Careformance: Erema launches Recycling 4.0 at K 2016

Erema gave some 100 international journalists an insight into their trade fair plans for K 2016 at the official ‘K Preview’ press conference on 29 June in Düsseldorf. With Careformance the company is heralding the age of Recycling 4.0 as the first in the plastics recycling industry to present an extensive Smart Factory package for both recyclers and producers. Recycling 4.0 is no future trend, it will be reality starting at K 2016.

Manfred Hackl, CEO of Erema
Manfred Hackl, CEO of Erema

At the K 2016 show Erema will be building on the success of its Intarema technology presented in 2013, this time with its trade fair theme of ‘Careformance – We care about your performance’ to grow its pioneering role this year with Industry 4.0 applications. “Building on the high degree of automation of the Intarema systems we have developed a Smart Factory package which enables us to give our customers a clear competitive edge and make them fit for the future,” says Erema CEO Manfred Hackl. The company will be recycling the plastic waste of the K show on site at the Careformance Recycling Centre in the outdoor area of the trade fair, with machine, quality and process data being transferred in real time to Erema’s Stand C05 Hall 9.

QualityOn package

Careformance consists of four components, with the Intarema system forming the basis for further Smart Factory applications. In addition to the previous machine data, specially integrated sensors – the QualityOn package – can be used in future to record and evaluate MVR (Melt Volume Rate), color and moisture. The QualityOn package enables recyclers and producers to make their recyclates with consistent quality in accordance with the special requirements of their customers and document them transparently using online data acquisition and analysis. Recipes recorded electronically can be compared with each other and modified.


In order to make use of the vast amount of machine, quality and process data in a worthwhile and user-friendly way, Erema has developed a sophisticated MES (Manufacturing Execution System). With re360 you can keep track of the productivity of an entire range of machinery in five modules. “A key benefit of re360 is that it works independently of the plant manufacturer,” emphasises Hackl. “Customers can integrate not only different systems but also their global production locations.” re360 gives you an overview of the capacities/stoppage times of the systems for management, documents key quality data of the recyclates for the location manager and informs the operator about upcoming maintenance jobs.

Spare parts online

The extent to which re360 was developed with customer requirements in mind becomes clear with the link to Erema’s online web shop. Any upcoming maintenance work and the replacement of individual parts is displayed in good time by re360. Spare parts can be ordered online to keep downtime as low as possible and customer systems’ information and previous orders are stored online.

More than 450 systems worldwide

At the last K 2013 Erema launched Intarema based on Counter Current technology. Intarema achieves process stability while maintaining flexibility with ease of operation and considerably less energy consumption. This stability enables automation processes such as Smart Start or the Recipe Management System, which in turn form the basis for modern Industry 4.0 applications. Since the technology was launched in autumn 2013 more than 450 Interama systems have already been sold worldwide.