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Plastic Distillation

Plastic pollution is one of the biggest climate-related problems mankind has. So what are your options? A bioplastic machine can help create an alternative to traditional plastics. Bioplastics, differently from regular plastics, don’t cause environmental contamination. Also, they don’t contain harmful ingredients and additives. Even with these benefits, the annual production of bioplastics is still less than one percent of all plastic making. However, the market is witnessing steady growth due to a rise in demand.

Bioplastics

When he was in Haiti in 1493, Christopher Columbus noticed that the natives were bouncing on rubber balls made from the milky sap of Hevea brasiliensis, also known as a rubber tree native to South America. The milky sap was nothing but latex, the source material for natural rubber. Latex processing technology includes equipment for coagulation techniques and rollers for natural latex and a sequence of mixers, pumps, and sieves for synthetic latex.

Latex

Also known as color concentrates for plastics, masterbatches are plastic granules that contain additives for coloring plastics. Their major purpose is to bring vibrance and improve the final product's appearance. In the process of making them, masterbatch production equipment is used to combine two major constituents—colorants and polymer-specific carriers.

Masterbatches

All plastics are polymers, but not all polymers are plastics. Polymer production is a multi-step process that transforms raw materials into products that we use in our day-to-day life with the help of polymer process equipment such as extruders, calenders and injection molding machines.

Polymers

The ubiquitous plastic shopping bag was first designed as a reusable carrier. Its inventor, Sten Gustaf Thulin, will have been appalled to see his creation turn into a single-use object. But this disposable tendency is common to all plastic materials, from screw taps to milk carton lining. With plastic recycling equipment, however, plastic waste can be reprocessed and given a second lease of life.

Recycled plastic

Despite only one letter difference, silicon and silicone are two different things. While silicon is the 14th chemical element on the periodic table, silicone is a synthetic material that, among other chemical elements, contains silicon. Although commonly observed as plastic, technically silicone is rubber. Among others, silicone processing equipment mainly involves several high-temperature machines, mixers and molds.

Silicone

As traced back to the first half of the 19th century, attempts at synthetic rubber production were simply to reproduce the original material due to the rubber shortage following World War II. Synthetic rubber production processes differentiate between producing the rubber, which can be done via solution polymerization and emulsion polymerization and creating the final product with the help of techniques such as molding and vulcanization.

Synthetic rubber

Nut oil

Fish oil was a folk remedy long before scientists identified the nutritional value of essential fatty acids. But Omega 3 processing has come a long way since the days of raw fish parts fermenting in a barrel. In fact, new supplement formulations of polyunsaturated fatty acids (PUFAs) may not use fish at all.

Omega 3 oil

The rapeseed flower evolved high concentrations of substances that are anti-nutritive at best and toxic at worst. But new varieties developed in the 1970s lowered the content of glucosinolates and erucic acids. From then, the use of oilseed rape spread to several applications, from edible oil to biofuel to animal feed. Rapeseed oil processing technology has thus become foundational to industries spanning food production, energy, cosmetics, and pharmaceuticals.

Rapeseed oil

Everything tastes like porridge, the saying goes. That may be an exaggeration, but in theory, reaction flavors could make everything taste the same. Thankfully, flavorists and chemists in the flavor industry are more inventive than that, and colorful process flavors treat our taste buds to a broad palette of sensations, flavors and aromas.

Reaction flavors

Can process temperature sensitive high boiling products

Can handle viscous and fouling products

Configuration based on customer's requirement is possible

Short Path Distillers

Wiped film distillers

Chemical

Food

Pharmaceutical

Industrial Distillation Equipment

Industrial distillation equipment is used in the process of separating different constituents of a liquid mixture. Considerations for choosing suitable distillation systems include the boiling points of the components, heat sensitivity of the product of interest, pressure requirements during the process, and the scale of production. Distillation is used for concentrating extracts such as herbal extracts, flavors, and aromas in the food industry. In the pharmaceutical industry, distillation is used in the production of active ingredients and in the chemical industry for the purification of chemical products.

Distillation

Find industrial distillation equipment to set up your production line and connect directly with world-leading machine and equipment manufacturers.

