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Starlinger
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  • Offer Profile
  • Starlinger leads the world market in production machinery for sacks, packaging fabrics, and technical textiles woven from plastic tapes. The company has been in this business for 45 years and also looks back at more than 25 years’ development and production experience in recycling machinery for plastics.

    European competence - solution oriented

    Since the early 1970’s Starlinger is supplying high-quality machines for woven plastic packaging production, i. e. coated or uncoated standard woven sacks, leno sacks, valve sacks, FIBC’s (Big Bags), or AD*STAR® block bottom valve sacks. Sacks produced on Starlinger machines are in use worldwide for safe and low-cost packaging of various bulk goods, e.g. cement, chemicals, seeds, grain, flour, sugar, citrus fruits, fertilizer, animal feed, and similar products.

Product Portfolio
  • Packaging

  • Starlinger textile packaging

    Many tasks, one solution: woven fabric.

    Today the range of applications for woven plastic fabric is almost unlimited, and new uses for this outstanding material pop up at a tremendous pace.
    One of the driving forces behind this triumphal procession of woven fabric is without a doubt Starlinger.

    Starlinger leads the world market in the field of machinery and process technology for woven plastic sack production. This means:
     
    • the widest range of woven sack plant machinery
    • machinery for the most comprehensive scope of processes in connection with woven sack production
    • worldwide presence
    • 45 years of global market experience
    • the largest number of customers
    • the biggest range of possible end products
      • Printing Technology

      • Simple “potato stamping”, once seen everywhere on sacks, no longer makes the grade. Even in the bulk trade, where looks never seemed to matter much, multicolored logos and artful writing have become the norm – whether for marketing reasons or simply in order to differentiate the product from other brands.

        Starlinger’s research departments invest day-to-day effort in order to perfect both printing technology and its visual result.
          • Printing machine - dynaFLEX DX

          • This roll-to-roll printing machine for coated and uncoated fabric combines outstanding print quality in 4 or 6 colours with a maximum of product flexibility. The same printing cylinders are used for varying bag lengths, which makes the dynaFLEX ideal for small to medium lots. Easy touch screen operation, chambered doctor blade system for sharp printing with minimum ink consumption.

            Advantages
            • One fixed printing cylinder per color deck: no storage, no maintenance - and no purchase costs for additional printing cylinders
            • 180 meters per minute production capacity
            • Infinitely variable repeat length
            • Dynamic and flexible printing concept
            • Worldwide proven direct drive technology
            • High efficiency and minimum waste due to semi-automatic roll change
            • Color-saving doctor blade system
            • Perfect process printing (coated fabric)

            Technical Data

            Printing variants 6C: 1:5 / 2:4 / 3:3 / 6:0
            Printing variants 8C:
            2:6 / 3:5 / 4:4
            Printing variants 9C: 
            3:6
            Production capacity: 
            180 m/min
            Fabric width (max.):
            850 mm
            Printing width (max.): 
            840 mm
            Printing length (max.): 
            850 mm
            Repeat length: 
            450 - 1500 mm
            Repeat length (AD*STAR): 
            550 - 1200 mm
            Plate and tape thickness:  
            min. 2.29 + 0.5 mm
                                                              max. 6.02 + 0.1 mm
            Side register: 
            +/- 10 mm
          • Printing machine - rollFLEX PX

          • The rollFLEX PX is a roll-to-roll printing machine for coated and uncoated tubular PP tape fabric. It combines highest levels of productivity - production speed of up to 250 meters per minute - and quality with easy handling and low maintenance.

            Advantages
            • 6 colour stack-type printing on both sides
            • Production speed of 250 meters per minute
            • Maintenance-free direct drive technology
            • Fully automatic roll change
            • Standard automatic roll change
            • Gearless drive system
            • Roll diameter of 1.5 meters
            • Process printing
            • Lifting support for change of printing cylinders
            • Operator-friendly


            Technical Data

            Printing variants 6C: 1:5 / 2:4 / 3:3 / 6:0
            Production capacity: 
            250 m/min
            Fabric width (max.):
            850 mm
            Printing width (max.):
            840 mm
            Repeat length: 
            450 - 1450 mm
            Plate and tape thickness: 
            min. 2.29 + 0.5 mm
                                                             max. 6.02 + 0.1 mm
            Side register: 
            +/- 6 mm
        • Conversion Lines

        • At the end of the production process, the tubular fabric becomes a sack. And it is the conversion line that gives the sack its final, individual form, cutting it to length, sewing it, and adding the desired closure type – or forming a brick-shaped AD*STAR® sack in a special adhesive-free heat welding process.
            • Conversion line - multiKON 55

            • The new generation multiKON for bottom-sewn sacks is a multi-talent, suitable for leno fabric, for coated or uncoated standard fabric, also for tubed or OPP laminated fabric. A variety of closure options are available to match the wide variety of applications for this type of sack.

