Challenge: Eliminate Waste and External Recycling Costs

The customer, a major UK supplier of specialist blown film products—including vacuum bags, heavy-duty sacks, and high-barrier packaging—was shipping all post-industrial scrap off-site for recycling. This process was costing over £100,000 per year in transport alone and offered no direct return on material value.

With a zero-waste goal in mind, the customer sought a cost-effective way to recycle internally, reintroducing scrap directly into the production process. However, they needed a solution that required minimal labour, complied with food-grade production standards, and delivered fast ROI.

Solution: Alpha S Plus Re-Pelletiser by Plasmac

UK Extrusion provided a loan unit of the Plasmac Alpha XS for trials. Installed and commissioned by UK-based engineers, the system demonstrated excellent results—producing high-quality re-pelletised material that could be fed directly back into new product runs.

Following successful trials, the customer placed an order for a higher-throughput Alpha S Plus, equipped with a roll feeder and trim basket for seamless inline recycling. Designed in accordance with BRC standards and powered by Plasmac’s short screw technology, the Alpha S Plus ensured high efficiency and low running costs. The intuitive, operator-friendly system allowed for semi-automatic operation with minimal labour requirements.

Results: Zero Waste, Zero Transport, Rapid Payback

With the Alpha S Plus now fully operational, the customer has eliminated their off-site recycling requirements and is running a fully closed-loop operation. Key outcomes include:

• Payback achieved in under 9 months
• Over £105,000 saved in 7 months through reduced transport, energy, and labour costs
• Machine runs semi-automatically, requiring minimal operator input
• Energy-efficient operation: savings of over £2,000/month
• Zero-waste operation: all post-industrial scrap is now re-used in production

The Alpha S Plus was exactly what we wanted—simple to use, low labour, and once running, it just works. The local support from UK Extrusion and Plasmac was excellent. We’re very happy with our decision.
— Customer feedback

Interested in Reclaiming Your Scrap In-House?

Contact us to discuss your application or to arrange a trial of the Alpha XS or Alpha S Plus systems. Talk to UK Extrusion today.

The post Case Study: Zero-Waste In-House Recycling with the Alpha S Plus Re-Pelletiser first appeared on UK Extrusion.

Meeting European Demands for Recycled Content

With EU regulations requiring 30% recycled content in PET bottles by 2030, and 1.4 million tonnes of recycled PET already being used for food-contact packaging, manufacturers are racing to develop cost-effective ways to validate r-PET for use in their processes.

However, variations in flake quality, high cost compared to virgin material, and the need for major equipment adaptation remain key hurdles. To address these, fast and accurate lab-scale testing has become an essential part of R&D for recyclers and converters alike.

A Smarter Way to Test r-PET

The Microex Cast system is engineered specifically for extrusion testing using PET flakes, removing the need for regranulation and allowing trials that better reflect real-world production.

Key features include:

• Low sample requirement: Run tests with as little as 300g of material, minimising waste and expense.
• Direct flake feeding: Forced dosing system enables direct use of r-PET flakes, simulating real production conditions.
• In-line defect detection: Built-in visual system categorises imperfections in real-time, helping to optimise feedstock and fine-tune processes.
• Thermo-regulated calender: Allows greater process flexibility and supports a wide range of testing scenarios.

In-Person Testing at EUR.EX.LAB

UK Extrusion and EUR.EX.MA welcome interested companies to experience the Microex Cast system first-hand. Testing can be carried out in the UK or at the dedicated EUR.EX.LAB facility near Milan, which houses the full EUR.EX.MA range including:

• The Microex Cast
• X-TR 25 single-screw regranulator
• X-TWIN S twin-screw regranulator

Ready to Improve Your r-PET Testing?

Book your demonstration with UK Extrusion and explore how the Microex Cast can support your transition to more sustainable, reliable recycled materials.

The post Case Study: Microex Cast – Simplifying r-PET Quality Testing with EUR.EX.MA first appeared on UK Extrusion.

Overview

Samco Agricultural Manufacturing Ltd is at the forefront of sustainable agriculture, supplying innovative biodegradable mulch films to farmers around the world. As part of their commitment to continuous improvement, Samco recently upgraded one of their COEX blown film lines in partnership with UK Extrusion and Syncro Group.

The goal was clear: improve throughput, enhance film quality, and boost operational reliability, particularly when producing delicate biodegradable films.