Distillation &ndash; Making.com

Industrial Distillation Equipment - Making.com

Biopharmaceuticals are drugs in which the active substance is manufactured or extracted from biological origin materials. They are usually produced in bioreactors by plant cells, microbial cells, yeast cultures, or mammalian cells. Also known as biomanufacturing, they are used to either treat or diagnose and prevent a patient’s medical condition or disease. Biopharmaceuticals are typically complex macromolecules administered by injection or infusions, and examples include vaccines, serums, and insulin.

Biopharmaceuticals

Cannabinoids are natural compounds obtained from the Cannabis sativa plant. Delta-9-tetrahydrocannabinol or THC is a psychotropic substance. Cannabidiol, or CBD, is non-psychotropic and often used for nutraceutical purposes. Cannabinoid equipment extracts THC and CBD from the plant and prepares the substance for formulations that treat pain, nausea, anxiety, and inflammations. Cannabinoids are processed in various forms, including creams, capsules, and oils.

Cannabinoids

Due to their potential hazardous nature, chemicals are classified for proper identification and safety during production. Chemical classification depends on their properties, structures and functions. In the chemical industry, you can regard them as basic chemicals such as acids, chemical products to produce plastic materials and finished chemicals for use in cosmetology. As a manufacturer or engineer, you want to know their reactivity when using chemical processing equipment.

Chemicals

Essential oils are known as the liquid gems of nature. The sweet-smelling essences impact not just our senses but also our biochemical and cellular make-up. Besides aromatherapy, the products of an essential oil extraction system found applications in pharmaceuticals and foods.

Essential oil

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

Pharmaceutical developments walk side by side with health advances to provide new medicines, treatments, and therapies that have increased life quality and extended life expectancy by years. Pharmaceutical manufacturing equipment helps deliver products to a great deal of the population, but there’s a significant share that doesn’t benefit from them yet. Over 2 billion people cannot get the medicines they need, according to the United Nations Industrial Development Organization, and local production might be a way to provide for these people.

Pharmaceuticals

Ancient civilizations discovered that plant extracts were useful for the treatment of pathologies. The origin of plant extraction cannot be specifically verified, but we can infer that the earliest attempts at plant extraction were more intuitive than scientific. Today, the extraction of compounds is a precise process with plant extraction systems complimenting traditional knowledge.

Plant extracts

Can it be said that we live in the Plastic age? Basically, yes. From pillows over toothbrushes, and packaging to utensils, plastic is a widely used material in our day-to-day lives. But what is it? Plastics are synthetic or semi-synthetic materials built of polymers that are easily shaped into various structures with the help of plastic processing equipment such as extruders and molders.

Plastics

Process

R&amp;D

Continuous

Purification is the removal of contaminating substances and by-products to increase the level of purity of the desired substance. Considerations for choosing a suitable purification system in the industry, include the physical state of the mixture, the desired product, required level of purity, the type of mixture, heat sensitivity of the product, number of purification steps needed, and the production volume. Industrial purification systems are used for the production of pure water in the food pharmaceutical and biotech industries.

Purification

Industrial separation equipment encapsulates the separation process which is to separate components of a liquid mixture, for recovering dissolved solids from liquids. The choice of a suitable technology depends on the identification of the key physical or chemical property, such as size, mass, density, or boiling point, which sets the product of interest apart from the rest of the components. Separation technology is widely used in the pharmaceutical and chemical industries for the isolation of active ingredients and high-purity chemicals. As well as in waste management and recycling industries.

Separation

liquid

Pilot multi-stage distiller combines short path and wiped film distillation methods to helo you achieve the quality of your product.

If generating an scalable data and bring in results with small sample quantities of high-boiling, heat sensitive and highly viscous products using a short

Pilot multi-stage distiller &ndash; Making.com

We open production technology to everyone

Making.com

Koala bears diet exclusively on eucalyptus leaves. But the large concentration of cineole in the tree keeps most other predators at bay. Humans, though, discovered ways to extract the substance and use it as a remedy against inflammations and other diseases. The eucalyptus oil production process keeps evolving to maximize yields, ensuring enough eucalyptus forests for koalas.

