Fluff-Tec

Your solution for recycling fluffy materials

Optimal handling of fluffy materials

For rigid bulk materials made of PE, PET, PP, ABS, or PS, there are effective recycling solutions today. Fluffy materials, by contrast, are difficult to handle. ‘Fluffy materials’ refers to soft or thin films—sometimes multi‐layer packaging films—rigid films (e.g. from hard‐shell packaging), as well as foams, textile fibers, and even wool residues.

Films are often divided into two categories:

Flexible (2D = Type A): lightweight agricultural films with very low bulk density and thickness

Rigid (3D = Type B): for example, PET flakes

Fluffy Materials at a glance

Type A

Soft or thin films with a layer thickness < 200 μm (single- or multilayer packaging films for flexible packaging)

Type B

Rigid or thick films with a layer thickness between 200 and 1,000 μm (packaging films for rigid containers or hard-shell packaging)

Type C

Elastic granulates or agglomerates

Type D

Foams

Type E

Strips or chips

Type F

Fibers or filaments – loosely bound (textile fibers from recycled tires)

Type G

Nonwovens, woven fabrics, or wool – strongly bonded

May we assist you in finding the right solution?

Solutions for the future

FLUFF-TEC – Always the right concept!

Zeppelin Systems boasts decades of experience in the plastics sector and in recycling processes—and has direct access to the corresponding plants. This expertise is integrated into our Fluff-Tec® concept. In close collaboration with the customer, we develop a bespoke solution concept, which, if required, includes trials at a Zeppelin technical center. We then select the appropriate technology or product for the application—and, if necessary, design new components. This ensures that your recovered materials are processed safely and economically at all times.

Handling is crucial

To ensure reliable handling, fluffy materials must be understood, examined, and characterized. The key factors are flowability, conveyability, storage behavior, and bulk density. Many fluffy materials readily alter their bulk shape under even slight external mechanical stress or their own weight, as air escapes from their voids. The entire bulk can be heavily compressed (1). Once the load or fill height is reduced, a pronounced elastic rebound occurs (2)

The optimal process for your bulk material

Together with you, we define the handling and processing method for your bulk material. If the material can be stored and conveyed normally, proven standard technologies from Zeppelin Systems are used in subsequent processing. Problematic, low-flow fluffy materials—such as film remnants—tend to bridge and consolidate over time, preventing discharge from silos. These materials can be processed by compacting, homogenizing, and further handling with specialized integrated solutions from Zeppelin Systems.

PROCESS EXPERTISE MEANS ZEPPELIN SYSTEMS The key to handling fluffy materials is mastering the entire process. It is not enough to adapt individual components to the process; the entire process engineering must be considered holistically—from filtration and separation to energy-optimized compaction and homogenization.

Technologies and Products

Economical recycling

Zeppelin Systems provides comprehensive expertise and process-engineering solutions for every step of the recycling process

Anti-bridging solutions

Tailored solutions adapted to your bulk material that keep it in continuous motion

Film sifter

Specialized film sifter as the proven solution for process-secure storage of plastic fractions in silos

Test- Silo

Special pilot silo with adjustable cone angle for accurate evaluation of fluffy materials’ storage capabilities

Compaction

Compaction solutions that account for all pellet parameters for energy-efficient process steps

Need more details? Our contact person will be happy to assist you

Dr. Julian König

Head of Recycling & Technology Sales

julian.koenig@zeppelin.com +49 7541 202 1972

Services

Discover our comprehensive range of services

Zeppelin Technical Center

Industrial-scale testing

Testing is good; testing at a 1:1 scale under real-world conditions is even better. To support this, we have established optimal facilities at our Friedrichshafen technical center: based on your recipe and desired throughput, we identify the plant technology tailored to your needs—and test the complete system for you in live operation.

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Automation

Automation with foresight

Above all, your plant must do one thing: run and deliver. That’s why we provide you with reliable, professional service. Rely on our global service network for expert consultation and extremely fast spare-parts supply to minimize downtime. When needed, we’re also at your side digitally—from virtual troubleshooting to online-supported commissioning.

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Service

Service without compromise

In the 21st century, optimization often means automation. We ensure that your automation project is a complete success in terms of both efficiency and cost-effectiveness. To achieve this, we rely on cutting-edge control systems whose open architectures prepare you for the challenges of tomorrow—and beyond.

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Resources

Brochures for download

FOR OPTIMAL HANDLING OF FLUFFY MATERIALS

Download PDF | 2MB

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