              Also in sack conversion, Starlinger has paid special attention to material-saving techniques, because even optimized folding can save significant quantities of fabric. A few millimetres of fabric saved, sack for sack, add up in mass production to a real financial advantage for the customer.

              Advantages
              • Operating speed 55 sacks per minute
              • Minimized bottom folding for fabric saving
              • Precise cutting length for fabric saving
              • Easy-open feature for consumer applications
              • Production of transparent sacks
              • Fast top feed sewing machine
              • Modular design
              • Operator-friendly

              Technical Data

              Roll diameter for trolley (max.): 1500 mm
              Coated/uncoated cloth width (max.): 
              250 - 850 mm
              Sack length: 
              450 - 1350 mm
              Production data for sacks 500 x 1000 mm:
              Uncoated fabric: 
              up to 55 bags/min
              Coated fabric: 
              up to 55 bags/min
              Option: easy-open (for coated fabric): 
              up to 40 bags/min
              Option: handle inserter standard bags:
              up to 40 bags/min
              Option: handle inserter easy-open bags: 
              up to 40 bags/min
            • Conversion line - multiKON KX

            • The multiKON KX is a high-performance conversion line that operates with the innovative IC*STAR® technology. It cuts and seals coated, uncoated, OPP-laminated, printed and unprinted endless tubular PP fabric in a continuous, fabric-saving process, producing high-quality IC*STAR® sacks that feature low fabric weight and high closure strength.

              The conversion line is equipped with the sealTEC bottom closure module, jointly developed by Starlinger and STATEC BINDER. Instead of a sewing unit, the IC*STAR concept features a welding device which, in a continuous process, welds a coated sealing band onto the sack bottom by means of hot air - no glue is required. The mouth of the sack remains open and can be closed, after filling on the filling line, either by welding with another sealing band or by sewing.

              The sealTEC module requires less maintenance than a sewing machine and needs considerably fewer replacements of spares and wearing parts. Both coated and uncoated IC*STAR sacks can be produced by this new method in an efficient and material-saving process.

              Advantages
              • Hot air sealing unit sealTEC
              • Very high closure strength
              • Operating speed up to 45 sacks per minute*
              • Fabric weight reduction
              • Minimized bottom folding for fabric saving
              • Precise cutting length for fabric saving
              • Production of transparent sacks
              • Modular design
              • Operator-friendly

              Technical Data

              Roll diameter for trolley (max.): 1500 mm
              Coated/uncoated cloth width (max.): 
              250 - 850 mm
              Sack length:
              450 - 1450 mm
              Production data for sacks 500 x 1000 mm:
              IC*STAR® sacks, coated/uncoated fabric          
              up to 45 bags/min
            • Conversion line - ad*starKON SX, SX+

            • In a league of its own: High-speed valve bottomer ad*starKON SX+
              Combining outstanding production speed, high-precision bottom closure and superfast format change, the latest model in the Starlinger AD*STAR conversion line series gives converters a technological head-start in poly-woven block bottom sack production.

              Advantages
              • Worldwide patented hot air sealing technology
              • Production of standard, 2-ply, open mouth, pocket valve and BOPP laminated AD*STAR® bags
              • High precision bottom geometry through fabric width monitoring system
              • Tempering/preheating of the patch and valve material
              • Super-fast format change
              • Adjustment of valve and cover patches during production
              • Self-documenting graphical user interface
              • Sensors at strategic process points
              • Fabric roll monitoring system
              • Easy changeover to microSTAR perforation
              • Compact design
              • Extended bag format range

              Technical Data - ad*starKON SX

              Machine speed (max.): 85 sacks/min
              Sack width: 
              35 (30) - 60 cm
              Sack length:
              45 (43) - 91 cm
              Bottom width:
              8 - 18 cm          
              85 sacks/min
            • Shopping-Bag Conversion line - cb*starKON

            • cb*starKON is the world’s first conversion line for the automatic production of carrier bags made of woven polypropylene. The cb*starKON processes flat fabric into carrier bags with side gussets and a block bottom. Tubing and bag-making are effected in-line on a single machine. A modern glue application system glues the backseam and the bottom with hot melt.

              The modular construction allows quick and flexible modifications according to customers’ requirements. Bag dimensions can be varied semi-automatically; punched handles and, as an option, flat handles can be fitted automatically. The small working height of the cb*starKON allows continuous production monitoring and intervention.

              cb*starKON achieves an output up to a max. 90 bags per minute. Thanks to a high degree of automation the cb*starKON makes industrial production of these bags a profitable enterprise.