Eucalyptus oil

Panax ginseng is a medicinal plant with a long history steeped in myth. The term “panax” itself is derived from a Greek word for “panacea” or “cure all”. As ginseng processing technology continues to develop, this famous traditional extract keeps finding new applications.

Ginseng extract

Lavender oil is one of the most common essential oils in the market currently. Extracted from the herb Lavandula spp., this essential oil is used as a complementary medicine and as an additive. Studies have shown that lavender oil has sedative, carminative, anti-depressive, and anti-inflammatory properties. Like other essential oils, lavender oil extraction equipment must be capable of distillation, condensation, collection, and separation processes.

Lavender oil

Rose oil is an essential oil extracted from the petals of either Rosa damascena and Rosa centifolia. Also known as liquid gold, rose oil production originated from Greece and is currently manufactured mainly in Bulgaria, Turkey, and Morocco. Studies have shown that rose oil has medicinal properties, exhibiting anti-inflammatory, anti-infective, and wound healing actions.

Rose oil

The ancient Greeks believed feeding sea buckthorn to their horses would give them a lustrous hide. Indeed, full of lipids and carotenoids, the fruit did contribute to glowing, reddish coats. However, the thorny plant also has benefits for humans. Sea buckthorn processing equipment extracts this unique vegetable oil full of fatty acids. The liquid is a prominent component in various food, cosmetic, and pharmacological preparations.

Sea buckthorn oil

Tea tree oil, also known as melaleuca oil, is an essential oil with immune system stimulants produced mainly in Australia. The tea tree oil manufacturing process starts from the leaves of Melaleuca alternifolia. In terms of market value, the one for tea tree oil was valued at 38.8 million USD last 2017 and is projected to increase to 59.5 million USD by 2025.

Tea tree oil

Mineral water is mother nature’s cocktail of dissolved solids. The concentration of essential chemicals in the water makes it an excellent source of nutrients and electrolytes. Although your bottled product retains most of the properties present at its natural condition, the water still needs some help before it can be safely consumed.

Mineral water

Can be configured based on customer's requirement

PLC and visualization option can be selected

Batch

The VTA Laboratory multi-stage distiller is a combination of the short path and wiped film distillation technique.

A laboratory multi-stage distillers that combines the wiped film and short path distillation technique allows you to test the separation of high-boiling,

Laboratory multi-stage distiller &ndash; Making.com

Only one percent of the entire plant species on the planet produces essential oils, but that amount has found its way into various products, from perfumes to foods. Flower extraction systems are similarly diverse, and picking the right ones depends on the organic material and the final product.

Flower extract

Oleochemicals

Provides visual observation of the distillation process

Proper and reliable tests can already be performed with 2 kg of crude material

Can be operated at pressure range of 0.1 mbar to 1,000 mbar

Can handle material with max. Viscosity of 15,000 mPas (cP) at operating temperature

Options of continuous feeding systems and continuous discharging systems for distillate and residue can be selected

The VTA wiped film distillation laboratory unit is designed to distill small product quantities for acquiring reliable data of the separation process.

Reach reliable conclusions testing the distillation of high-boiling or highly viscous material using as little as 2 kg of crude material. Small scale

Laboratory wiped film distiller &ndash; Making.com

<h2>Making plastics - from crude oil to plastic pellets</h2>

Although originally a natural product, nowadays plastic is mostly synthetic and widely produced. The production starts with <a href="https://www.youtube.com/watch?v=ggh0Ptk3VGE" target="_blank" rel="noopener">extracting oil</a> from the underground with the help of pumps that produce between 5 and 40 liters of oil per stroke, which is then transported to an oil refiner through pipelines. The crud oil is poured into preheater, where it is boiled and sent to a furnace. There, according to its molecular weight, oil is separated into several groups of <a href="https://making.com/products/chemicals">chemicals</a> — petroleum, gasoline, paraffin, etc.

For plastic manufacturing, <a href="https://www.livescience.com/how-oil-is-turned-into-plastic.html" target="_blank" rel="noopener">what's essential is naphtha</a>. Naphta has to be broken down into smaller units in a cracking process to get ethene. There are two types of <a href="https://www.bpf.co.uk/plastipedia/how-is-plastic-made.aspx#[3%20NEW" target="_blank" rel="noopener">cracking processes</a>. Stem cracking is done at high temperatures and pressure, which is not required for catalytic cracking, which uses catalyst instead. Ethene is forwarded into a reaction chamber where the process of polymerization links the hydrocarbon monomers together into thick, viscous substances used to make plastics. The resulting product, polythene, is processed into strings in an extruder before being ground into pellets dispatched to factories to be molded into end products using various plastic machinery.

