GNEUSS RSFgenius Series Melt Filtration Systems
The GNEUSS RSFgenius series is an advanced automatic melt filtration system developed to remove solid contaminants from polymer melts in plastic extrusion and recycling processes. Based on the patented Rotary Filtration System (RFS) principle, these systems enable continuous production while maintaining constant process pressure. RSFgenius technology offers particularly high performance when processing recycled materials with high contamination levels.
RSFgenius filtration systems are designed in such a way that the extrusion process continues without interruption even during filter changes. This ensures stable process conditions and maintains consistent product quality. The system also provides high filtration precision, low melt loss, and long filter service life, enabling high efficiency in plastic processing operations.
Rotary Filtration System Technology
The RSFgenius series is based on the rotary disc filtration technology developed by GNEUSS. In this system, filter elements are arranged in a circular configuration on a rotating disc. The filter cavities on the disc can be changed in a zone isolated from the melt flow channel, allowing the production line to continue operating.
The operating principle of the system is as follows:
The polymer melt enters the filtration system from the extruder.
The melt is cleaned as it passes through the active filtration surface on the filter disc.
As the filter surface becomes contaminated, the disc rotates to bring a new filter surface into operation.
The used filter elements are automatically cleaned and prepared for reuse.
Thanks to this design, pressure and flow remain stable in the extrusion line, which is a critical advantage for maintaining process stability.
Backflush Cleaning Technology
One of the key technologies used in RSFgenius filtration systems is the high-pressure segmental backflush cleaning system.
In this system, the filter elements are automatically cleaned before re-entering the melt channel. During the cleaning process, a small section of the filter surface is flushed in the reverse direction with high-pressure polymer flow.
Key characteristics of the cleaning process include:
polymer flow pressure of approximately 30 - 80 bar
only about 1% of the filter surface is cleaned at a time
the cleaning process occurs without interrupting production
This technology allows filter elements to be reused many times and significantly reduces operating costs.
Technical Features and Performance Values
The RSFgenius series is available in different models designed for a wide range of extrusion capacities.
Main technical specifications include:
Active filtration area: 55 - 2,800 cm²
Maximum operating pressure: 180 - 350 bar
Processing capacity: 260 - 13,000 kg/hour
Heating system: electric or liquid heating
These technical values show that RSFgenius filtration systems can be used in both medium-scale and high-capacity industrial production lines.
Filtration Precision
RSFgenius filtration systems can achieve extremely high filtration accuracy.
Filtration fineness:
up to 1 micron
This high filtration precision is particularly important for applications such as:
PET recycling
plastic film production
fiber production
engineering plastics processing
Ultra-fine filtration ensures that even the smallest particles in the polymer melt are removed.
Service Life of Filter Elements
The filter elements used in RSFgenius systems can be reused multiple times thanks to the automatic cleaning system.
Typical service life:
100 - 400 cleaning cycles
This significantly reduces operating costs and minimizes the frequency of filter replacement.
Process Stability and Product Quality
One of the most important advantages of RSFgenius filtration systems is their ability to maintain process stability.
Because the active filtration surface remains constant, the following parameters remain stable:
melt pressure
temperature
viscosity
production capacity
This ensures that the final product quality remains consistent at all times.
Additionally, the residence time within the melt filtration system is less than one minute, allowing extremely fast material or color changes.
RSFgenius Design Features
RSFgenius filtration systems have a compact design optimized for modern plastic processing plants.
Key design features include:
fully enclosed filtration system
compact machine design
low energy consumption
easy maintenance and service
Thanks to the enclosed system design, the polymer melt is protected from environmental influences during filtration. This prevents external factors such as oxygen and moisture from affecting polymer quality.
Applications of RSFgenius Systems
RSFgenius filtration systems are widely used across the plastic processing industry.
Main application areas include:
plastic recycling lines
PET bottle recycling
plastic film production
polyester fiber production
polymer compounding
pipe and profile production
These systems provide significant advantages, particularly in recycling applications where raw materials have high contamination levels.
Integration with GNEUSS Extrusion Technologies
RSFgenius filtration systems are typically used together with other GNEUSS technologies, including:
MRS extruder technology
MDS extruder technology
vacuum degassing systems
VIS online viscosity measurement systems
OMNI recycling lines
When combined, these technologies allow extrusion, degassing, and filtration to operate as a fully integrated system in plastic recycling processes.
Advantages of RSFgenius Filtration Technology
The RSFgenius series offers several important advantages in plastic extrusion and recycling processes.
Key advantages include:
fully automatic operation
constant process pressure
uninterrupted production
ultra-fine filtration
low operating costs
high process reliability
These features make RSFgenius technology one of the most advanced filtration solutions available in the plastic extrusion industry.
Importance of RSFgenius Technology in Plastic Recycling
In modern plastic recycling facilities, raw material quality often varies significantly. The RSFgenius filtration system enables even highly contaminated plastic waste to be converted into high-quality polymer raw materials.
With this technology:
the quality of recycled plastics improves
process stability is maintained
energy and operating costs are reduced
sustainable plastic production becomes possible
Today, RSFgenius technology is widely regarded as one of the most advanced melt filtration systems used in plastic recycling and extrusion lines.