              Advantages
              • Automatic production of woven shopping bags
              • Fast and easy bag size changeover
              • Automatic and manual fitting of handles
              • Modular design

              Technical Data

              Machine speed (max.): 70 - 90 bags/min
              Bag width:
              300 - 480 mm
              Bag length: 
              400 - 650 mm
              Gusset width: 
              90 - 160 mm
              Flat fabric width: 
              816 - 1315 mm
              Handle types autom. fitted:
              punched handle, flat handle
            • Pinch-Bottom-Bag Conversion line - pp*starKON

            • The PP*STAR® concept, featuring side gussets and pinch bottom, is produced on the pp*starKON, the world’s first pinch bottom bag conversion line for woven PP.
              The pp*starKON processes flat fabric into open-mouth pinch bottom bags with side gussets and a stepped cut. The pinch bottom is closed inline with a special glue, while on the pinch top reactive glue is pre-applied. This allows fast and clean sealing during the filling process. The heat-sealing guarantees good closure against external agents.
              The PP*STAR® can be supplied with different opening features. The PP*STAR® bag length ranges from 500 – 1070 mm and the bag width is anywhere between 250 and 480 mm.

              Advantages

              Laser cutting: flexibility on all levels

              • works with many different material types and thicknesses
              • settings can be adjusted during production; many different cutting shapes possible
              • no downtime/costs for tool change, maintenance-free, no set-up time – just choose the desired recipe on the machine control
              • Reliable operation

              Glue: strong and reliable
              • increased strength
              • attractive appearance because of full utilization of the printed area
              • increased flexibility, especially regarding possible fabric types and weights
              • reduced material thickness, higher productivity

              Easy-Open: be different!
              • Shape/position freely customizable
              • Production of Easy-Open strip at full machine speed
              • Low cost: Easy-Open is the most cost-effective one-time opening solution for this type of packaging.


              Technical Data

              Machine speed (max.): 120 bags/min
              Bag face width: 
              250 - 480 mm (10 - 19")
              Repeat length: 
              500 - 1070 mm (20 - 42")
              Gusset width:
              50 - 200 mm (2 - 8")
              Flat fabric width:
              600 - 1400 mm (24 - 55")
          • Finishing Touches

          • Versatility and flexibility in the production equipment are the growing-ground for new product ideas. A comprehensive equipment range needs to include good concepts for quality control and for optional production steps that can pave the way to new products and markets. At Starlinger, experience meets the current of change in a spectrum of effective solutions.
              • Tubing line - tubeTEC TX

              • Tubing is the simple but effective process of forming a tube from flat fabric. Among other advantages, this procedure makes overall printing of the sack possible.

                The tubeTEC TX was designed to tube coated or laminated flat fabric made out of PP with or without inliner at highest standard for consumer bag applications.

                Advantages
                • Operating speed of 150 m per minute
                • Single or double layer (inliner) tubing
                • Low friction folding plates in tubing section
                • Constant fabric tension in the whole line

                Technical Data

                Roll diameter (max.): 1000 - 1500 mm
                Fabric width (max.): 
                1350 mm
                Tube width: 
                250 - 650 mm
                Layer: 
                1 or 2
                Operating speed (max.):
                150 m/min
              • Strip slitter - slitTEC

              • The roll slitter slitTEC cuts flat cloth into strips to be used for bottom patches and valve parts of valve sacks. The fabric is drawn off from an unwinding stand with brake device, taken via a centering system and cut on the supporting frame with cold knives. Subsequently the cut strips are rewound to small rolls on the rewinding system.

                Technical Data

                Cloth width (max.): 700 mm
                Roll diameter on unwinding stand: 
                1500 mm
                Roll diameter on rewinding system: 
                1200 mm
                Inside diameter of core on rewinding system: 
                203 mm/8"
                Operating speed (max.):
                100 m/min
              • Hydraulic sack press - baleTEC

              • The heavy duty sack press was specially designed for the packing of a determined number of sacks or cloth cut-offs.
                The sacks provided for packing are transported into the hydraulic press on one of the trolleys (included in our scope of supply) or on a pallet. The stroke of the press ram can be exactly adjusted through a limit switch by which the bale size can be exactly determined and maintained constant.
                Subsequently the compacted material is strapped with plastic bands. The finished bales are transported out of the hydraulic sack press on the trolleys or pallet.