<h2>Plastic processing equipment and transformation of pellets into usable products</h2>
Forming usable plastic products, for instance, bottles, hoses, or toys, is executed using <a href="https://www.britannica.com/science/plastic/The-processing-and-fabrication-of-plastics" target="_blank" rel="noopener">various processes</a>: compounding, <a href="https://making.com/technologies/forming">forming</a>, thermoforming, <a href="https://making.com/technologies/extrusion">extrusion</a> and molding. Compounding is the first step - mixing liquids with other ingredients according to the desired recipe in conventional stirred tanks. Other essential plastic processing equipment includes two types of mixers; the workhorse mixer, which applies heat and pressure simultaneously, and the Banbury mixer which reminds of a robust dough mixer with two interrupted spiral rotors.

The next step is forming plastics into various shapes by melting, shaping, and solidifying. Extrusion and <a href="https://making.com/technologies/moulding">molding processes</a> create finished or semi-finished products. During extrusion, the melted <a href="https://making.com/polymers" target="_blank" rel="noopener">polymer</a> is continuously forced through an orifice in an extruder for products such as sheets, tubing, and grocery bags. Various types of molding rely on molds to create the desired shape.

To illustrate, <a href="https://www.activeplastics.co.nz/types-of-plastic-moulding" target="_blank" rel="noopener">rotational molding</a> produces large, hollow products such as kayaks. On the contrary, blow molding is used for small hollow pieces - bottles or fuel tanks. With compression molding, plastic parts can replace metal in the automotive industry. Finally, the most common type, injection molding, has virtually limitless uses with a large production capacity.

Plastics are classified according to their unique properties acquired during production processes. The main classification is based on how plastic responds to heat - it is differentiated between <a href="https://plasticseurope.org/plastics-explained/how-plastics-are-made/" target="_blank" rel="noopener">thermoplastics and thermosets</a>. Thermoplastics are more common than thermosets. They can be heated without burning, melted, cooled and reheated without losing their properties. On the other hand, thermosets can be heated only, typically during injection molding, once due to irreversible chemical changes.

Classification of plastics 

Any further heating would result in burning. For this reason, thermosets are not recycling-friendly. Further categorization is between amorphous, also known as shapeless, material and semi-crystalline material. While the former gradually softens when exposed to heat, the latter maintains its shape until a certain temperature point, when it rapidly becomes liquid. Finally, according to their monomer composition, plastics can be classified as homopolymers, made of a single type of monomer, or, on the contrary, copolymers.

<h2>Bioplastics, biodegradable plastics and recycled plastics - ecological alternatives?</h2>

The environmental effects of plastic are a widely known topic. It takes up to 450 years for a plastic bottle and <a href="https://australian.museum/blog-archive/science/interesting-plastic-facts/" target="_blank" rel="noopener">50 to 80 years</a> for a plastic cup to decompose. Alternatives to traditional plastics are <a href="https://www.explainthatstuff.com/bioplastics.html" target="_blank" rel="noopener">biodegradable, bio-based and recycled plastics.</a> Biodegradable plastics are made of petrochemicals but degraded by microorganisms. However, it can be safely done under warm conditions; otherwise, it degrades into harmful microplastic.

<a href="https://making.com/bio-plastics" target="_blank" rel="noopener">Bioplastic</a> is sourced from renewable natural materials (corn, sugarcane, cellulose), which are compostable. The downside is that using food sources, as well as that, owing to chemical and mechanical differences, can be challenging to recycle. Finally, <a href="https://making.com/recycled-plastic" target="_blank" rel="noopener">recycled plastic</a> does not exploit raw material, but it can be used only to produce lower-grade products. Furthermore, it uses energy, water and emits gases. However, it is important to <a href="https://www.fortum.com/products-and-services/recycling-waste/fortum-circo/news-and-articles/bioplastic-vs-recycled-plastics-terms-sustainability" target="_blank" rel="noopener">recycle already existing materials</a> as replacing them with mass production of non-reusable lower-quality products is not the ideal solution either.

