Plastics Recycling

Multi-Layer Film Recycling

Closed-Loop Solution for Recycling of Multi-Layer Film Production Waste

Recycling multi-layer film has long posed a challenge since such films can only be reclaimed in very complicated ways and not without residues. Coperion has developed a closed-loop approach solution in which up to 100 percent of multi-layer film production waste can be re-processed and fed back into the production process in a closed-loop.

For this process, multilayer film waste is pneumatically conveyed and fed into the ZSK extruder via high-accuracy Coperion K-Tron feeders. Within the ZSK twin screw extruder, it is intensively dispersed and degassed. Subsequently, the high-quality melt can be fed back into the multilayer film production process.

Advantages of Coperion’s Closed Loop Solution for Multi-Layer Film Recycling

  • Up to 100 percent of multi-layer film production waste can be re-processed and fed back into the production process
  • High-accuracy feeding from Coperion K-Tron
  • First-class homogenization and dispersion in the co-rotating ZSK Mc18 twin screw extruder
  • Intensive devolatilization within the ZSK extruder for consistently highest end product quality

The Process: Closed-Loop Using the Most Advanced Technologies

Coperion, Jochen Schofer

Sustainability is becoming more and more important. We’re proud that, with our visionary technological solutions, we can contribute to a promising, forward-looking closed-loop approach.

Jochen Schofer , Business Segment Manager, Recycling & Direct Extrusion at Coperion

Multi-layer film waste resulting during the production process is shredded as a first step before it is fed into the ZSK extruder via pneumatic conveying and high-accuracy Coperion K-Tron feeders.

There, the material is homogenized and devolatilized with very high intensity in the co-rotating ZSK Mc¹⁸ twin screw extruder. Within the extruder, dispersion and devolatilization performance are crucial to end product quality – with gentle product handling and very good mixing behavior even at very high throughput rates, thus achieving consistently high product quality.

Following homogenization in the ZSK extruder, in Coperion’s closed-loop concept, the recycled material is added back into the multi-layer film production process; with no quality loss and the proportion of added recyclate is very high. Multi-layer film manufacturing thus takes place sustainably, highly efficiently, and resource-friendly with the aid of advanced technologies.

Video: Coperion Multi-Layer Film Recycling

Comprehensive product range

Coperion ZSK twin screw extruder

ZSK Twin Scew Extruders

ZSK Mc18 twin screw extruders are at the heart of Coperion's multi-layer film recycling systems. With their intensive homogenization and high devolatilization performance they enable that up to 100 percent of multi-layer film production waste can be re-processed and fed back into the production process.

ZSK Mc¹⁸ Twin Screw Extruder
Coperion's ZS-B MEGAfeed Side Feeder

ZS-B MEGAfeed Side Feeder

Using Coperion’s innovative ZS-B MEGAfeed side feeder, plastic recyclate with bulk densities starting as low as 20 kg/m³, long considered intake-limited and thus not worth recycling, can be reliably fed in large quantities into the ZSK twin screw extruder and be concurrently recycled and compounded.


Feeding Equipment

Coperion K-Tron feeders are ideal for high-accuracy feeding of multi-layer film production waste as well as additives into the ZSK extruder. The wide range of products available includes twin screw feeders, single screw feeders, bulk solids pumps, vibratory feeders, weigh belt feeders as well as other types in a variety of sizes and configurations.

Coperion service technician


From the basic inspection to the full service: We offer a comprehensive range of services tailored to your individual needs to maximize your machine and system availability.

Wide range of services


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