Post-Consumer Recycled Material Processing

What we do

As we transition to a circular economy, the efficiency of processing post-consumer recycled material in high quality polymer applications is essential. Filtration is critical in the processing of post-consumer recycled materials by enhancing the quality and usability of recycled materials. To deliver the benefits of filtration, it is necessary to understand how fouled filters can be recovered for reuse. The diversity of contamination streams and contaminant loading in post-consumer recycled streams can pose a challenge for filtration systems. If these elements are not appropriately cleaned, they can result in premature clogging, high pressures upon installation, reduced efficiency of the filter and contaminant bypass into the melt stream. Carolina Filters carefully designs a custom cleaning profile for each customer to include specialized cleaning methods and technologies that target a wide variety of organic and inorganic contaminants found in the PCR stream.

Carolina Filters has successfully assisted many customers with PCR related filtration issues. We were contacted by a manufacturer of a laser melt filters who had a customer seeing decreased on-stream life with their filters. The customer processed parts through high-temperature cleaning cycles without success and were considering filter replacement. Carolina Filters worked with the customer to identify the source of their contamination and utilized targeted chemistries to fully remove the contamination from the fine screens. The screens were able to be returned to the customer’s process and performed like new.

On a separate occasion, a long-time customer of Carolina Filters began to introduce PCR into their melt stream during the manufacture of PET blow molded products. The introduction of the PCR resulted in failing of post-cleaning cleanliness tests at Carolina Filters after multiple processing through traditional cleaning methods. Carolina Filters worked to qualify a new cleaning technology for these filters to increase the efficiency of the cleaning protocol and reduce turnaround and costs associated with additional cleanings. A trial was designed using DEECOM® technology, and the combination of superheated steam and pressure swing cycles resulted in efficient removal of polymer and residual additives and contaminants from the PCR streams that traditional cleaning methods were leaving behind.

Validation of integrity and cleanliness is equal in importance to the actual cleaning process. Carolina Filters offers numerous testing methods to ensure the integrity and cleanliness of filters and parts following the cleaning process.