Binova BiReC: One-step process

Recycling and compounding line with co-rotating twin-screw extruder

Binova developed a new line able to process in one single step what normally is made in two: recycling and compound. This technology is able to process the post-consumer polyolefin material in the form of ground sheet coming from a washing line. The pellet obtained guarantees a high-quality final product.

Despite the origin, by using dual automatic filtration, Binova is able to guarantee to the end user, the possibility to produce films with thicknesses of about 20 microns.  

The line in question uses a co-rotating twin-screw extruder which can produce between 1400 and 1800 kilograms per hour according to the material introduced.

The plant is able to compound post-industrial waste with high residual moisture (up to 8%) with particular blends of pellets. The presence of a high-vacuum degassing system distributed over almost the entire length of the extruder barrel (3 vacuum degassing flues and 1 atmospheric exhaust flue) allows the granulation of highly printed films; up to 80% of printed area. The mixing of the raw materials, which occurs directly in the machine, leads to a perfectly homogeneous material able to increase the quality of the final product. 

The dosing system of the various materials can be both gravimetric and volumetric. A new gravimetric control system for ground film, although with a bulk density of around 0.05 kg/dmc, has been patented and developed within the research and development department of Binova: this guarantees the exact percentage of ground sheet which will feed the extruder. The production of this technology is entirely made in Italy, with particular attention to the quality of all the components.

Competitiveness in a single step

Being able to perform this process in a single step makes BiReC lines very competitive. With this plant Binova is very competitive, for the moment it offers its customers something unique. In addition to the reduced handling of the materials inside the factory, another very important thing is the proven reduction in energy consumption compared to other plants on the market today: for LDPE based polyolefin materials, consumption will not be higher than 0.26/0.27 kW/kg whereas for polypropylene or polystyrene based materials, such as PP, PS or HIPS, a consumption around 0.22/0.23 kW/kg (excluding the cooling of the process water).

Compared to a traditional line with a single-screw, here there is almost 30% of energy saving due to the co-rotating twin screw which has a higher degree of optimization. This plant was projected to meet the specific needs of a customer who wanted to obtain the same product with higher yields, but it is perfectly suited to the demands of the entire market. 

Software and remote control

The line is equipped with a software that controls the whole production, even in the event of high working rhythms. The plant is equipped with an automatic OP control panel with Internet connection, which can also be managed remotely. In this way, the technician or the production manager can check the status of the process data of the line, even at a distance, from their smartphones.

Binova introduces the new operational headquarters

In order to satisfy the growing market demand at the best, Binova has invested in new operational headquarters of approximately 2,000 square meters in the industrial area of Mezzomerico (Novara). The structure is located a few kilometers from the current production site of Oleggio (Novara), in a strategic position easily reachable from Malpensa airport, the lakes, and Milan-Turin highways. This is a further step in the growth strategy of the company, which intends to expand its market.

The new headquarters will make it possible to respond to the need for more space, to reorganize warehouse management through the use of new IT tools, to strengthen the assembly and testing processes of several plants simultaneously and to increase the workforce, thanks to the availability of large spaces dedicated to offices. The investment also provides for the updating of all corporate information technologies, in order to streamline the design and procurement processes and to better plan the flow of materials and assembly activities, as well as to improve cost control. This will also make it possible to further improve the after-sales and spare parts services.