Infrastructure and facilities

Possible production quantities are: lactide up to 10 kg, PLA and other polymers in batches up to 5 kg, continuous PLA in twin-screw extruder up to 10 kg, polymer dispersions up to 20 kg.

• 25 L enamel full-view vessel with distillation peripherals, up to 200 °C, -1 to 0.5 bar
• 12 L stainless steel reactor with distillation peripherals, up to 300 °C, -1 to 10 bar
• Fractionating column with 30 theoretical plates, max. 250 °C, 10 L feed vessel
• Melt crystallization, 1.5 L and 7.5 L batch vessels
• 1 L, 1.5 L and 7.5 L stainless steel polycondensation vessels, up to 300 °C, -1 to 60 or 25 bar, torques up to 3,000 Ncm, digital data acquisition
• 12 mm twin-screw extruder 36 D, throughput 0.1 - 2 kg/h, up to 400 °C, 8 heating zones, 3 degassing or dosing openings
• Strand pelletizing

We have facilities that allow us to realize melt spinning as well as solution spinning processes.

Our melt spinning plant (Fa. Fourné) is available for the production and sampling of filament yarns from biobased thermoplastics (PLA, PBS, PA, etc.) on a kg scale with the spinning-stretching process.. 

• Processing temperatures ≤ 400 °C
• Melt throughput max. 3 kg/h
• Take-off speeds: 180 – 1,800 m/min
• Spinning nozzle geometries: round, trilobal, bico
• Filament count: 1 - 120

Solution spinning plant (max. 120f):

• Continuous transformation of spinning solutions into multifilament yarns (200 ml solution already sufficient)
• High chemical resistance of the products
• Flexible plant design for different applications

Modular stretching unit for post-processing:

• max. 6,000 tex
• integrated commingling unit
• heated stretching godet and/or heating plate
• max. 300 m/min

Different analysis methods are used to assess aging and degradation behavior, such as documenting optical changes using microscope images or determining polymer-physical and -chemical properties.

• Test duration depending on the task and material between four weeks and two years
• Tests in various substrates (e.g., compost, freshwater)
• Temperature range for solid substrates: 20 to 60 °C
• Adjustable substrate moisture
• Use of UV radiation to investigate the influence of sunlight
• Recognized testing laboratory of the Bundesgütegemeinschaft Kompost and recognized testing laboratory of DIN CERTCO for examinations of the compostability of materials according to DIN EN 13432, DIN EN 14995, ASTM 6400

For simulated weathering in the laboratory, xenon arc weathering instruments and devices for quick testing with mercury vapor lamps are available (norm-based tests or according to customer specifications). Short test times are achieved by using tailored weathering cycles and meaningful early detection methods, which we develop or provide for you.

• Weathering (WoM Ci4000, Xenotest Alpha, Suntest XLS+, QUV weathering tester)
• Weathering also in saltwater conditions (Suntest XLS+, Bandol-wheel)
• UV-C aging (intensities between 0.05 and 45 mW/cm2 for periods between a few hours and several weeks), reciprocity test (UV & UV-C), temperature-moisture cycling, climate storage, moisture resistance (WK-600), heat aging.
• Climate tests at relative humidity (rH) from 10% rH to 98% rH between 10 °C and 95 °C
• Temperature storage in the range from -40 °C to 180 °C
• Extensive measuring equipment is available for the detection of plastic aging.
• Integration of ultrasound measurement technology and NMR sensors in weathering devices (in-situ tracking of material changes and optimization of weathering cycles)
• Non-destructive testing of weathered polymer coatings by ultrasound microscopy
• Classical structure elucidation using imaging and scattering methods, dynamic mechanical analysis, or differential scanning calorimetry
• Detection of chemical changes by determining molecular weights and optical spectroscopy

In addition to numerous chemical, physical, and mechanical methods for polymer and material characterization, various special methods tailored to plastic recyclates are offered. In particular, for polyolefins (PE/PP), characterization and authentication of recyclate-virgin blends are offered (PET under development):

• Detection of the declared proportion of recyclate in a sample
• Improved understanding of the chemical and physical changes caused by material recycling
• Tailor-made method development for elucidating structure-property relationships

Special methods for polymer and recyclate analysis:

• High-temperature GPC for polyolefins
• Room temperature (RT) GPC for technical polymers (POM, polyester, polyamides, etc.)
• High-temperature HPLC (Hypercarb or silica column; alternatives on request)
• Room temperature HPLC (Hypercarb, NP, RP)
• High-temperature 2D-LC (online)
• Room temperature 2D-LC (offline)
• High-temperature NMR (Varian Mercury-VX 400)
• Confocal Raman microscopy (WITec Alpha 500)

In the development of new flame-retardant plastic compositions, the aim is to achieve an optimal combination of flame retardancy, processability, and mechanical properties. Special analytics and expertise are offered for examining flame retardant properties:

• Flame classification tests according to UL94
• Cone calorimetry
• Limited oxygen index (LOI)
• Comparative tracking Index (CTI)
• Glow-wire ignition temperature (GWIT)
• High-voltage tracking resistance testing (IPT)

Pyrolysis plants are available in various scales (0.1-70 kg/h) for thermochemical recycling:

• Patented continuously operated screw reactor
• Patented combined heat exchanger system
• Prevention of tar formation and clogging of condensation chambers through innovative clarification unit
• Rapid temperature ramp-up, skipping critical temperature ranges for dioxin and furan formation
• High process stability and plant availability
• Temperature up to 700°C, adjustable residence time
• Flexible scalability from 70 kg/h to > 5t/h
• Low preprocessing requirements

In conjunction with tailored material formulations, plastics can be processed up to demonstration scale. Complex process chains can be developed or replicated modularly on a pilot plant scale.

