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Description
Polimarky manufactures modified thermoplastic compounds which are mainly used in the production of cables and electrical wires. This activity is closely linked to the project in which we are developing a technology for the production of halogen-free compounds. They will be made of the so-called recyclate, i.e. plastics and other materials obtained from the secondary market (80% of the composition). As a result, cable coating of a high-class fire resistance and durability will be produced. The modified production process will make it possible to obtain clean, impurity-free raw material which will be additionally stabilised against ageing by means of special additives. For this purpose, we will use the results of previously conducted development work, and conduct further research (determination of critical working conditions of the material and testing of cables) in cooperation with R&D units. The project will bring about a significant expansion of Polimarky''s product offer, as the Polish market lacks recyclates and recycling processes that produce raw materials with comparable characteristics.
Under the project, the production line used in our plant to-date will be adapted and retrofitted, to introduce modern technological solutions and reduce the negative impact on the environment. That effect will be enhanced by the installation of photovoltaic panels at two of our production plants, with a capacity of 465 kW and 391 kW. The project will reduce the company''s electricity demand by 0.81 GWh and CO2 emissions by 627.9 tons per year.
Summary of project results
The aim of the project is to develop and implement in Polimarky Sp. Zoo. SK pro-ecological technologies and products that increase the competitiveness of the company through:
- product innovation: release and implementation of halogen-free falem retardant compound "EKO1" and "EKO2" on recyclate base polymer (up to 80%), use in the production of sheeting meeting specific fire resistance classes;
- process innovation: release and implementation of production technology offrecycled base polyolefins as material for the production of "EKO1" and "EKO2" - The aim of the process is to obtainclean and contamination free regranulate, , which is necessary for achive high quality material - only materials obtained in this way allowed the production of not halogen-free regular parameters.
IMPLEMENTATION OF POLYOLEFINE RECYCLING TECHNOLOGY at the plant in Rzeszów. The work included retrofitting the currently used production lines in the plant by implementing the necessary additional devices, i.e.:
- slide plate melt filter for the compounding line - a device used to filter the recycled material from foreign impurities and contamination;
- compactor for a technological line - a device used for compacting and thickening crushed and ground waste;
- pressure feeders with neodymium magnets - device for feeding waste to the technological line with the separation of metallic impurities;
- press for assessing the purity of the material - a laboratory device used to assess the purity of the regranulates.
DEVELOPMENT OF HALOGEN-FREE MIXTURES "EKO1" AND "EKO2". The scope of work was carried by the R&D department, the technological installation in Zaczernie and the involvement of a scientific and research unit and an external laboratory. The raw material with the best parameters, developed and manufactured in Rzeszów as part of stage 1, was used to produce a compouds EKO1 and EKO2 on the ZE-75RX38D line in Zaczernie.
The tests performed allowed us to determine the most effective parameters for the compounds and their composition (proper homogenization, humidity and output). The parameters that prove the desired result are tensile strength, elongation, MFR, LOI and flammability class min. V2. The developed compound was testedt on the cable prototyping line.
EVALUATION OF THE RECEIVED PRODUCT CONDUCTED BY RESEARCH AND SCIENTIFIC UNITS.
The selected research unit and laboratories analyzed the combustion process, resistance tests and determined the critical operating conditions of halogen-free cable compounds "EKO1" and "EKO2". The tests were carried out using a cone calorimeter, the research center will was responsible for determining the parameters:
- heat release rate;
- effective heat of combustion;
- mass loss rate;
- time to ignite;
- rate of release of toxic gases.
IMPLEMENTATION OF THE PRODUCTION TECHNOLOGY OF "EKO1" AND "EKO2" MIXES with a significantly increased share of recyclate in Zaczernie. The work included retrofitting the plant by implementing additional devices.
Retrofitting the plant enables the introduction of new products to the market that meet the requirements for cable materials in terms of required resistance and fire resistance. Thus, the technological possibility of carrying out the production process of "EKO1" and "EKO2" compounds with the desired parameters will be ensured.
As a result of the tests carried out on the RESLEN REF EKO 1 and EKO 2 system - thermoplastic, halogen-free cable compounds with required fire resistance, used as sheeting and insulating materials for low-voltage cables, ensuring very good electrical and mechanical properties.
Additionally, the installation of photovoltaic cells at 2 production plants, increased the share of renewable energy use in own production. It will contribute to a more ecologically effective operation of the company.