage and can support increased throughput. The short residence time in the SSP reactor is highlighted as a central design feature, intended to minimise thermal stress on the material while still achieving the required IV increase and stabilisation of the flakes.
The SSP process used in iQonicTwin HyperPET operates without nitrogen purging. No operating resources other than electricity are required, which simplifies the process layout compared with nitrogen-based SSP systems. In addition, the overall arrangement is described as having a compact footprint and simplified operation, aimed at enabling integration in both pilot and industrial-scale PET recycling lines.
Key technical advantages
The main technical advantages of the iQonicTwin HyperPET platform as presented include:
- extremely short dwell time in the SSP reactor
- stabilisation of intrinsic viscosity in rPET flakes to bottle-grade levels
- nitrogen-free operation, with electricity as the only operating resource
- simplified process setup and compact installation footprint
- energy-efficient process due to pre-heating and reduced extrusion energy demand
Together, these elements are intended to support consistent pellet properties in terms of IV, colour and acetaldehyde content, which are critical parameters for food-contact PET applications.
Feedstock flexibility beyond bottle-to-bottle
Traditional food-grade PET recycling has largely focused on bottle-to-bottle systems, limiting the usable feedstock mainly to post-consumer PET bottles. The HyperPET configuration is presented as a means to extend this scope towards future tray-to-bottle recycling. In this approach, both bottle regrind and PET tray regrind can be processed, either as single streams or in blends, thereby expanding the available raw material pool.
By including PET trays as a potential feedstock, the system is designed to reduce the dependence on post-consumer bottles and address market situations where bottle collection volumes or quality are constrained. This feedstock flexibility is also linked with the objective of improving return on investment through broader sourcing options.
Operational and economic aspects
The iQonicTwin HyperPET solution is aimed at producing stable, high-quality rPET pellets that comply with demanding food-contact regulations. The key operational and economic aspects highlighted for the system include:
- production of pellets with consistent intrinsic viscosity, colour and low acetaldehyde content
- compliance with strict food-contact legislation for PET packaging
- lower operating expenditure (OPEX) due to energy savings and a simplified process
- enhanced sourcing flexibility for rPET feedstock, supporting improved ROI
These features are intended to support users targeting both established bottle applications and emerging recycled PET packaging segments.
Capacities and portfolio context
The iQonicTwin HyperPET platform is available in three capacity ranges, which allows installation as part of pilot lines as well as full-scale industrial recycling plants. Specific throughput figures are not disclosed, but the modularity of the concept is positioned as a way to support different plant sizes and project stages, from development through to commercial operation.
Within MAS’s broader offering, iQonicTwin HyperPET forms part of a newly structured portfolio that also includes an rPET SSP solution and an rPET Regran solution. These systems together address multiple steps in the PET recycling and regranulation chain, from IV build-up and stabilisation to the production of regranulate targeted at various end-use requirements.
Collaboration with PET specialist Christian Schiavolin
For the development and integration of the HyperPET concept, MAS is collaborating with PET recycling specialist Christian Schiavolin. His established SSP solution is being integrated into the MAS iQ Series as part of the iQonicTwin HyperPET platform. Through this cooperation, Mas aims to strengthen its position as a provider of comprehensive solutions for plastics recycling and upcycling, with a particular focus on PET-based packaging streams.
Market introduction at K Show 2025
The official launch of the iQonicTwin HyperPET solution was planned for K Show 2025 in Düsseldorf. The system was presented from 8 to 15 October in Hall 9 at Booth D30. During the event, visitors had the opportunity to receive live consultations from the Mas team and PET recycling specialist Christian Schiavolin on the technical aspects of the HyperPET configuration, application fields, and potential integration into existing or new recycling plants.