• Various twin-screw extruders:
  Screw diameter: 16 to 32 mm, process length: 36 to 60 D
  
• Flat film machine with up to 200 mm film width
  
• Gravimetric scales for dosing granules, powders, and flakes from a few grams per hour to more than 250 kg/h
  
• Dosing scales for ground/cut fibers, gas dosing station for nitrogen, hydrocarbons, and carbon dioxide, dosing systems for liquid and high-viscosity media, liquid dosing for suspensions of nanoparticles
  
• Melt filter systems
  
• Ultrasonic and microwave applications in extrusion
  
• Process integration of inline analysis methods (viscosity, Raman and NIR spectroscopy, pressure, temperature, residence time)
  
• Strand pelletizing, underwater pelletizing (also for microgranules) as well as hot-cut air pelletizing, variable use on all extruders
  
• Various vacuum pumps based on water ring or rotary vane technology
  
• Various systems for filament production for 3D printing
  
• Safety devices and exhaust systems for working with nanomaterials and hazardous substances on the extruder

The mechanical preparation pilot plant offers facilities for shredding (<100 µm to 50 mm), screening, sorting, classification, and material characterization:

• Pre-shredding
• Erdwich single-shaft shredder 550, sieve insert 15 – 60 mm

Dry milling of viscoelastic, ductile, tough, and fiber-reinforced materials and mixtures:

• Cutting mills:
  Alpine Hosokawa 28/40 ROTOPLEX, dry milling, sieve insert 2 – 50 mm
  Alpine Hosokawa 20/12, ROTOPLEX, dry milling, sieve insert 2 – 20 mm
  Retsch SM 2000, sieve insert 1 – 10 m
• Fine impact mills:
  Alpine Hosokawa 160 UPZ, hammer mill and pin mill, sieve insert 0.1 – 3 mm
  Retsch UZM 100, sieve insert 0.2 – 6 mm
• Hammer mills:
  Alpine Hosokawa 25 MZ, sieve insert 0.25 – 30 mm
  Ball mill - dry and wet milling
  Welte drum wet mill WN30D
  Annular gap ball mill COSMO II 

Sorting

• Hydrocyclone
• Bückmann Zick Zack air separator ZN 15, 80 x 120
• TrennSo static air oven TTS 200
• Quicktron metal separator 03 R
• S+S non-ferrous metal separator SNF

Classification

• Mogensen screening machine SZ 0254, sieve insert 0.15 – 25 mm
• Retsch analysis screening machine type AS 200

Sample preparation

• Riffler for the separation of larger sample quantities
• Rotating sample divider Retsch PT 100 for smaller sample quantities

The following components are available for solvolysis processes:

• Process development on a laboratory scale (up to 2,000 ml)
• Demonstration on a small technical scale TRL 4-5 (5-10 kg)

Preparation of solvolysis products

• Mixer-settler for liquid-liquid extraction
• Rectification plants (350 °C) at an operating pressure up to 1 mbar at 1 kg/h throughput, column DN50 (40 theoretical stages)
• Membrane filtration reverse osmosis, nanofiltration, ultrafiltration, microfiltration, batch and continuous

The following components are available for solvent-based recycling processes:

• Process development on a laboratory scale (up to 2,000 ml)
• Explosion-proof demonstration plant on a small technical scale TRL 4-5 (10 kg)
• Cross-flow membrane filtration for the separation of dissolved additives
• Spray drying for polymer and solvent recovery on a small technical scale TRL 4-5 (10-20 kg)

The Kurtz Wave Foamer offers a radiofrequency-based processing process for particle foams made from renewable raw materials and recyclates. Thanks to the water- and steam-free processing technologies, often hygroscopic bio-based polymers can be processed and the proportion of recyclate in recyclate-based foams can be increased. Furthermore, compared to conventional steam-based processes, up to 90 % energy can be saved (EPS reference system).

Specifications:

• Tools with 300 x 300 x 10 / 25 / 50 mm are available
• Processing frequency: 27.12 MHz
• Wavelength of EM radiation: 11 m
• Maximum generator voltage: 10 kV
• Fully automatic dosing and filling station available
• Tool temperature control (oil) available

The tandem foam extrusion plant consists of two extruders connected in series with an L/D ratio of 30 and 60, respectively.

The first extruder is used for melting the polymer and homogenizing the blowing agent in the melt, while the second extruder is used for cooling the melt. Depending on the installed die geometry, plates or films can be extruded. Both standard polymers as well as bio-polymers and recyclates can be used on the plant.

Specifications:

• Blowing agents: CO2, N2, organic blowing agents, inorganic blowing agents
• Throughput: 30 – 60 kg/h

Composite of hydraulic press and bold-on injection molding unit for modular sampling of large-volume components with combined process technology as well as industrially automated production in a development environment.

Dieffenbacher CompressPlus DCP-G 3600/3200 AS

• Clamping force up to 36,000 kN (regulated parallel operation)
• Tool installation height from 750 mm to 1,500 mm
• Tool width max. 2,900 mm
• Tool length max. 2,100 mm

Arburg SPE 4600

• Screw diameter of 80 and 90 mm
• Dosing volumes up to 2290 cm³
• Cylinder temperature up to 450° C
• Direct fiber feed
• Eightfold cascade control
• 64-zone hot runner control

Periphery

• Handling system 7-axis robot Kuka KR 210 R2700 Prime

• IR heating field up to 1720 mm x 1450 mm and 500 °C

Rapid development, iteration, and implementation of ideas into prototypes using digital manufacturing.

• CAD, parametric design, 3D scanner
• Additive manufacturing: FDM, SLA, SLS (also material development), paste printer
• Subtractive manufacturing: CNC milling, water jet cutter, laser cutter, cutting plotter
• Electronics workshop: IOT, microcontroller, sensors, actuators