Double Filtration in Plastics Recycling: more than a trend

In the face of growing environmental concerns and regulatory pressures, the plastics industry is undergoing a significant transformation. Central to this change is the adoption of more advanced recycling technologies, particularly double filtration systems. As the demand for high-quality recycled plastics intensifies, double filtration is emerging as a critical process that ensures the purity and consistency of recycled materials, making them suitable for a wider range of applications.

The global plastic waste crisis has reached alarming levels, with millions of tons of plastic waste generated annually. Much of this waste ends up in landfills or the environment, where it can take centuries to decompose. Recycling offers a solution, but traditional recycling processes often struggle to produce materials of sufficient quality for reuse in high-value applications. Contaminants such as dirt, oils, and non-plastic materials can compromise the integrity of recycled plastics, limiting their use and market value.

The increasing demand for high-quality recycled plastics, driven by both consumer preferences and regulatory mandates, is leading to broader adoption of double filtration systems in recycling facilities. Companies across the plastics value chain are investing in advanced recycling technologies to enhance the quality of their output and to stay competitive in a rapidly evolving market.

For example, in Europe, where stringent regulations like the European Union's Single-Use Plastics Directive are driving the need for more sustainable plastic solutions, double filtration is becoming a standard practice in many recycling plants. In the United States, similar trends are emerging as states and municipalities enact laws aimed at reducing plastic waste and increasing recycling rates.

In response to these challenges, the industry is increasingly turning to double filtration techniques. This process involves passing plastic materials through two successive filtration stages during recycling, significantly improving the purity and quality of the end product.

This second filtration stage employs a finer filter or an additional specialized filtration system designed to remove even smaller particles and contaminants that may have passed through the first filter. The result is a much purer, higher-quality recycled plastic that can meet the stringent requirements of various industries, including automotive, packaging, and consumer goods.

Despite its advantages, double filtration is not without challenges. The process requires significant investment in equipment and technology, which can be a barrier for smaller recycling operations. Additionally, the increased complexity of the recycling process can lead to higher operational costs.

However, FIMIC has a proven double filtration technology that allows to process heavily contaminated plastic waste streams, with only one machine and two filtration steps: ERA melt filter.

With the ERA filter, some very contaminated material streams can be effectively processed, bypassing the need to install two separate melt filters and a melt pump between them, or two separate extruders. Recyclers not only avoid a higher investment but also a longer residence time of the melt in the different parts of the line which could take to degradation issues caused by prolonged friction.

It is in fact proven that processing plastic waste at lower temperatures, lower pressure levels and shorter residence times leads to superior quality of the final product. FIMIC is specifically concentrating to reach such levels with post-consumer material streams, by keeping an eye on low operational costs, which is one of the many advantages of FIMIC range of products.

By placing a first screen and a second finer screen in the second filtration chamber, recyclers can obtain a pre-filtration in the first scraping chamber of the ERA Filter and discharge the contamination from the first discharge valve. The same can be done with the contamination left on the second screen, by discharging it from a second discharge valve (independent from the first one and placed at the bottom of the melt filter). Being the two discharge valves independent, the one on the second chamber works at a slower pace and will discharge much less material compared to the first one.

This new FIMIC technology allows to process heavily contaminated plastic waste streams, with only one machine and two filtration steps, by using a much cheaper filtering screen to filter out the coarser (and usually the most dangerous) impurities to then proceed to a finer filtration screen (i.e. the most expensive one).

FIMIC’s Melt Filter ERA represents a significant advancement in plastics recycling technology, offering a solution to some of the industry’s most pressing challenges. With its automatic operation, self-cleaning system, and ability to handle high contamination levels, the ERA melt filter is setting new standards for efficiency, quality, and versatility in the recycling process. As the demand for high-quality recycled plastics continues to grow, the ERA is poised to play a crucial role in the industry’s efforts to achieve sustainability and reduce plastic waste.