SIPA’s Xtreme Renew di SIPA is the first circular system in the world that produces preforms and bottles while saving the environment, energy and money.
SIPA, in partnership with EREMA, has developed XTREME RENEW, the first technology in the world to produce PREFORMS from 100% r-PET washed FLAKES in a single energy cycle.
An environment-saving and cost reducing technology, this revolutionary “bottle-to-bottle” system was designed for the circular economy: XTREME RENEW uses fewer raw material (-10%), saves more energy (-30%), has a low TCO (-15%) and reduces logistic cost (-20%) compared to any other technology.
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One of the key benefits of the patented VACUREMA® technology from EREMA is that decontamination and the removal of moisture already takes place BEFORE the extrusion.
This is a clear bonus for the quality of the melt and, as a result, of the end product, because IV values are very stable as a guarantee of top mechanical properties of the finished product.
The key components of the system include a vacuum reactor which is connected directly to a single-screw extruder.
Thanks to the ingenious function of the mixers in the vacuum reactor they feature three ultra-efficient function zones which interact perfectly with each other to decontaminate and predry the PET material.
With very low residual moisture the clean, perfectly prepared PET material enters the intake zone of the extruder.
This material transfer takes place under high vacuum. As a result, no additional degassing ports are required on the extruder.
This means that VACUREMA® technology drastically reduces the length of the extruder, lowers its energy consumption, improves the colour values (b value) of the processed material and keeps AA values to low level.
Moreover, the strong homogenisation performance of the extruder plays a significant part in turning the different input IV values into a stable output IV value.
In the downstream large-area high-performance fine filter, the material is filtered with a mesh screen width of 25 – 62 µm (typically with 40 µm, depending on the end application: CSD, water, etc.)
The filter system is equipped with a patented fully automatic self-cleaning system that enables long filter service life.
The melt is now ready and can be transferred directly to the downstream unit.
Rotary molding wheel:
Cooling is made with cold air at high speed on external and internal surface of the preform.
There is no need to change the personalization parts since grippers are self-adjastable.
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XTREME RENEW produce a wide range of light weighted food-grade preforms with up to 100% r-PET starting from simply washed flakes for a wide range of applications: mineral water, juices, RTD tea, milk, edible oil, etc.
European technology that makes it possible to produce PET bottles entirely out of post-consumer waste has been recognized with a prestigious WorldStar Packaging Award at a gala ceremony hosted by the World Packaging Organisation (WPO) in Prague, Czech Republic.
The WPO presents World Star Packaging Awards every year to what are considered by independent experts to be the best packaging solutions and applied technological innovations.
XTREME Renew technology is unique in the world in its ability to produce bottles, suitable for food contact and with properties as good as those of bottles produced from virgin PET, directly from flakes of post-consumer scrap, in a single heat cycle.
The system can produce over 300 million containers per year.
“This is a solution that represents the perfect response to the requirements of the new circular economy,” says Gianfranco Zoppas, President of SIPA parent company Zoppas Industries.
“Waste reprocessing is rendered sustainable and economical while producing new products of the highest quality."
This innovative technology uses 30% less electricity than traditional recycling processes, thanks largely to systems integration, while CO2 emissions are cut by 25% – a massive 60% when you compare it to bottle production from virgin resin.
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