Coperion has enabled Benin-based blown film manufacturer Asahel Benin Sarl. to produce sustainable, bio-based plastic films in the future by delivering a complete compounding system and sharing the corresponding process engineering expertise. The system includes a ZSK 26 Mc18 twin screw extruder, four highly accurate feeders from Coperion K-Tron, as well as a water bath, an air wipe and a strand pelletizer from Coperion Pelletizing Technology. Before plastic bags and packaging were banned in Benin in July of 2018, this west African manufacturer had made its plastic films using polyethylene (PE). The new law forced the company to completely convert its production. Following a successful test and training phase at Coperion’s Stuttgart test lab, Asahel Benin Sarl. will produce biodegradable compounds in its home country with the aid of the ZSK twin screw extruder, and will then further process these on its existing blown film machinery into biodegradable bags and packaging materials.
Importation, production, sale, and possession of petroleum-based plastic bags and packaging has been forbidden in Benin since 2018. Until then, Asahel Benin Sarl. had used both new PE compounds as well as recyclate for manufacturing its films that were then used predominantly in household products and in shopping bags for supermarkets.
Intensive tests at Stuttgart test lab
When the new law took effect, the blown film manufacturer had to radically alter its production. Asahel Benin Sarl. turned to the compounding experts at Coperion. From this first contact, a cooperative partnership quickly arose, as did a new corporate strategy thereafter. Asahel Benin Sarl. ordered a laboratory-scale compounding system to develop a biologically degradable compound formulation that could be used in existing blown film manufacturing facilities. The lab-scale system includes a ZSK 26 Mc18 twin screw extruder, four highly accurate powder, pellet, and liquid feeders, as well as a water bath, an air wipe and a strand pelletizer type SP 50. Before the complete system could be delivered to Benin and put into service, it was assembled and tested intensively at Coperion’s Stuttgart location in the test lab.
Sharing process engineering expertise
Throughout the entire project, Asahel Benin Sarl. could fall back on Coperion’s comprehensive, process engineering expertise, for both the mastery of the entire system’s complexity as well of as the seamless interaction of its components, and in particular relating to the twin screw extruder’s configuration. Formulations with starch content, for example, represent a particular challenge for configuring the twin screws, as the melting zone in the extrusion process must both melt polymers and plastify non-meltable starch while adding liquid. Moreover, David Romaric Tinkou, Development Leader of Asahel Benin Sarl., received comprehensive training on the compounding machine’s operation. Thus began the development of a formulation for the necessary biopolymer.
Flexible set up
Coperion’s experts designed the compounding system for Asahel Benin Sarl. very flexibly in order to enable maximum freedom in developing a suitable formulation. In so doing, the system can allow materials to be added from many different components as well as intensive melt devolatilization. Following the die head with nozzle comes a water bath for strand cooling, dewatering of the strand surfaces using an air wipe, and a strand pelletizer.
David Romaric Tinkou is very satisfied with how the project went: “It was clear quite quickly that we needed a new business strategy to keep operating our blown film plants here in Benin. I’m very happy that with Coperion, I encountered experienced experts in the field of biodegradable compounds. Coperion delivered not only the necessary technology, but also shared the necessary process engineering expertise with me so that we can manufacture biodegradable compounds ourselves now in Benin.”
Peter von Hoffmann, General Manager Business Unit Engineering Plastics & Special Applications at Coperion, explained: “We’re thrilled that we could support Asahel Benin Sarl. in switching over their production in order to accomplish it more sustainably. Biodegradable compounds from renewable raw materials unite high production-technical demands with environmental sustainability. Particularly for manufacturers of short-lived household, industrial and agricultural products, these compounds represent a long-term, sustainable alternative to petroleum-based raw materials such as PE. Typical areas of application include single-use flatware, trash bags and trash can liners, food packaging, shopping bags, drinking straws, and agricultural films.”
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Twin screw pump
Cooperation between Gea and Itt Bornemann
The pump experts from Gea and Itt Bornemann are now working together to manufacture and market a twin screw pump for the food, beverage and pharmaceutical industries. While Gea has so far concentrated primarily on hygienic centrifugal pumps, the cooperation now means that a joint model of a positive displacement pump is ready for introduction: Gea Hilge Novatwin. The Gea Hilge Novatwin is a flexible twin screw pump based on the proven Bornemann design that meets the highest hygienic requirements for gentle product handling and clean-in-place (CIP) with just one pump. The new Gea Hilge Novatwin will be available in 6 sizes and will be part of the Gea Varipump line, which stands for pumps with a high degree of flexibility for optimum adaptation to individual customer requirements.
Consistent expansion of hygienic pump portfolio
The addition of this future-oriented pump type to the portfolio in addition to the established rotary lobe pump Gea Hilge Novalobe will significantly strengthen Gea’s position in the field of positive displacement pumps. Gea will thus be in an even better position to cover the various customer requirements with the ideal pump solution from its own broad product portfolio.
Pump and clean with one pump
Twin screw pumps are equipped with two screws, which intermesh without contact and together with the pump housing form a closed chamber. The screws rotate and thus move the medium along the screw axis from the suction to the discharge side.
Like positive displacement pumps in general, twin screw pumps stand for the gentle conveyance of chunky, shear-sensitive and abrasive media. They offer exceptionally high flexibility for pumping liquids of various viscosities.
“The special feature of the twin screw pump is its dual function, because twin screw pumps can not only pump the actual product but can also function as a CIP pump at the same time, as they can operate at very high speeds. This saves the use of an additional CIP pump compared to alternative solutions,” explains Product Manager Ulla Främke from Gea.
With Gea and Bornemann two strong partners work together
“This cooperation with Bornemann is a real win-win situation for both partners,” says Bastian Tolle, head of product management at the Gea Flow Components business unit. “The twin screw pumps we see in the market today are mostly derived from Bornemann’s original development. The expertise is impressive, we can learn a lot from such a partner and from the experience gained over decades in the application of this special positive displacement pump”.
“We will benefit from Gea’s strong distribution network”, adds Bornemann’s Managing Director Markus
Schwarte. “Gea has a broad customer base, a large network and an excellent reputation among decision-makers, particularly in the food sector and in local markets such as the USA. We want to benefit from the synergy between the leading technology and the first-class global network in the food industry”.
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Processing and Packaging Technology
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