                Technical Data

                Dimensions of the stack on trolley before compression (max.):     l x w x h: 1500x800x1230 mm
                Sack quantity to be proceeded: 
                500 - 1000 pcs
                Dimensions of the stack on pallet before compression (max.):     
                l x w x h: 1500x1200x1500 mm
                Sack quantity to be proceeded:
                8000 pcs
                Pressure load (max.):
                120 kN
              • FIBC testing equipment - stacoTEST 300

              • stacoTEST 300 has been specially designed for testing procedures for which the bag is suspended on its top and for the cyclic charge of FIBCs having one, two or four lifting loops. The machine is appropriate for testing the conformity to international standards such as DIN EN 1898, EFIBCA STANDARDS 03/04/05, the new European and ISO Standards, UN specifications, British Standards BS 6382 and French Standards FN H34-012.

                Technical Data

                Tensile load Container with 1 or 2 lifting loops (max.):                    
                159 kN (16.2 t)
                Compression load Container with 4 lifting loops (max.):                
                196 kN (20 t)
                Height of bag (max.): 
                2.5 m
                Filling capacity of bag (max.): 
                3 m³
                Filling time for 1 m³:
                3 min
              • Tape compactor - compSTAR

              • This integrated material handling solution facilitates the tape production process by removing and compacting broken tapes and tape scrap. The endless tapes are sucked into the container, cut and pushed towards the heated channel where they melt and are compressed into blocks. Compared to endless tapes, the blocks are a lot easier to handle and reduce production and recycling costs.
                The blocks are optionally recycled with our recoSTAR universal line. This equipment can handle hard-to-grind material by the ACTIVE shredder / extruder combination.

                Technical Data

                Capacity up to: 
                120 kg/h
                Heating capacity: 
                10 kW
                Volume reduction: 
                up to 90%
                Block size: 
                220 x 220 mm
                Density of block: 
                for PP: 200 - 400 kg/m³
                                                for PE: 200 - 550 kg/m³
                                                for PET: 250 - 600 kg/m³
                Connected load: 
                45 kVA
            • Consumer Bags

            • For the packaging of dry bulk goods destined for the end-consumer market and carrier bags with high standards for long life, attractive design and environment-conscious use, there are solutions that meet all requirements head on: PP*STAR® and CB*STAR® from Starlinger.

              Attractive PP woven packages are seen more and more often in retail stores. For these consumer bags a transparent PP film, printed in photo quality on its reverse side, is laminated onto the fabric. The product is presented with optimum market appeal, and the precise readability of the bar code is ensured. Ideal for dry bulk goods in quantities of 10 kg or more such as rice, cereals, and pet food – the PP woven sacks are stronger and cheaper than the conventional multi-layer paper sacks, and are completely recyclable.

              Durable, reusable, eco-friendly

              Woven shopping bags are gaining in popularity and have visibly become a part of our everyday shopping culture. For good reason: no other type of bag meets the increasingly high standards for long life, attractive design and environment-conscious use of resources so well.

              Woven consumer bags offer the following advantages over conventional single-use bags:
              • Light but resistant
              • Durable
              • Less raw material input
              • Economical production
              • Environmental friendly
              • 100% recyclable
                    • CB*STAR® shopping bags

                    • A new generation of eco-friendly carrier bags

                      CB*STAR® is the world’s first woven polypropylene carrier bag to be produced with full automation – on the cb*starKON conversion line manufactured exclusively by Starlinger.

                      Our new CB*STAR® carrier bag meets the increasingly high standards for long life, attractive design and environment-conscious use of resources as well.

                      The CB*STAR® concept, featuring side gussets and a block bottom, allows for various styles of handle, automatically or manually applied.
                    • PP*STAR® pinch bottom sack

                    • 1st pinch bottom bag worldwide made fully automatically from PP fabric

                      The PP*STAR® concept unites the best qualities of woven polypropylene tape fabric and printed BOPP film to create a cutting-edge packaging material for dry bulk goods sold in the retail sector. Designed as pinch bottom bags, PP*STAR® bags are perfectly suited for packaging dry pet food or fertilizer, but also meet the requirements of other products such as seeds, flour, sugar, or rice.

                      PP*STAR® - Advantages
                      • A packaging option for many applications
                      • Stronger than steel
                      • Perfect shelf display
                      • Cutting the edge in material saving
                      • No leaking, no humidity intake
                  • Recycling

                  • Starlinger recycling technology offers a spectrum of innovative machinery solutions for the efficient recycling of a variety of plastics, such as PE and PP, PET, PA, PS, PLA, PMMA, and many more.
                    Starlinger’s Recycling Division, founded in 2002, is the company’s second eldest field of endeavour. Yet thanks to entirely new recycling technologies and proven machine concepts, Starlinger’s product line recoSTAR quickly asserted its place in the market and has become a global and leading player in the field of plastics recycling.
                      • recoSTAR product line

                          • Recycling line - recoSTAR direct

                          • The recoSTAR direct has been specially designed for recycling medium and large quantities of heavy regrind materials (> 300 g/l) such as PE, PP, PS, PA and PC.