The Challenge

The original auxiliary equipment on Samco’s COEX blown film line delivered a line speed of 80 m/min and a throughput of 125 kg/h. While suitable for conventional materials, the system struggled to meet Samco’s increasing production goals and tighter quality tolerances for biodegradable films.

The Solution

Samco worked closely with UK Extrusion and Syncro Group to implement a custom upgrade package, incorporating three advanced Syncro technologies:

• TYPHOON Y2-048 Automatic Air Ring: Designed with a lightweight carbon fibre chamber and a tailor-made lip-set, the air ring provided precise flow control and bubble stability, crucial for biodegradable materials.
• SKYMEX Non-Contact Capacitive Measurement System: This system allowed real-time thickness monitoring without touching the film, helping to maintain consistent 8-micron film thickness with an impressive ±0.4 micron accuracy.
• SYNTROL INFINITY Supervisory System: An intelligent control platform that automates profile adjustment and improves monitoring, reducing manual intervention and enhancing overall process efficiency.

The Result

The Syncro upgrade delivered exceptional results:

• 30% increase in production
• New line speed: 110 m/min
• Increased throughput: 180 kg/h
• Improved film consistency and accuracy

This marks the third time Samco has upgraded with Syncro components, highlighting their long-standing trust in Syncro’s advanced technology and UK Extrusion’s local support.

Ready to Modernise Your Blown Film Line?

Whether you’re working with biodegradable materials or aiming to improve line speed, consistency, and efficiency, UK Extrusion and Syncro can help. Contact us today to discuss your requirements.

The post Case Study: Samco Upgrades Biodegradable Film Production with Syncro Technology first appeared on UK Extrusion.

The Challenge:

• Material: PET – including pellet, bottle flakes, and dusty internal film regrind
• Issues:
  • High energy consumption (0.9 kWh/kg)
  • Agglomeration problems with film regrind
  • Moisture levels around 300ppm
  • Crystalliser required excessive floor space
  • Reduced IV (Intrinsic Viscosity) post-extrusion

The Solution:

UK Extrusion supplied an SMC MWD1000 Microwave Dryer, replacing the existing crystalliser. This cutting-edge system combines crystallisation and drying in a single, compact unit.

Performance Improvements:

• Energy Efficiency: Reduced to 0.70 kWh/kg – a 23% saving
• Productivity:
  • Regrind & bottle flakes drying to ≤ 50ppm moisture
  • Throughput: 1,000 kg/h
  • Mono-screw extrusion output increased by 20%
• IV Retention:
  • Before MWD: 0.59–0.61 dl/g
  • After MWD: 0.68–0.70 dl/g
• Space Saving: Smaller footprint freed up valuable production space
• Process Flexibility: Enabled 100% use of in-house PET film regrind

The Result:

By switching to the SMC microwave dryer, the customer achieved substantial energy savings, improved product quality, and boosted extrusion output—all while reducing their factory footprint.

Looking to improve your PET recycling process?

Contact UK Extrusion today to learn how we can help can boost your output, reduce energy costs, and maximise regrind usage.

The post Case Study: Microwave Dryer Technology Transforms PET Film Recycling first appeared on UK Extrusion.

Aligned with Coveris’ No Waste sustainability strategy and its ReCover mission to keep plastic circular, the recycling facility in Louth, Lincolnshire (UK), employs innovative de-inking technology to transform printed polyethylene (PE) residual waste into high-quality recyclate, known as ReGen.

Water plays an essential role in the de-inking process, and the new treatment plant, supported by an onsite ReCover Lab, achieves greater control over water quality for improved recycling and repelletisation. This advancement leads to cleaner, more consistent, and higher quality ReGen pellets, with significant sustainability and operational benefits for the ReCover Louth plant.

The new ClearFox treatment plant was developed exclusively for the facility through a collaboration with PPU Environmental Technology GMBH and UK Extrusion Ltd. The water treatment follows a three-stage process: pH correction, coagulation, and flocculation, to remove waste material, and supports optimisation of the de-inking process by enabling onsite treatment, improved automation, and more efficient chemical usage.

