Advanced fiber-to-fiber recycling

The Yarns is characterized by very good UV properties are achieved by addition of a tailor-made masterbatch during the extrusion process. The additive is physically-mechanically bonded to the polymer and is therefore inherent.

Having performed multiple exposure tests according to PV1303 (based on DIN 75202/ISO 105B06 with an irradiance of 420 nm, 1.2W/m²) results clearly show that the new UV-stabilized PET multifilament yarns, after the same exposure time, have 120% more residual strength than the standard polyester high-strength multifilament yarn without the UV stabilizer. With black-colored multifilament yarn, the residual strength increases by a further 20%.

The weathering simulation tests according to DIN/EN ISO 4892 (Artificial Irradiation or Weathering in Equipment - Xenon Arc Lamps - Methods of exposure to laboratory light sources - Xenon-arc lamps) make the differences even clearer: 60% higher residual strength compared to non UV-stabilized PET yarn.

The properties of the new functional high-performance multifilament yarns are clearly superior to the current UV-stabilized filament yarns. Strengths of 60 cN/tex at an elongation at break of 20.0% and free shrinkage values (180°C; 15min) of 1.3% are achieved, making it possible to manufacture textiles with special properties. In addition, individual customer demands can be tailor-made.

Due to the 2-stage manufacturing process, the properties such as shrinkage, specific strength/stretch are extremely constant.

Thanks to its unique molecular structure, 710UV shows significantly lower strength loss than conventional UV-stabilized polyester yarns.

In contrast to topically applied UV treatments, 710UV PET has an inherent protection that does not wash off or degrade over time.

These new PET high-strength filament yarns can be used, for example, in textile architecture, tents, silos, tarpaulins, aerospace, automotive, or outdoor/indoor sun protection.

The new yarn family will be available in titers from 76 dtex up to 6600 dtex and, if required, will also be available with S or Z twist from 60-300 twists/min. Polyester is known for its tendency to absorb moisture, which can degrade its molecules during extrusion and weaken the polymer. The MRS multi-rotation extruder by Gneuss Kunststofftechnik GmbH, Bad Oeynhausen/Germany, removes moisture during the process and preserves the properties of the polymer, providing an efficient solution to this challenge. Reintegrating recycled PET fibers into extruders often becomes complicated due to the fibers’ low "bulk density" and residual moisture and spin finish oils.

During the exhibiton, Gneuss presents the Omnimax recycling system, a robust, integrated solution that efficiently processes waste fibers. Omnimax brings together several Gneuss products and technologies to form a system tailored to specific recycling requirements, including a 3C rotary feeder, a finely tuned vacuum system, an improved MRS extruder, an automated RSFgenius melt filtration system and an online VIS viscometer.

The Omnimax recycling line is highly compact, reducing the required operational space and lowering energy consumption massively. Its design allows for integration into existing production setups and direct adaptation to a fiber production line, eliminating the need for intermediate pelletizing steps. This efficient operation not only decreases electricity and gas usage but significantly shrinks the CO2 footprint of the recycling process.

MRS extrusion process and Rotary Filtration Systems are appreciated worldwide for their effectiveness in contamination removal, ensuring that recycled materials adhere to stringent quality standards. The brief material residence time in the system preserves the chemical properties of the recycled materials, making them nearly identical to virgin materials.

With its innovative Omnimax system, Gneuss has created a compact solution for direct fiber recycling that can be combined with existing fiber systems, thus considerably saving on labor and energy costs.