In 2025 we installed a new EREMA Intarema TVEplus DuaFil Compact line. Here is what it changed, in numbers, and what it means if you source PE regranulate from us.
The headline figures
Three things changed in 2025 that show up directly in the material we ship:
- Capacity up 15%. More output per hour means larger orders, shorter lead times, and room to absorb demand spikes without trade-offs on quality.
- Energy down from 0.50 to 0.45 kWh per kilogram. A ten percent reduction looks modest until you factor in that we moved from single to dual filtration at the same time. Lower energy on a more demanding process is real progress, and it feeds straight into our cost structure.
- Cleaner, more consistent output. Dual filtration means fewer contamination points and visually cleaner pellets, resulting in better mechanical properties and a cleaner, more consistent appearance of the blown film.
Why we invested, and why then
The timing was not comfortable. Making a major capital investment when the market feels uncertain is the kind of decision most businesses postpone. We did not.
PPWR was moving from discussion toward real compliance deadlines, customers were getting more demanding about certified recyclate, and margins on average-quality material were thinning. We had been evaluating the DuaFil Compact for some time and ran trials across several machinery manufacturers before committing. We also looked seriously at adding a second filtration stage to our existing line, but on colored materials that path hit a ceiling. The DuaFil Compact was built for exactly the feedstock we work with.
As Monika, our CFO & Business Development Manager, put it: "Investing in new technology is a necessary part of running this business, and this was a key decision for us even if it did not come at the easiest time. In periods of uncertainty, many businesses choose to wait. We chose to invest because we believed it was right. And it was."
What dual filtration changes
Our previous line had one filtration stage. The new line has two - that is what "DuaFil" refers to. It sounds like a small change. It is not.
The line runs a Laser Filter and a Back Flush Filter in sequence, each more effective against a different type of contaminant. The combined result is cleaner material. The second filter also acts as a safety net: on a single-filter line a compromised sieve can go unnoticed until a customer flags it, whereas a second filter shows any anomaly immediately, before the material leaves the plant.
On materials, we want to be precise: this is not about processing anything and everything. The films and industrial waste we have always run, we now run with a better result and in higher volume. You cannot make first-grade material out of poor feedstock - but on our feedstock, the output is measurably better.
We verify quality the way we always have. Before being homogenized into a full truck batch, each big bag is sampled, blown into film, and evaluated visually. It is not a lab-instrument setup but 30 years of knowing what good film looks like the moment it comes off the head. The difference with DuaFil is clearly visible: fewer specks, more consistent color, and stronger film. Customers who had been specifically waiting for this line have confirmed the results through their regular orders.
Installation: one week, no surprises
The machine arrived at the end of February 2025. Switching from a running line means you cannot afford a long production gap, so we moved fast: installation, testing, and commissioning took a little over a week from start to finish.
That speed was not luck. The drawings and specifications were ready well in advance and the site was fully prepared. The line went live in March and has run at full capacity since.
The honest version is that it wasn’t entirely smooth. Unexpected challenges are simply part of industrial recycling. What mattered is that when issues came up, EREMA was not just a supplier. We worked through them together, and that kind of relationship matters more than most buyers realise when they evaluate a machinery partner.
The second milestone: Recyclass certification
The new line is only half of 2025.
In November 2025 we completed our full Recyclass audit - the first full-year audit run with a complete set of operational data. An initial provisional audit followed a shorter period in December 2024, but the November audit is the full, proper certification.
For EU manufacturers, Recyclass is increasingly non-negotiable. If you are sourcing regranulate to meet PPWR recycled-content targets, your supplier's certificate becomes part of your own compliance documentation. It validates the process against EN 15343, confirms traceability of material origin, and gives you a document you can put in front of your own auditors. We will publish a dedicated article on what that means in practice shortly.
What it means if you buy from us
- Consistent, controlled material. Our combination of reliable recycling technology and strict quality control ensures consistent film-grade LDPE and LLDPE regranulates with low contamination and stable material properties, which is important when blowing film or extruding profiles to tight tolerances.
- Reliable supply. Our production setup gives us the capacity and flexibility to maintain consistent volumes while keeping quality and lead times under control.
- Certified recyclate, ready for PPWR. Our production processes, combined with Recyclass certification, ensure that material leaving RE-PLAST comes with the documentation and traceability increasingly required by EU regulations.
Looking ahead
2025 confirmed something we already believed: the market rewards suppliers who invest in the right infrastructure at the right time. The customers who had been waiting for our DuaFil output now order regularly, and Recyclass is opening doors with buyers for whom that document is a prerequisite.
In 2026 we will be at IFAT Munich in May - not as spectators, but with a clear view on where PE recycling is heading and what it takes to do it properly.
If you want to see what the new line produces, the fastest way is to request a sample and run it on your own machines. No presentation, no sales call - just pellets.
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RE-PLAST has been producing PE film since 1992 and PE regranulates since 2005, supplying LDPE and LLDPE film-grade regranulates to manufacturers across Europe. We are proudly Recyclass and ISO certified.