Considering that bioplastics, biodegradable plastics and recycled plastics have downsides, <a href="https://dailytimes.com.pk/572643/the-hungry-gut-bacteria-that-enable-waxworms-to-live-on-plastic-waste/" target="_blank" rel="noopener">scientists from Canada’s Brandon University</a> have found a unique possible solution. Namely, they discovered that waxworms could live off polyethylene. Their guts contain bacteria that biodegrade plastics and turn them into glycol. In the lab-controlled environment, 60 waxworms can eat more than 30 square centimeters of a plastic bag in less than a week. While it is unrealistic to expect that waxworms can solve the plastic pollution issue, understanding the symbiosis of waxworms and gut bacteria could lead to the development of better plastic biodegradation systems.

Green innovations - plastic-eating waxworms 

Plastic Processing Equipment

Find production technology for processing plastics and connect directly with leading machine and equipment manufacturers worldwide.

Plastics &ndash; Making.com

Plastic Processing Equipment - Making.com

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At the industrial level, the application areas of pellets range widely in fields such as feeds, biomass, wood chips, sawdust, and other renewable raw materials. To adapt to the most diverse requirements, the pelleting presses must have a modular design while keeping maintenance costs low and providing a long service life.


<h2>Producing pellets using a modular pelleting press with an energy-efficient direct drive</h2>
The MAXIMA Pellet Mill from SALMATEC is an industrial-grade pelletizer capable of producing pellets for various applications like feeds, woodchips, recycled plastics, and many more renewable raw materials. The system has a vertical ring die with optional 2 or 3 rollers that can be equipped with a cooling system. The rollers press the product through the ring die at the highest possible pressure before cutting it down to the right size with its adjustable knife. The system has a lifting frame to support heavy parts such as rollers and dies removed during maintenance.

The unit has a central lubrication system that automatically lubricates the rollers and the main bearings. A maintenance drive is equipped inside a well-ventilated housing for larger units to ensure slow and safe die rotation for work on the press tools. The system is made from high-quality materials and complies with the latest safety standards and guidelines. The Maxima provides energy efficiency and equal power transmission thanks to a one-step operated v-belt drive. The system is available in various capacities of up to 50 tons per hour, depending on the type of machine and product application.

Industrial pellet mill

Large industries are shifting towards more environment-friendly technology, such as recycling wastes and utilizing them as an alternate energy source. For instance, sawdust and wood chips from wood mills are collected and processed into pellets which can be used in households or large industrial plants as a source of energy for heating systems. Plastic waste can also be recycled and made into pellets. Later these will be used in injection and molding machines to produce bottles, containers, or bags.


<h2>Turning wood and plastic byproducts into uniform pellets using a complete pelletizing system</h2>
The Complete Pellet Line from SALMATEC is a pelletizing system that includes multiple processes from conditioning raw materials and turning them into uniformly sized pellets. The entire system is specifically designed for the required product specifications. The conditioner helps the products achieve the optimum amount of moisture before feeding them to the pelletizer. The moisture content of raw materials can be controlled through a conditioning system in which the product moves inside a chamber while steam is also injected.

The pelletizer can be equipped with 2 or 3 rollers and multiple knives to cut the extruded products from the die into the necessary pellet size. The pellets then go to the cooler to prevent them from sticking to each other before storing them for at least one day in the silos. This process allows the structure of the pellets to stay intact and prevents them from breaking into tiny particles. Each complete system is designed according to the desired production capacity, raw material input, and high safety standards.

Complete pellet line

Plastic recycling has a dynamic duo: mechanical and chemical. Chemical recycling is still in the research stage, aiming to convert plastic into its

Every pellet counts! Let’s make the plastic recycling process greener &ndash; Making.com

Every pellet counts! Let’s make the plastic recycling process greener

Deborah

Find production technology for Plastic Distillation, and connect directly with leading machine manufacturers worldwide.

Plastic Distillation

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Pilot multi-stage distiller

Laboratory multi-stage distiller

Laboratory wiped film distiller

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