Two filters, one goal: maximum regranulate quality at RE-PLAST

Founded in 1992 by Ján Krčula Sr. and headquartered in Zvončín, Slovakia, RE-PLAST, s.r.o. has established itself as a trusted name in the European plastics recycling industry. With more than three decades of experience, the company currently processes approximately 1,200 tonnes of polyethylene (PE) film waste each month – primarily LDPE, with occasional volumes of LLDPE and HDPE.

Through advanced recycling processes, RE-PLAST transforms plastic waste into high-quality LDPE regranulates available in various colors, including Natural, Colormix, and Black. These regranulates are widely used across Europe in the production of bin bags, construction films, and other plastic products such as sheets, tubes, and buckets. The majority of the company’s output is dedicated to film blowing applications, supporting the sustainable manufacture of films and bags.

In order to be able to efficiently process even more heavily contaminated post-consumer and post-industrial waste, RE-PLAST invested in a new recycling machine, the INTAREMA® 1714 TVEplus® DuaFil® Compact from EREMA. The highly flexible double filtration machine combines proven TVEplus® technology with the new, patented DuaFil® Compact design – and impresses with its particularly gentle melt treatment, powerful degassing and fine final filtration.

Energy-saving dual filtration solution

“The new EREMA line is a real game changer for us. Thanks to the compact DuaFil® technology, we have been able to significantly reduce melt temperature and energy consumption while maintaining consistent quality,” explains CEO Ján Krčula Jr.

A central element of the system is the continuous high-performance Laserfilter LF 2/406 filter, supplemented by the SW 4/250 RTF as a second filtration unit. This combination enables a consistently stable process – even with heavily contaminated material. The mild, shortened extruder screw reduces shear stress, while a customised melt pump takes over the pressure build-up for the second filter.

“The robust design, high degree of automation and ease of operation of EREMA technology were decisive factors for us. Our employees are familiar with the lines, and process reliability is guaranteed even with less qualified personnel,” Mr. Krčula continues.

Digitalisation improves spare parts management

RE-PLAST also appreciates the high standard offered by EREMA in the area of digitalisation: the BluPort® customer portal offers enormous time savings with its Spare Parts Online Tool. “A really great tool – it has already saved us a lot of time in our spare parts management and is extremely helpful,” praises Ján Krčula.

With the new line, RE-PLAST processes around 9,000 tonnes of washed plastic waste annually. “We also tested other manufacturers, but EREMA was the clear number one for us – because of the technology, reliability and support,” says Mr. Krčula, summarising the decision.