Czech packaging specialist Unipack has upgraded its polyester strapping production line by replacing the previously used extruder with a Gneuss OMNI extrusion system. The new setup has been operating successfully since the beginning of 2026. According to information provided by the companies, the implementation resulted in increased production output, a clearly more stable process, and noticeable energy savings. Unipack manufactures polypropylene and polyester strapping on several production lines and has systematically expanded its production capacity in recent years. The upgrade involved replacing the older extruder with a complete Gneuss system comprising a 4-component dosing unit, an MRS 90 extruder, a 25 mbar vacuum unit, an RSFgenius melt filtration system, a VIS online viscometer, a melt pump, and a strapping die head.
According to project manager Dušan Rejthar, the new solution made it possible to eliminate costly raw material preparation in the form of drying and crystallization, which previously required a material residence time of 5 to 6 hours. In addition, the plant can monitor material viscosity continuously and, thanks to effective filtration, run production in a stable manner without unnecessary interruptions. Rejthar also indicates that output increased, while the scrap rate fell from 7% to 3%. As feedstock, Unipack mainly processes colored PET bottle flakes, including green, red, and brown material that is typically no longer suitable for bottle-to-bottle recycling. The system used makes it possible to use up to 100% recycled feedstock. The company points not only to higher throughput but also to consistent quality of the strapping produced. As reported, this quality has already received positive feedback from end users, and the mechanical properties, especially elongation and tensile strength parameters, have improved significantly.
Effects of the line upgrade
Dušan Rejthar assessed the implementation as follows: “Thanks to the new Gneuss technology, we do not need costly material preparation, namely drying and crystallization, with a residence time of 5 to 6 hours. We can monitor material viscosity online and, most importantly, thanks to very good filtration, we run stable production without unnecessary interruptions.” He also added: “Our output has increased, and the amount of scrap has fallen from 7% to 3%.”
The Unipack representative also emphasized the operating performance of the system and the cooperation during commissioning: “We are very satisfied with the system’s performance. Cooperation with the Gneuss service team during installation and commissioning was also excellent.”
Gneuss OMNI recycling system integrated into Unipack’s strapping tape production line