                            From a feeding hopper, the material is transported directly into the extruder by a screw conveyor without being precut or compressed. The rate of material feeding is controlled automatically by the load on the extruder motor. The system is designed so that overloading and underloading are avoided.
                            Solid foreign substances are filtered by a continuous melt filter available with or without backflushing system. Depending on the type and quantity of the material the line can be equipped with a water ring, strand or underwater pelletizing system.

                            The particular advantage of the recoSTAR direct is that no heating or other treatment of the material is necessary before extrusion. A clear and easy-to-use touch screen ensures a comfortable starting and stopping process and operation of the line. The recoSTAR direct series comprises five machine sizes which together cover an output range of 130 – 1200 kg/h. Each machine can be equipped with degassing, high vacuum, backflushing filter and any one of three pelletizing systems.

                            Technical Data

                            Output: 130 - 1200 kg/h
                            Energy consumption: 
                            0.25 - 0.35 kWh/kg
                            Extruder screw diameter (L/D): 
                            65(24;40) - 165(24;40) mm
                            Extruder AC drive:
                            45 - 315 kW
                          • Recycling line - recoSTAR dynamic

                          • Ecological, economical, energy-saving

                            - these are the three keywords to describe the new recoSTAR dynamic recycling line. The pioneering machine concept is characterized by a very energy-efficient production process as well as a high grade of automation, which accounts for reliable and constant production, higher output, and wider range of applications.

                            The recoSTAR dynamic will also be the first of the Starlinger recycling lines to carry the "rECO" stamp. By using exclusively motors with the best efficiency ratings, energy consumption and CO2 emissions are reduced significantly. Features such as energy recovery systems in various process steps as well as infrared heating further slim down the energy costs for machine operation.

                            Designed for recycling plastic scrap from industrial and post-consumer applications, recoSTAR dynamic lines are especially suited for processing hygroscopic, wet and/or pre-ground and foamed materials. The SMART feeder optimally prepares the material prior to extrusion through performing simultaneously the following:

                            • S hrink & cut
                            • M ix & homogenize
                            • A ctive feed & control
                            • R otate & friction
                            • T emperature & dry

                            The dynamic automation package ensures that the system is running at the ideal operating point. Consequently, higher output is achieved with lower energy consumption, and higher levels of humidity can be processed. The produced high-quality regranulate is suitable for a wide range of end use applications.

                            The recoSTAR dynamic series is available in six sizes and covers an output range of 150 - 2600 kg/h.

                            Technical Data

                            Output: 
                            150 - 2600 kg/h
                            Energy consumption: 
                            0.2 - 0.35 kWh/kg
                            Diameter SMART feeder: 
                            900 - 2050 mm
                            SMART feeder drive power: 
                            37 - 400 kW
                            Extruder screw diameter (L/D): 
                            65(24;40) - 215(24;40) mm
                            Extruder AC drive:
                            45 - 560 kW
                          • Recycling line - recoSTAR universal

                          • Versatility, Accessibility and Intelligence are the key highlights of the recoSTAR universal recycling line. New advanced features complement a well-proven technology. This state-of-the art recycling line with extended functionality and innovative process adaption through the ACTIVE shredder is especially designed for processing films, fibres and filaments, nonwovens, tapes, fabrics, as well as solid lumps, start-up scrap, injection moulding parts, and any type of regrind; from materials such as PE, PP, PS, PA, PES, PET, PPS, PLA, and others. The most efficient solution for rigid, flexible, and hard-to-grind materials.

                            ACTIVE shredder - ideal material preparation before the extrusion process due to:

                            • A ccessibility & quick material change
                            • C ontrolled cutting & dosing
                            • T ight knife clearance & high performance
                            • I ntelligent & innovative
                            • V ersatile & wide material range
                            • E asy start & stop operation

                            The material is fed without pre-cutting to the shredder by conveyor belt, film reel feeder or edge trim cyclone. The ACTIVE shredder ensures perfect material preparation for high output through exact cutting geometry and double-coil rotor design. A hydraulically driven pusher presses the material against the rotor, where it is cut between the rotary and stationary knives. However, cooling is kept to the necessary minimum so that the energy generated in cutting can be utilized in the extrusion process.

                            The load-controlled dosing screw allows stable extruder feeding even when the bulk density varies. The machine is designed so that overloading and underloading are avoided. Easy access and maintenance leads to high uptime and availability.

