GNEUSS OMNIboost PET Recycling Systems
GNEUSS OMNIboost plastic recycling systems are advanced recycling lines specifically developed for the recycling of PET and polyester-based plastic waste. The OMNIboost series systems are designed for applications requiring high viscosity and enable PET waste to be converted directly into high-quality recycled raw materials. These systems combine advanced extrusion technology, powerful degassing systems, automatic melt filtration, and polymerization reactor technology to achieve high efficiency and superior quality in plastic recycling.
OMNIboost systems represent one of the most advanced configurations of the GNEUSS OMNI recycling platform and are specifically optimized for the production of rPET with high intrinsic viscosity (IV). With these systems, PET bottles, polyester fibers, thermoform PET waste, and PET film materials can be processed within a single process to produce high-quality pellets or raw materials that can be fed directly into production lines.
OMNIboost technology strengthens the molecular structure of recycled polymers, enabling the production of materials with excellent mechanical properties. For this reason, the system is particularly preferred for bottle-to-bottle PET recycling, polyester fiber recycling, and the production of high-performance packaging materials.
Core Technologies of OMNIboost Systems
GNEUSS OMNIboost recycling systems achieve high performance through the integration of several innovative technologies. The main components of the system include:
3C Rotary Feeder feeding system
MDS extruder technology
RSFgenius automatic melt filtration system
advanced vacuum degassing system
JUMP polyreactor technology
VIS online viscosity measurement system
Through the combined operation of these technologies, plastic waste is fed, melted, degassed, filtered, and the polymer chains are restructured within a single process to produce high-quality plastic pellets.
3C Rotary Feeder Feeding Technology
The 3C Rotary Feeder used in OMNIboost systems ensures efficient feeding of low-density and bulky plastic waste into the extrusion system.
The operating principle of the system is as follows:
Ground plastic waste is transferred to the feeding hopper via a conveyor system
Knives mounted on a rotating disk cut and densify the material
During this process, the material receives energy and enters a pre-heating and degassing stage
The prepared material is automatically transferred into the extrusion system
This technology allows PET fiber waste, BOPET film waste, and other low-density plastic materials to be processed without requiring additional densification equipment.
MDS Extruder Technology
The MDS extruder used in OMNIboost recycling systems is a patented extrusion technology developed by GNEUSS. This extruder features a special design with variable screw and barrel diameters, allowing optimized energy input and degassing performance.
The main characteristics of the MDS extruder include:
variable screw diameter design
high-efficiency degassing performance
low shear polymer processing
suitability for high-viscosity polymers
Before entering the degassing section, the polymer melt is briefly exposed to thermal energy, enabling volatile components to be removed much more efficiently under vacuum conditions.
OMNIboost Capacity and Technical Data
OMNIboost recycling systems are available in various capacity ranges. Depending on the extruder size, system capacity can vary significantly.
Typical PET recycling capacities include:
OMNIboost 70 : 200 kg/hour
OMNIboost 90 : 450 kg/hour
OMNIboost 110 : 650 kg/hour
OMNIboost 130 : 1000 kg/hour
OMNIboost 160 : 1400 kg/hour
OMNIboost 200 : 2000 kg/hour
Approximate machine dimensions:
Height: 4200 - 4700 mm
Extrusion height: 1150 - 1450 mm
Machine width: 6000 - 7400 mm
System length: 11,000 - 17,000 mm
These technical values demonstrate that OMNIboost systems are suitable for both high-capacity industrial recycling facilities and medium-scale recycling lines.
RSFgenius Automatic Melt Filtration System
The RSFgenius rotary filtration system used in OMNIboost recycling systems ensures highly precise filtration of the polymer melt.
Key features of this system include:
automatic backflush cleaning system
no filter replacement required during operation
continuous production capability
high filtration precision
Filter elements used in RSFgenius systems can be reused up to 400 times, and filtration precision can reach below 10 microns.
This high filtration quality ensures that recycled plastic pellets are produced with very high purity.
JUMP Polyreactor Technology
One of the most distinctive components of OMNIboost recycling systems is the JUMP polyreactor system.
The JUMP reactor is based on liquid-phase polycondensation technology used to increase the viscosity of PET melt. Inside the reactor, the polymer melt is spread into a thin film over rotating elements, continuously creating a large surface area. Since this surface is maintained under vacuum, volatile substances can be effectively removed.
With this reactor technology, the intrinsic viscosity (IV) of PET melt can be increased to up to 0.95 dl/g.
JUMP technology offers several advantages:
production of high-IV rPET
alternative to conventional SSP processes
short process time
energy-efficient operation
Thanks to this technology, PET polymer can be directly fed into production lines without requiring additional remelting steps.
Vacuum Degassing Technology
The vacuum system used in OMNIboost recycling systems is designed to remove volatile contaminants from the polymer melt.
The system includes the following equipment:
water ring vacuum pump systems
deep vacuum degassing units
automatic separator systems
Through this technology, the following contaminants can be efficiently removed:
moisture
volatile organic compounds
solvent residues
odor-forming substances
Vacuum degassing technology is particularly critical for post-consumer PET recycling applications.
Online Viscosity Measurement System (VIS)
OMNIboost recycling lines can be equipped with the VIS Online Viscometer for process quality control.
This system provides the following advantages:
real-time measurement of melt viscosity
continuous monitoring of process stability
monitoring of product quality
automatic process optimization
Online viscosity measurement ensures that the molecular structure and mechanical properties of the recycled polymer remain under continuous control.
Advantages of OMNIboost Systems
OMNIboost plastic recycling systems offer several key advantages:
production of high-viscosity rPET
compact plant design
low energy consumption
high production capacity
short processing time
compatibility with a wide range of materials
The system also enables recycled raw materials to be fed directly into production lines by ensuring highly efficient plastic recycling processes.
Application Areas of OMNIboost Recycling Systems
OMNIboost recycling machines are primarily used for the recycling of PET and polyester-based materials.
Main application areas include:
PET bottle recycling
PET film recycling
polyester fiber recycling
thermoform PET recycling
textile polyester recycling
These systems are also widely used in packaging and textile applications that require high intrinsic viscosity rPET production.
