Obtaining new profile from old PVC windows Materials
handling from AZO - resilient and wear-resistant
Requirements
•increase in overall productivity
•high degree of flexibility in conveying materials thanks to vacuum conveyor
•components chosen to make best use of overall height
•simple, flexible design of conveying distances using pipes
•modular concept
•robust, cost-effective concept for wear protection
•integration of existing technology
•improved working conditions thanks to reduction in generation of dust
•separation of residual dust
The customer
In founding the company of Dekura kunststoffrecycling GmbH in 2016, REHAU, the experts for polymers, and Tönsmeier, the plastics recycler, drew on their consolidated expertise in the recycling of PVC and disposal of old windows. The company takes delivery of offcuts from window production, in addition to old windows and roller shutters, and reprocesses them. The collected materials are used to produce high quality secondary raw materials, which can then be used again in the manufacture of window profiles and in other areas. This closes the loop for recoverable materials and helps protect the environment. Producing and using granulate from old windows saves 90% CO2 compared with use of virgin material.
The old windows are shredded and ground up. The PVC is then separated from the glass and hardware, washed and processed to a clean granulate using melt filtration. Up to 70% recycled PVC can be used in making new PVC windows.
“The structures established at the Höxter site soon made it clear that we needed to have a master plan outlining the best solution for site in the future. It was at this point that AZO came on the scene.”
Stefan Valerius, Manager, DEKURA
The situation report and drawing up of a master plan were carried out together with AZO®e&s (engineering & services) as part of a pre-engineering process.
This planning assignment covered the following:
•in-depth review of existing situation
•design of a new workflow with an optimum logistics concept
•taking existing equipment into consideration as far as possible
•concept for handling recyclate to provide maximum flexibility and resilience
•concept should afford maximum wear protection on account of abrasive recyclate and contaminants in them (reinforced PVC in part, metal residues, glass residues, etc.)
•reduction in downtimes, less time for service and retooling
•step-by-step plan for implementation including concept for modernisation
•optimised concept for controls
•optimise the entire reprocessing workflow with regard to process logistics and overall output
The AZO solution
In close cooperation with DEKURA, AZO drew up a solution based on the above-mentioned specifications during pre-engineering. Vacuum conveying systems from AZO constitute part of the concept. These have been specially adapted to the situation on account of the low overall height.
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