                            The recoSTAR universal series comprises five machine sizes which together cover an output range of 150 – 1300 kg/h. Each machine can be equipped with degassing, high vacuum, backflushing filter and any one of three pelletizing systems.

                            Technical Data

                            Output:
                            150 - 1300 kg/h
                            Energy consumption: 
                            0.2 - 0.35 kWh/kg
                            Single shaft cutter width: 
                            800 - 2000 mm
                            Single shaft cutter drive power:
                            55 - 160 kW
                            Extruder screw diameter (L/D): 
                            65(24;40) - 165(24;40) mm
                            Extruder AC drive:
                            55 - 355 kW
                          • Recycling line - recoSTAR PET (non food)

                          • The decisive criterion for all PET applications is that the use of repelletised material may not influence either extrusion or any following process, nor may it prejudice the quality of the end product. The Starlinger recoSTAR product line offers the ideal solution for PET recycling, as it fulfils both conditions with optimal pre-drying of the PET flakes and optional solid stating.

                            The recoSTAR PET line is state-of-the-art recycling technology for the in-house recycling of PET flakes from bottles, preforms, strapping bands and sheets as well as for the recycling of post-consumer bottle flakes after the washing process. The end product is melt-filtrated, uniform granulate that can be used for a wide range of applications (containers, sheets, fibers and nonwovens, strapping).

                            recoSTAR PET features the following advantages:

                            • Modular design ensures flexibility and adaptability to different input material and the changing requirements of rPET users.
                            • High automation and userfriendliness leads to highest efficiency and consequently fast ROI.
                            • Careful treatment of flakes, avoiding dust, high IV loss and degradation. FIFO ensures uniform treatment of the input material.
                            • Direct material flow at the melt filtration reduces stress of material. Finest filtration is available on request.
                            • The inline viscosimeter optionally measures the IV for immediate quality control.
                            • Pellets size and bulk density are adjustable for all pelletising systems available.
                            • The optional inline crystallisation after underwater pelletising ensures optimised foot-print, energy saving and high crystallinity.
                            • Increased energy efficiency by using gas, steam, or the residual heat of previous process steps.
                            • The visualisation panel features archiving, maintenance list, alarm list, etc.

                            Technical Data - recoSTAR PET

                            Output: 
                            150 - 2900 kg/h
                            Energy consumption: 
                            0.25 - 0.35 kWh/kg
                            Extruder screw diameter (L/D): 
                            65(40) - 2x165(40) mm
                            Extruder AC drive:  
                            45 - 500 kW
                            High-vacuum:
                            ≤ 10 mbar
                          • recoSTAR PET for food-contact

                          • Starlinger recycling equipment has proven its high decontamination capability in a series of challenges tests. The rPET produced on Starlinger recycling machinery can be used at a rate of up to 100 % for direct food-contact packaging.
                            Due to a variety of input qualities and requirements in terms of reapplication, Starlinger recycling technology has designed four approaches to achieve food-contact rPET.

                            recoSTAR PET with Starlinger iV+ technology features the following advantages:

                            • FIFO principle for flakes and pellets ensures defined residence times
                            • Modular design ensures flexibility and adaptability to different input material and the changing requirements of rPET users.
                            • Careful treatment of flakes, avoiding dust, high IV loss and degradation.
                            • The high-vacuum degassing extruder reduces viscosity loss during extrusion and purifies the melt from volatile contamination.
                            • The optional inline crystallisation after underwater pelletising ensures optimised foot-print, energy saving and high crystallinity.
                            • Inline colour measurement guarantees first-class colour value.
                            • IV increase is adjustable and consistent (variation rate similar to virgin resin)
                            • The SSP units have a small footprint, convenient height and can be quickly installed on standard industrial floors
                            • The modular system allows simply adding another SSP unit in case higher IV is needed or the IV of the input material decreases over time
                            • Flake treatment, extrusion and solid-stating can be used both stand-alone or inline
                            • And the most important point: rPET produced using Starlinger recycling technology enables preform producers to replace virgin material without having to change the production process or materials handling.

                            Technical Data - recoSTAR PET FG / FG+

                            Output: 
                            150 - 3300 kg/h
                            Energy consumption: 
                            0.25 - 0.35 kWh/kg
                            Extruder screw diameter: 
                            (L/D) 65(40) - 2x165(40) mm
                            Extruder AC drive:
                            45 - 630 kW
                            High-vacuum:
                            ≤ 10 mbar
                          • Optional equipment

                          • Material feeding
                            Depending on the physical form of the material, any recycling line can be equipped with an edge trim cyclone (for inline operation), reel feeder (for films on rolls), or a feeding conveyor (for loose material, bales, flakes).

