A €5.5 million investment programme initiated by Netherlands-based R&D consulting and sustainable polymers producer SenbisPolymer Innovations through its subsidiary SPIC Facilities B.V. in 2020 has reached an important milestone, the companies have announced.
A versatile new pilot plant for multifilament yarns and monofilaments has now been commissioned in the Chemport Europe Region that aims to advance the development of sustainable plastics, yarns and fibres. The scale - up to 50 kg/h is unprecedented in Europe, said Senbis, as is the range of different polymers and processes that can be trialled.
The plant was custom made for SPIC - an acronym for Sustainable Polymer Innovation Cluster - by Fibre Extrusion Technology Limited (FET), a bespoke extrusion equipment supplier in Leeds, UK and machine manufacturer KraussMaffei, in Munich, Germany. It is fed with two extrusion systems: a twin screw extruder and a bico extruder. The twin screw extruder, supplied by KraussMaffei has a capacity of 50 kg/h and can be used in combination with a water bath and cutter for compounding. The bico extruder system consists of a small-sized extruder with an output of 1-10 kg/h, and a larger extruder with a capacity of 4-40 kg/h.
The flexibility of the set-up is apparent from the fact that one of these may be used as a mono extruder; or both in a bico setup; or both combined, thus enabling a throughput ranging from 1 to 50 kg/h.
Both extruders of the bico machine, as well as the twin screw extruder, are flushed with nitrogen, a prerequisite for the processing of moisture-sensitive polymers like biopolymers. The maximum temperature of the twin screw extruder is 420 °C, and the maximum temperature of the bico extruder is 450°C, which means that almost any polymer can be processed, including high-temperature polymers such as PEEK and PEI.
The pilot plant can be used for meaningful research trials as well as small production runs for application field tests, including:
1. the compounding of polymers (with the option of adding additives such as plasticisers or natural fibres);
2. the compounding and filtration of recycled polymers;
3. the production of drawn monofilaments;
4. the production of multi filament yarns, including textile yarns;
5. the production of bicomponent yarns.
Since its founding in 2017, Senbis has focussed on the development of a range of proprietary products based on sustainable polymers in sectors varying from agriculture and the marine industry to sports. The company has sought to create biodegradable alternatives for products that have a high likelihood of ending up in the environment and becoming a source of pollution. Given sufficient market demand and a profitable business case, Senbis will invest in the development of a sustainable alternative. Previous products range from compostable horticultural twine and a biodegradable trimmer line to biodegradable and recyclable artificial turf. These products have been sold since 2021 by Senbis Sustainable Products B.V.
The new equipment will enable Senbis now to expand its scope and look into more challenging applications, such as marine-degradable or in-soil biodegradable yarns and filaments for use in dolly rope and mussel socks.