Significant reduction in water consumption and transport emissions  

The environmental benefits of the new treatment plant are notable, reducing overall water consumption while increasing the volume recycled by 35% versus the previous water treatment installation. The volume of water transported offsite for treatment has been reduced by 70% since the opening of the ReCover Louth recycling facility, dramatically cutting transport emissions. As part of stringent water quality controls, technicians in the ReCover Lab conduct onsite testing, which is further validated by external bodies, with the aim of achieving full ‘discharge to drain’ by Q1 2025, pending approval by the local water authority.

Closing the plastic loop

The ReCover Louth facility is key to supporting Coveris’ sustainability strategy as it processes packaging waste from the group’s own manufacturing operations, its customers, and the wider industry. The waste feedstock is de-inked, recycled, and repelletised into ReGen, and used as UK Plastic Packaging Tax-compliant recycled content in Coveris’ sustainable packaging solutions. By removing ink during recycling, ReCover enables materials that were once downcycled to remain in the packaging supply chain as part of a circular lifecycle.

Mark Dalby, ReCover UK Managing Director, commented: “When we first launched the ReCover de-inking facility, Coveris set a new standard for recycling innovation in the packaging industry and developed a unique integrated set-up for high-quality recycled content in packaging films in the UK and beyond. This upgraded water treatment plant builds upon that foundation, helping us further optimise our processes while enhancing sustainability.

“By treating more water onsite, we’re not only increasing efficiency but also reducing our environmental footprint while improving the quality and consistency of our ReGen recycled resin. No Waste is at the heart of Coveris’ operations and packaging sustainability strategy; this new addition to the ReCover Louth plant is another step forward enhancing our environmental performance”, added Dalby.

In recognition of Coveris’ commitment to sustainability, ReCover Louth, opened in May 2023, received the top award for ‘Environmentally Sustainable Company – Production’ at the FlexoTech Awards in October 2024. Coveris’ ReCover also won the Green Packaging Star Award 2024 in the ‘Environmentally Friendly Production Process’ category, presented by Kompack and the Austrian Research Institute for Chemistry.

Contact Steve Trainor for further information about how UK Extrusion can help you improve your recycling processes at steve.trainor@ukextrusion.com.

The post New waste water treatment system enables recycling plant to make major improvements first appeared on UK Extrusion.

This updated configuration of our MICROEX CAST benchtop cast film machine is specifically designed to enhance industrial process efficiency by testing new formulations on a small scale. By
integrating MDO stretching technology this system unlocks the potential of a wide range of materials, paving the way for cutting-edge solutions in the plastics industry.

Sustainability Meets Cost Efficiency

Polyethylene (PE) is one of the materials that benefits the most from this technology, significantly improving the stiffness, transparency, and barrier properties of the film, making it an effective
substitute for materials like PET or PP. Linear low-density polyethylene (LLDPE) also sees remarkable advantages, enabling the production of thinner films that retain or enhance mechanical performance while reducing material consumption and operational costs.

Advantages and Performance

The adoption of MDO offers several key benefits:

• Enhanced Mechanical Properties: MDO-treated films exhibit greater tensile strength, reduced elongation, and improved dimensional stability.
• Optimised Optical Properties: The orientation process enables higher transparency and better gloss, ideal for aesthetic applications.
• Improved Barrier Performance: The technology enhances resistance to gases, moisture, and external agents, making films suitable for food and industrial packaging.
• Thickness Reduction: MDO allows the production of thinner films without compromising performance, reducing material usage and costs.

Versatile Applications of MICROEX CAST + MDO Technology

This laboratory machine is highly versatile and supports a wide range of applications, including food packaging with high-barrier films for extended preservation, industrial applications requiring durable films for protective layers and insulation, and the development of mono- and multi-layer materials optimized to meet sustainability standards, such as stand-up pouches and recyclable laminates.

Find out More about our laboratory solutions by talking with our experts. Contact us today!

EUR.EX.MA provides an extensive portfolio of complementary products from all Syncro Group companies—Syncro, Plantech-CST, Plasmac, AceLabs, and SBDry. United by the
ambitious #ZEROWASTE project, we aim to reduce post-industrial waste and energy consumption, thus opening and closing the loop of the circular economy.

The post MICROEX CAST + MDO | Benchtop Cast Line with Stretching Technology first appeared on UK Extrusion.

A major customer in the converting industry believed in the advantage of installing an innovative and high-performance laser marking and macro-micro perforation system, like the ones designed and created by SEI LASER, on a TEMAC slitter rewinder machine, and the result has been excellent!

