Sustainable Partnership with AST

Sustainable Partnership with AST

Posted in: Success Stories
13. March 2024

AST Kunststoffverarbeitung once again relies on the proven shredder-feeder-extruder combination from Next Generation Recyclingmaschinen GmbH (NGR).

“Satisfied customers during acceptance at the NGR plant in Feldkirchen an der Donau. From left to right: Patrick Gattringer, Stefan Musner, Lukas Pöchtrager (NGR), Stefan Feige, Murat Cebi (AST), and Karl-Heinz Berger (NGR). The NXT:GRAN shines in a customer-specific ‘AST Blue’.”

For four decades now, AST Kunststoffverarbeitung GmbH has been one of the key players in the production of blow-molded plastic packaging, especially plastic canisters and barrels with hazardous goods approval. As a family-run company, since its founding in 1977, AST has held a firm place in the industry, consistently focusing not only on quality but also on sustainable production. With branches in Germany, the UK, Belgium, Poland, and the Netherlands, the company has specialized in packaging management – from delivery to the proper processing of all industrial packaging. An important part of their commitment is also a take-back and recycling system called Cipacks, which takes back used containers, cleans them, and either reuses them as raw material or as a complete product.

Long-standing trust in proven technology

To seamlessly reintegrate the residues generated during production back into the production cycle, AST has once again opted for the proven shredder-feeder-extruder combination from Next Generation Recyclingmaschinen GmbH (NGR). This longstanding partnership was recently strengthened by the investment in a fourth NGR machine, the NXT:GRAN 085-70 V HD. With a processing capacity of up to 430 kg/h for LDPE films and lumps as well as HDPE canister waste, this milestone not only marks the success of the past years but also consolidates the shared vision for a sustainable future.

To ensure optimal performance and efficiency, the NXT:GRAN 085-70 V HD has been precisely tailored to AST’s requirements and equipped with various customizations.

The machine with special paintwork has been equipped with a special conveyor belt with integrated metal detector to detect and remove metal impurities during the recycling process. A webcam system on the feed hopper continuously monitors the material flow and detects deviations at an early stage. A modular degassing unit ensures the effective removal of excess gases during the extrusion process.

Additionally, a screen changer and a vacuum pump stand ensure optimized performance. The machine has also been equipped with a hot-cut granulation unit, enabling fast and efficient granulation of the recycled material and guaranteeing high-quality pellets. A downstream unit ensures the smooth transition to the next phase of the production process.

NXT:GRAN for highly efficient post-industrial recycling

The shredder-feeder-extruder combination patented by NGR relies on ONE-STEP technology and combines shredding, feeding, and extrusion in a single operation. With over 1000 patented shredder-feeder-extruder combinations worldwide, the NXT:GRAN has established itself as a guarantee of highest performance and reliability. The shredder-feeder-extruder combination enables zero-waste production while ensuring the full retention of the material’s value, while also minimizing labor and energy consumption.

By increasing the cutting performance in the shredder, the machine can process large, thick, or bulky parts without prior shredding, significantly increasing its versatility and flexibility. An optimized material feed to the extruder, which is positively arranged to the extruder screw, provides additional power to the NXT:GRAN.

The ON/OFF single-button automation enables easy start-up and shutdown of the machine, as well as smooth start-up of the components. Even after unforeseen shutdowns, the machine can be restarted in less than two minutes.

Thanks to the Dump-and-Run operation, the material level in the hopper is continuously measured, and the feed is controlled accordingly, enabling continuous operation and further increasing productivity.

NXT:GRAN 085-70 V HD – combines shredding, feeding, and extrusion in a single, highly efficient step (ONE-STEP technology)

A look into the future: Sustainability and Responsibility

Stefan Feige, Head of Technology at AST, emphasizes the importance of the long-standing partnership: “Next Generation Recyclingmaschinen GmbH is more than just a supplier for us. The NXT:GRAN technology has not only optimized our production processes but also made a significant contribution to our vision of sustainable and environmentally friendly production. The NGR machines are extremely robust and meet our requirements to our fullest satisfaction.” We appreciate the reliability and efficiency of the machines as well as the continuous support we receive from NGR to ensure that our recycling processes run smoothly and effectively.”

In a world where the need for sustainable resource management is becoming increasingly urgent, the long-standing partnership between AST Kunststoffverarbeitung and Next Generation Recyclingmaschinen GmbH demonstrates that sustainability and profitability can go hand in hand. Through close collaboration and a shared commitment to efficient and environmentally friendly solutions, it is clear that ecological responsibility can be compatible with business success. This partnership not only enables the loss-free return of waste generated during the production of plastic products to production but also sets an inspiring best practice example for a sustainable future in the

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