                            Dosing and compounding
                            Due to our commitment to continuous technological progress, the recoSTAR product range has been extended to integrate compounding into the recycling process. By means of exact dosing of various additives in liquid, pellet, or powder form, the properties of the regranulate may be adjusted to meet the requirements of the final application.

                            Degassing
                            Regardless of the pre-treatment process, the plastic is being compacted and molten by means of a single screw extruder; our unique screw design results in excellent product quality. Optionally, every extruder may be equipped with a vacuum unit, a double-vacuum unit, a high-vacuum unit, or a C-VAC module. Through the use of vacuum, loss of viscosity is reduced, and volatile contamination and monomeres are extracted.

                            Filtration
                            Solid foreign particles are being extracted by means of a melt filter. With regard to filtration, our customers may choose between the following filtration systems: discontinuous, continuous, and continuous with a high-capacity backflushing mode (power-backflush). The continuous filter consists of a double piston, whereby each piston is equipped with a filter unit. In relation to extruder size, each filter unit is large enough to filter 100% of the melt during backflushing or filter change. The main advantage of this design is a melt flow that is free of deflection and dead corners. Otherwise, the material would start to accumulate and degrade, and in case of it being carried along, it would contaminate the purified melt flow. For higher levels of contamination, we recommend our power-backflushing filter, or alternatively our continuous rotation filter.

                            Pelletizing
                            Depending on the application, one of three pelletizing systems is selected:
                            • Water ring pelletizing
                            • (Automatic) Strand pelletizing
                            • Underwater pelletizing

                            Our patented waterring pelletize ensures the optimal cutting of the polymer melt which is pressed through a vertically perforated plate. The centrifugal force transports the granulate into the process water of the drum. After its separation from the water, the lense-shaped granulate is dried gently in a centrifuge.
                            By means of the conventional strand pelletising, the polymer strands are led through a water bath, and after cooling, the strands are cut to cylindrical granulate. The automatic strand pelletising is particularly user-friendly and allows for high availability of the recycling line.
                            The advantages of the underwater pelletiser are easy start-up, fully automatic operation, minimal need for operating personnel, economical use of floor space, and reduced consumption of cooling water. The process water flushes the die plate as well as the knife head; the granulate’s form is spherical. Optionally, an inline crystallisation may be installed in order to produce granulate with a high level of crystallinity.

                            Energy efficiency and alternative energy

                            rECO is an innovative approach that improves the energy efficiency of the recycling line. The overall energy consumption kW/kg is reduced by approx. 10 %. Benefit for the client is reduced costs, benefit for the environment is reduced carbon footprint.
                            The rECO package includes amongst others:

                            • New drive concept for the main drive of the extruder
                            • Main motors in IE3 standard resp. NEMA Premium, the most energy efficient motors available.
                            • Barrel heating is done with infrared heaters.
                            • Energy recovery solutions are optionally available for various process steps.

                            recoSTAR lines can alternatively use natural gas or steam as a heating medium.
                        • Applications

                        • Recycling applications: innovation and flexibility in step with the future

                          Recycling of production and post-consumer scrap means adapting to continual changes in incoming materials. Engineering must also take into account potential uses of the recycled product. This poses challenges not only for the line itself, but above all for us as developers and suppliers of innovatively designed plants.
                            • Recycling technology for film

                            • Production and post-consumer scrap are valuable secondary resources to produce first-class products.

                              The material to be processed can be in different conditions in terms of humidity, contamination, printing, and of course form. The reuse of the material is either in the same or various other applications; goal is a content of up to 100 %.

                              For the film recycling industry, Starlinger recycling technology offers a spectrum of innovative machinery solutions (recoSTAR dynamic and recoSTAR universal) for the efficient recycling of all kinds of film materials. Source of waste is in-house production scrap, post-industrial waste from e.g. film conversion, as well as post-consumer waste including agricultural film. Polymers (or their blends) such as PE (LDPE, HDPE, LLDPE), PP (BOPP), PA (BOPA), PET (BOPET), PS, PLA, etc. can be processed with a choice of pre-treatment, extrusion, filtration and pelletizing modules.
                            • Recycling Fibre & Non-Woven

                            • Amongst other industries, fibre and non-woven production is under tight competition, pushing for cost efficiency. Primary resin is a considerable cost factor in the production process. Although zero scrap in production is the goal, it is not entirely possible. Consequently recycling of production scrap considerably contributes to competitiveness. At the same time environmental consciousness and resource conservation call for recycling but quality requirements in the industry are very high. Thus the challenge is to provide equipment handling a variety of in-house production scrap with different characteristics whilst ensuring that regranulate even in a high proportion does not negatively influence the production process.