The slitter rewinder model is SRS 861, a compact machine characterized by a shaftless unwinding cart and two rewinding stations, everything on the front side. SRS 861 joints the extremely compact design of a single-side working station, with the possibility to handle big diameters. This machine can work a great number of flexible materials for many different needs: this feature has been highly appreciated not only by this specific customer, but also by other users of TEMAC machines.

These slitters are equipped as standard with a control console with an industrial Panel PC IP65 fanless with 15.6” Touch-Screen. The HMI interface design, based on one of the most powerful SCADA on the market, has been called “PCVISION”: it gathers all the machine’s functions and working parameters with simple, intuitive graphics, contextual help on every touch button, diagnostics offering extensive description and 3D images.

For what external connectivity is concerned, PCVISION allows several possibilities: from web sharing to connection of peripheral devices such as printers, code or RFID readers, images mirroring, additional software installation as MES, ERP, PLM ecc.

All the main hardware devices are linked together on EtherNet backbone, so as to be remotely interrogated or programmed.

The PC VISION interface combined with a real industrial PC makes the machine completely transparent and usable in combination with systems of different origins, as for example marking systems, slitting, perforation, die-cutting and decoration by SEI LASER.

Pioneer of laser technology in graphics and industry, over the years this company has verticalized its offer in textiles, label die-cutting, paper converting, flexible packaging, clothing & footwear (leather goods, denim and technical fabrics), and wood, but the field of laser applications can be further expanded.

Thanks to this integration readiness, the installation of a laser marking system on the SRS 861 slitter rewinder was successfully carried out: in just one day of work, directly at the customer’s site, all tests were carried out smoothly, to the great satisfaction of the technicians of both companies, present on site to ensure efficient and scrupulous work.

Obviously, the customer was also satisfied with the investment, which proved to be profitable and far-sighted, and will allow him to maximize productivity and have a high-quality finished product.

The added value of the TEMAC – SEI LASER cooperation undoubtedly lies in some key factors: on the one hand, the technical and technological predisposition that makes the machines perfect for integrating with each other, and on the other, the attention to the customer, both as taking charge of initial requests without fear of distorting the products “in the catalogue” to meet specific “customisation” needs, and as care of the finished work and after-sales assistance.

In addition, the “green” aspect is held in high regard by both companies. As far as TEMAC is concerned, the slitter rewinders meet the requirements of Industry 4.0 and 5.0, since among the more than 700 variables exchanged between the Industrial PC and the customer’s software there may also be those relating to energy consumption. In the machine configuration with 3 or more motors, moreover, the SRS 861 can also contribute to energy saving, since the running motor instead of causing energy dispersion into the environment in the form of heat (as a common axis managed by a brake would do), acts as an energy generator, energy that is then used by the machine itself.

As far as SEI LASER is concerned, the use of laser technology makes it possible to reduce the waste of raw materials and to optimise resources to obtain the best quality while minimising the environmental impact. Applied to sustainable, renewable and recyclable materials, laser technology makes it possible to obtain an all-round sustainable production process.

To discuss your slitter rewinder requirements please contact Stefano Nestri on 07547114153 or email stefano.nestri@ukextrusion.com

The post SLITTER REWINDERS AND LASER SYSTEMS: CONVERTERS’ PERFECT COMBINATION first appeared on UK Extrusion.

Get in touch for further information. Contact Stefano.Nestri@ukextrusion.com.

The post Case Study: Recycle your scrap with a Plasmac Repelletiser first appeared on UK Extrusion.

To help them stay at the forefront of their industry, Elite Plastics have invested in a bespoke 3 layer co-extrusion blown film line from Italian designer and manufacturer of complete extrusions line for packaging and converting, Bandera. See it in action above! 

Elite Plastics are one of the UK’s leading extruders of polythene, with a reputation for keeping up with the significant advancement and innovation in polymer technologies. Their research and development has enabled them to create ‘recipes’ that enable them to manufacture cutting-edge polythene films for multiple industries.

The Bandera Blown Film line has been developed to utilise at least 30% recycled content into the film recipe, whilst still maintaining the technical characteristics Elite’s customers demand. It features a compact and functional layout providing Elite with maximum flexibility for a variety of applications. It also has a flexo printing facility.

