Retrofit Solutions for Recycling as Virgin Material Prices Increase

Gneuss provides retrofit solutions that enable existing extrusion lines to process both virgin material and recyclates in a stable and controlled manner—without requiring complete system replacement.

Gneuss Retrofit Concepts

Increasing recyclate usage is both an economic necessity and a regulatory requirement. The key challenge lies in ensuring consistent product quality despite fluctuating input materials.

Gneuss retrofit concepts focus on the targeted optimization of extrusion and melt filtration. Combining these process steps enables a Super-Clean recycling approach, producing high-quality polymer melts even from contaminated post-consumer material—reaching virgin-like quality levels in many applications, including food contact.
The extrusion system is based on a specifically engineered screw design that not only ensures efficient melting and homogenization, but also supports intensive degassing and melt decontamination. This allows stable processing of materials with elevated moisture content, volatile contaminants, or low bulk density.
Melt filtration based on Gneuss Rotary technology ensures continuous, process-stable removal of solid contaminants. The fully automatic system operates without process interruption, even under fluctuating input conditions and high recyclate shares.
Extrusion and filtration systems can be implemented either as standalone upgrades or as an integrated solution. System configuration is tailored to specific objectives—such as increasing recyclate throughput, stabilizing product quality, or enabling food-contact compliance.
Due to their compact design, integration into existing lines typically requires minimal modification of the surrounding infrastructure.