Good practices in CP: 1. Optimization of plastic processing in the thermoforming process - closed raw material cycle (FAMED Żywiec)

Cost (implementation of good practice): Medium

Description of the problem: 

 

Thermoforming is a technological process in which products with specific shapes are formed from flat foils or ABS plates, preheated to a specific temperature characteristic of a given material. The resulting elements are formed by dropping the coat formed from the heated plastic, supported by a stream of air, into a mould, for example, corresponding to the shape of the furniture element. This way, a variety of elements are created, e.g. for furniture and equipment for medical purposes. The remaining parts of the ABS plate constitute a problem, because the coat (ABS plate) dropped into the mould has a rectangular shape, and after cutting out the desired element, pieces of these plates are left.

 

 

Production of granulate from the cut pieces of ABS plates
After thermoforming and removal of the protective film, the pieces of ABS plates are ground. A mill grinds them into granulate, which is used as a raw material for the injection moulding machine to make further manufactured elements. The plastic processing process operated in FAMED is an example of a process with a minimum amount of waste, in which the raw material is in a closed cycle (pieces of ABS plates are reused in the production process). Products made of secondary granules may be slightly less resistant to sunlight, but this does not prevent the production of internal components (e.g. connectors, sleeves, etc.).

 

 

Stages of a closed cycle in the process described above: thermoforming of ABS plates (picture in the upper left corner), cutting of moulded parts, grinding of ABS pieces, drying of granules, using granules for injection moulding
source: FAMED Żywiec sp. z o.o.