Josh Salmon, Commercial Director at Elite Plastics says “Bandera is among the world leaders in building complete blown film lines, their company started in 1947, and with this heritage comes decades of experience and expertise. They utilise the latest technologies to produce lines that will allow us to drive forward technical innovation in the film market. We asked Bandera to propose a state-of-the-art line for Elite Plastics and Bandera met the brief perfectly.”

It has been a long process for Elite Plastics to get to the point of commissioning this state-of-the-art line. The site had to be prepared and crucially the roof had to be raised to provide the required height. Additionally, Elite has taken the opportunity to install a large Solar PV system on the roofs of both their extrusion halls, which forms part of Elite’s Net Zero Strategy. It means that the film produced on the brand new Bandera line and their other lines will have been made partially utilising solar power, reducing the carbon footprint of their products.

Despite the large amount of work, Josh Salmon is confident that the result will be well worth the investment. “We will be extruding products like shrink films, high-performance films, form fill and seal films, lamination films, and other technical films using LDPE, LLDPE, EVA, MDPE, MLLDPE, etc.” he explains.

The project has been supported in the UK by the team at UK Extrusion who are agents for Bandera, and provide UK-based engineers to support Bandera installations and continued service. A bonus when travel becomes more and more expensive and sometimes unreliable. UK Extrusion is renowned for its relationships with its clients and this particular project has highlighted the effort they devote to each customer.  Josh Salmon describes the relationship between the two companies as “more of a partnership than a customer/supplier relationship.” Speaking about the commissioning he says “This has been fantastic as our engineering team has built the line, which has been a remarkable internal project, with support and communication from Bandera and UK Extrusion when needed at different phases. The engineers are now on-site completing final mechanical checks before we put power to the line and start all the electrical checks. We will then start running tests of the new line. The whole team are very excited to start running wet tests. We expect to be in full production at the beginning shortly.”

Steve Trainor, managing director of UK Extrusion comments “We always look on each project as a partnership with our client, and in this particular instance it could be seen as akin to a marriage. Josh and I have some colourful conversations, but behind the humour are two people who respect one another’s abilities and goals. It has been a pleasure for our team to work with Elite Plastics and we are very excited to see the first film coming off the new line.”

The post Blown Film Line a Success at Elite Plastics first appeared on UK Extrusion.

Emtelle is a worldwide manufacturer of pre-connectorised, blown fibre cable and ducted network solutions. As part of its four point sustainability strategy, Emtelle has a vision to reduce emissions, improve resource sustainability, reduce plastic waste, and be a fair employer and partner.

One of the components they manufacture for their range of solutions is polyethylene Microducta & sheathed Microduct Bundles for fibre optic cables.  In a step to address their desire to reduce plastic waste, Emtelle discussed with UK Extrusion the recycling of scrap tubing & sheathing. They were at that time putting scrap out to a third party for recycling, but could see the benefits of keeping as much of this activity in-house as possible. 

UK Extrusion placed a Plasmac Omega Shredder/Extruder/Pelletiser combination machine on an assessment loan for Emtelle to trial the recycling of plastic waste and assess the results. The Omega was considered a good fit for Emtelle as it is ideal for re-pelletising all forms of their scrap off-line, comprising scrap tubing, sheathing & reels, lumps or bales. It is a highly energy-efficient machine and allowed Emtelle to recycle its in-house plastic waste material, producing near-virgin quality recycled materials that can be introduced back into the extrusion process.

During the evaluation period, UK Extrusion Managing Director Steve Trainor, visited the site frequently to ensure that the machine was performing to the best of its ability and to ensure that Emtelle was utilising all its possibilities. On one such visit, he noticed that the Company had a skip in their yard containing polypropylene reels which were destined for landfill as there was no end use for such material at Emtelle. Steve pointed out that the Omega machine was more than capable of recycling these and by just changing the die on the machine, Emtelle would be able to utilise this material to create a greener, circular process to maximise on resources.

He additionally identified further plastic waste in the form of purged or lump waste from the tubing & sheathing extruders, which he showed could also be recycled by the Omega machine.

In identifying additional opportunities, UK Extrusion enabled Emtelle to make significant impact on reducing its plastic waste output. By re-pelletising what would previously have been considered scrap, Emtelle were able to implement a solution that was useful for business, whilst making a positive step towards reducing their carbon footprint.

The post Plasmac Omega Reduces Plastic Waste for Emtelle first appeared on UK Extrusion.