GNEUSS OMNImax Plastic Recycling Systems
GNEUSS OMNImax plastic recycling systems are advanced recycling lines designed to ensure high-purity recycling of industrial and post-consumer plastic waste. OMNImax recycling technology converts plastic waste into high-quality pelletized raw materials within a single process by integrating feeding, extrusion, degassing, melt filtration, and quality control systems.
OMNImax systems are specifically developed for demanding applications such as processing highly contaminated post-consumer plastic waste, fiber and textile recycling, PET bottle and packaging recycling, as well as film and thermoform plastic recycling. These systems use high-performance extrusion technology to
effectively remove contaminants, moisture, and volatile compounds from the polymer melt.
OMNImax recycling lines are compact and energy-efficient systems developed to provide sustainable production and highly efficient raw material recovery in modern recycling facilities. These systems are also suitable for closed-loop recycling applications and can achieve the cleanliness levels required for the production of food-contact compliant plastics.
Core Technologies of OMNImax Recycling Systems
OMNImax plastic recycling systems achieve high performance through the integration of several patented technologies developed by Gneuss. The main components of the system include:
3C Rotary Feeder feeding system
MRS or MRS pure extrusion technology
RSFgenius automatic melt filtration system
advanced vacuum degassing system
VIS online viscosity measurement system
Through the combined operation of these technologies, plastic waste is cleaned, degassed, filtered, and homogenized in a single extrusion step before being converted into high-quality plastic pellets.
3C Rotary Feeder Feeding System
The 3C Rotary Feeder used in OMNImax systems ensures stable feeding of low-density plastic waste into the extrusion system. This technology offers significant advantages particularly when processing plastic film, fiber, and lightweight plastic waste.
The operating principle of the system is as follows:
Ground plastic waste is transferred to the feeding hopper via a conveyor.
Knives mounted on a rotating disk cut and densify the material.
During this process, energy is transferred to the material and pre-heating begins.
The prepared material is automatically fed into the extrusion system.
Thanks to this pre-processing step, plastic waste with low bulk density can be introduced into the extrusion process without requiring additional densification equipment.
MRS Extruder Technology
The most critical component of OMNImax recycling lines is the MRS (Multi Rotation System) extruder technology. This extruder combines the principle of a conventional single-screw extruder with a multi-screw degassing section.
The key features of the MRS extruder include:
multiple satellite screws operating together with the main screw
a very large melt surface area
high-efficiency degassing under vacuum
polymer processing with minimal thermal stress
The satellite screws located in the Multi Rotation Section continuously renew the polymer melt and create an extremely large surface area. This allows moisture and volatile substances within the melt to be removed much more effectively.
OMNImax Capacity and Technical Data
The capacity range of the MRS extruders used in OMNImax systems varies depending on the type of polymer being processed.
Typical extrusion capacities include:
PET: 35 - 2000 kg/hour
PP + PE: 25 - 1400 kg/hour
PA: 28 - 2000 kg/hour
PS: 30 - 1600 kg/hour
Extruder technical specifications:
Screw diameter: 35 - 160 mm
Maximum screw speed: 90 - 220 rpm
Motor power: 25 - 540 kW
Depending on the extruder size used in OMNImax systems, production capacities can exceed 2000 kg/hour, starting from approximately 200 kg/hour.
RSFgenius Automatic Melt Filtration System
The RSFgenius rotary filtration system used in OMNImax 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
The filter elements used in the system can be reused up to 400 times, and filtration precision can reach below 10 microns.
Thanks to this high filtration efficiency, recycled plastic pellets can be produced with very high purity.
Vacuum Degassing Technology
The vacuum system used in OMNImax recycling systems is designed to remove volatile contaminants from the polymer melt.
The vacuum technology used in the system includes:
water ring vacuum pump systems
high-vacuum degassing units
automatic separator systems
Through the vacuum system, the following contaminants can be efficiently removed:
moisture
volatile organic compounds
oil and solvent residues
odor-forming substances
This technology is particularly critical for post-consumer plastic recycling and for producing plastics suitable for food-contact applications.
Online Viscosity Measurement System (VIS)
OMNImax recycling lines can optionally be equipped with the VIS Online Viscometer.
This system provides several advantages:
real-time measurement of melt viscosity
continuous monitoring of process stability
monitoring of product quality
automatic process optimization
Through online viscosity measurement, the molecular structure and mechanical properties of the recycled polymer can be continuously monitored.
Advantages of OMNImax Systems
OMNImax plastic recycling systems offer several significant advantages:
compact plant design
low energy consumption
high production capacity
compatibility with a wide range of polymers
high-purity pellet production
low operating costs
The system can also remove contaminants from the polymer melt within a single process, enabling the production of high-quality recycled raw materials.
Application Areas of OMNImax Recycling Systems
OMNImax recycling machines are suitable for a wide range of applications.
Typical application areas include:
PET bottle recycling
plastic packaging recycling
plastic film recycling
thermoform plastic recycling
textile and polyester fiber recycling
injection molded plastic recycling
HDPE cap recycling
PP and PS packaging recycling
OMNImax technology can also be used for plastic recycling processes that meet food-contact quality standards.
High-Performance Plastic Recycling with OMNImax
GNEUSS OMNImax recycling systems represent a modern plant concept developed for converting plastic waste into high-quality raw materials.
Thanks to advanced extrusion technology, powerful degassing systems, and high-precision filtration systems, OMNImax recycling lines provide high performance and reliability for the plastic recycling industry.
These systems are particularly preferred for applications such as:
food packaging recycling
textile recycling
high-purity rPET production
industrial plastic recycling