                              Production scrap happens throughout the process chain, from start-up scrap to off-spec material and conversion scrap. During the production process additives, e.g. finishing oils, are applied which can influence the material during the recycling process. Other additives might be required for later use, e.g. flame retardant. During material handling and storage, the scrap can get wet and contaminated. Finally the recycling material can be one type of plastic or a mixture of materials. To separate the components of polymer mixtures such as PES/PE or polymer/cellulose compounds, special filtration is applied. Certain viscosities pose a challenge during pelletisation.

                              Recycling into pellets with excellent flow characteristics is required as production scrap comes in different shapes. Right choice of equipment after having analyzed the characteristics of input material as well as process know-how enable production of high value regranulate improving cost efficiency and stability of the primary production process.

                              Flexibility through modular design:
                              Three different types of lines are offered to recycle fibre, textile or non-woven scrap. Depending on properties of input material and requirements, pre-treatment and down-stream equipment is chosen. Optionally, a vacuum SSP reactor provides adjustable IV increase and removal of released spin finish.
                            • PET Recycling

                            • PET is one of the few thermoplastics that can be upcycled to achieve resin-like quality through SSP treatment. Today, post-consumer bottle flakes are successfully used for food-contact packaging, high-IV strapping bands, and filaments. Bottle-to-bottle recycling requires the highest standards in terms of decontamination.

                              Due to its favorable characteristics, the use of PET (polyethylene terephtalate) for food-contact packaging is a success story. But it also causes more PET waste, which in turn raises public interest in this issue. Recycling contributes significantly towards a positive perception of PET packaging: It increases ecological awareness and induces collection of post-consumer waste and obligatory reuse of recycled PET (rPET). Also major brand-owners jump on the bandwagon and promote low carbon footprint and resource conservation.

                              Be part of the solution
                              It is projected that within the next ten years the worldwide consumption of PET bottles will double. Even assuming ambitious collection rates, the major share of PET waste will end up in land-fills. Washed and processed PET bottles are a valuable secondary resource. In this context, it is the consumers’ responsibility to contribute to recycling efforts and to welcome products with rPET content – bottles that are turned into fibres, filaments and nonwovens, sheet, strapping, and, most prominently, into bottles again.

                              Flexibility through modular design:
                              Flakes from production scrap and post-consumer waste of preforms, bottles and sheet can either be recycled to pellets or processed inline into a final product. PET flakes are decontaminated and IV-increased stand-alone or inline. In combination with the recycling extruder and pelletizing system the optional upsteam or downstream vacuum SSP reactor ensures outstanding rPET quality. Inline applications combine energy saving and value-adding in one step.
                            • Recycling woven bags

                            • Production waste is a valuable secondary resource: Recycling and internal re-use contribute to economic prosperity and continuity through cost savings on raw material and resource conservation.

                              PP and PE resin, the input materials for bag production, are too valuable to be wasted – no matter what the market price is.
                              Starlinger has put a lot of effort in increasing the efficiency of the bag production equipment to reduce production waste. Although zero waste is the goal, it is not entirely possible. And production waste is not only a loss of primary resin, but also a cost factor when it comes to material handling, storage, selling or disposal.
                              Through appropriate material handling and recycling the minimized though unavoidable production waste is converted into a valuable secondary resource.

                              Converting waste into a valuable resource
                              Production waste is generated during various process steps: extruder start-up, winding, weaving, conversion, printing, to name just a few. It can be contaminated during the production step – e.g. printing, or during handling – e.g. by humidity or dust. Thus, material handling plays a key role because the quality of the input material for recycling is crucial for high quality regranulate.
                              Knowing the bag production process as no other, Starlinger can provide valuable know-how on optimizing materials management and, equally important, recycling solutions designed for high production efficiency, energy saving and flexibility.
                            • Odour reduction

                            • Bad odours – this is an issue many recyclers of post-consumer plastic scrap have to deal with. The input material they are processing often contains migrated substances from food, cosmetics or cleaners, which cause an unpleasant smell during the recycling process. But also residues of monomers, oxidation or hydrolysis, as well as decomposition products (VOCs – volatile organic compounds) can be the reason for unwanted smells in recycled granulate. Solid contaminants and foreign matter, e.g. paper or wood, cannot be removed to 100 % even in intense washing processes and thus can cause odour development in the extrusion process.

                              Measures for odour reduction can be taken during the different stages of plastic production and processing. Usually, additives are added to achieve a reduction of unwanted odours. The use of additives, however, causes additional production costs with questionable results – an additive does not actually remove the odour, it only blankets it. This means that the original odour might return during the following process steps or in the final product. To avoid that, Starlinger recycling technology has developed a recycling process with odour reduction that does not require additives and has a permanent effect.