A New Regranulation Machine Strengthens Waste Management in Mellerud
Nearly three years ago, Henrik Johansson Kask, Production Manager at Emballator Mellerud, began looking for a specialised machine that could take the factory’s waste management to the next level. At the time, the team was already reusing trims and scraps from the blow moulding machines by processing them with in‑house mills.
“Our initial efforts involved using our own mills to reuse trims and scraps from our blow moulding machines, effectively reintegrating them into our production process,” says Henrik Johansson Kask.
This approach worked well, but the mills reached their limit when handling larger clumps and dusty residues. As a result, around 200 tonnes of material still became waste each year.
Moving from challenge to solution
To improve material recovery and reduce waste further, Emballator Mellerud partnered closely with the Swedish company Battenfeld. Together they explored new technology from NGR in Austria—an advanced system capable of handling the difficult fractions the existing equipment could not manage.
The machine was acquired nine months ago and installed in September. After a thorough testing phase, full operation began in October with support from NGR technician and electrician Andreas Himmelsberger. Battenfeld’s specialists, Michael and Kenneth Hiljemark, then helped fine‑tune the process.
“This strategic collaboration and the implementation of advanced technology have been crucial in taking our next significant step towards more efficient and sustainable waste management in our production,” says Henrik.
How the machine works
The regranulation machine handles material that previously couldn’t be reused. Waste clumps are shredded into smaller pieces, fed into an extruder, and transformed into pellets. These pellets are cooled in a water bath, dried through centrifugation and then transported to a cyclone before being collected in an octabin.
The result is clean, uniform material ready to be reintegrated into production.
Practical benefits and sustainability gains
The investment has had a clear impact. More of the factory’s waste is now converted into reusable material, improving both internal handling and material flow. Production efficiency has increased, and the reduced volume of waste contributes to a lower carbon footprint.
“The new regranulation machine marks a significant milestone in our pursuit of a more environmentally friendly and efficient production process and has, in many ways, redefined our approach to waste management and sustainability within the company,” Henrik concludes.
