Recycling specialist Rymoplast relies on technotrans thermal management
New central container cooling system combines process stability with BAFA-supported sustainability
Reprocessing plastics is essential if industry is to achieve its ambitious climate targets. In 2022, the Morssinkhof-Rymoplast Group, one of Europe’s largest plastics recyclers, significantly expanded its capacity with a new plant in Markranstädt, Saxony. Around 30,000 tonnes of film waste are processed there each year into high-quality recycled granulate. To ensure the high quality standards of its closed-loop philosophy in production as well, the company relies on a customised cooling solution from technotrans. The thermal management specialist developed and installed a 1.5 MW containerised cooling system which, thanks to intelligent free cooling, not only delivers maximum process stability but also saves almost 480,000 kilograms of CO₂ annually.
The Morssinkhof-Rymoplast Group is one of the leading providers in plastics recycling and the circular economy. The Dutch family-owned company, with more than 50 years of experience and around 800 employees, recycles almost 500,000 tonnes of plastic every year. With an investment of around EUR 30 million in a Rymoplast Deutschland GmbH site in Markranstädt near Leipzig, the Group sent a clear signal in 2022 for the expansion of post-consumer recycling (PCR) in Germany.
The goal in Markranstädt is ambitious: used commercial and industrial films are transformed into LDPE regranulate (low-density polyethylene) whose quality is comparable to virgin material. The process is complex. The delivered film bales are shredded, washed, dried and finally extruded. “Compressed air, water and a reliable cooling supply are the three pillars on which our process stability is based. If one of them fails, production comes to a standstill,” explains Mark Langenhof, Business Development & Application Engineer at Rymoplast Deutschland GmbH. Precise temperature control is particularly critical during the extrusion process, where the plastic is melted and subsequently granulated. If cooling is not correct, the granulate sticks together and quality declines dramatically.
From an empty production hall to an application-specific cooling supply
When planning the new plant in an existing but completely stripped-out building, Rymoplast turned to technotrans. The companies already knew each other from previous projects carried out by the Dutch parent company, where technotrans, then operating under the gwk brand, had successfully implemented cooling systems. “We were effectively starting with a blank sheet of paper. That gave us the freedom to dimension the system optimally from the outset, but it also required a partner capable of developing a coherent overall concept rather than simply supplying components,” says Langenhof.
Rymoplast defined specific requirements. The recycling specialist needed a solution for cooling the EREMA extruders and peripheral equipment that would ultimately provide 1.5 MW of cooling capacity. At the same time, valuable production space was not to be occupied by utility equipment. Cleanliness was another important factor. Dust is inevitably generated in a recycling plant through shredding and handling materials. “We wanted to avoid having the cooling technology installed inside the hall where it would gradually become contaminated. An outdoor solution minimises maintenance requirements and ensures the system’s long-term durability,” explains Langenhof.
Space-saving container solution in the customer’s corporate design
The answer from the technotrans engineers in Meinerzhagen was a customised container cooling system tailored precisely to these requirements. The entire technology package, including pumps, tanks, chillers and control cabinets, is integrated into a weatherproof container combination installed outdoors. As a visual detail, the technical container was painted in the customer’s specific blue colour to blend seamlessly into the site’s appearance.
“The advantage of this solution is obvious. We have completely enclosed all the technology outside production. Even after more than two years of operation, the interior of the container looks exactly as it did on day one,” confirms Langenhof. The system supplies production with a constant flow temperature of 15°C. A piping system transports cooling water to the consumers, namely the extruders and granulate cooling units. Rymoplast also placed great emphasis on redundancy. Twin-pump groups with frequency converters not only provide backup in the event of pump failure but continuously adapt motor output to actual demand. Thanks to precise speed control, the pumps always operate at their optimum energy point, significantly reducing electricity consumption during partial-load operation compared with fixed-speed systems.
Moving away from cooling towers: Closed system for hygiene and stability
From a technological perspective, the system represents a deliberate move away from open cooling tower systems, which are still widespread throughout the industry. Roger Schmidt, Sales Manager Cooling Solutions at technotrans solutions GmbH, explains the disadvantages: “Open systems are susceptible to contamination and carry a risk of legionella formation, resulting in strict regulatory requirements and extensive chemical treatment.” Instead, technotrans designed a closed-loop system.
Because a closed circuit must be cooled differently from an evaporative cooling tower, energy efficiency became the central design focus. Here technotrans fully demonstrated its solution expertise. The system combines highly efficient chillers with a powerful free-cooling unit mounted directly on top of the container. To maximise efficiency even at higher outdoor temperatures, the system also features adiabatic cooling. A spray-water distribution system lowers the intake air temperature through evaporative cooling, significantly increasing overall cooling system efficiency.
Substantial energy savings through intelligent sector coupling
Rymoplast also benefits from what is known as winter relief operation. The principle is as simple as it is effective. As soon as the outside temperature falls below the required return temperature of the process water, cooling is no longer generated actively via compressors but passively through ambient air in the free cooler. “In our climate, we can completely switch off the chillers, or at least significantly reduce their load, for many months of the year,” says Schmidt.
Compared with a conventional refrigeration system without free cooling, the technotrans installation in Markranstädt saves around 650 MWh of electricity annually. This corresponds to a reduction in CO₂ emissions of approximately 480,000 kilograms per year, representing savings of almost 40 per cent. Due to these high efficiency values, Rymoplast received investment funding from the German Federal Office for Economic Affairs and Export Control (BAFA). “Together with the consultancy GERATRADE GmbH, technotrans supported us not only technically but also in providing the documentation required to demonstrate eligibility for funding,” says Langenhof. For example, the pipework was specially insulated to minimise thermal losses and meet funding criteria.
High vertical integration creates trust
In addition to the technology itself, trust in the partner was a decisive factor for Rymoplast. A visit to the technotrans facility in Meinerzhagen during the project planning phase left a lasting impression. “There are many plant engineering companies, but only a few with such a high level of vertical integration,” emphasises Langenhof. “Seeing that technotrans possesses the expertise in-house, processes sheet metal itself, welds pipes and builds control cabinets creates trust. You can tell that this is not simply a case of purchasing components, but of genuine engineering expertise.”
This expertise was also evident in the flexibility demonstrated during the plant expansion. From the outset, technotrans designed the system to be modular and scalable. Initially supplying two extrusion lines when operations commenced in 2022, the planned expansion to a third line was completed in May 2025. “The connections and controls had already been prepared. Integrating the additional pumps and adjusting capacity was completed smoothly,” reports Langenhof.
Digitalisation and service from a single source
An important element of operational reliability is the system’s integration into digital monitoring. Through a remote maintenance interface, technotrans technicians can access the control system directly when required, analyse parameters and often resolve issues without needing to travel to site. At the same time, Rymoplast maintenance personnel have full visibility of pressures, temperatures and flow rates via a large HMI touch panel and mirrored desktop displays at their workstations. “For us, the system is a worry-free package,” concludes Langenhof. “We have a maintenance contract and even source the necessary cooling-water additives directly from technotrans to ensure the chemistry is correct.”
Conclusion: A partnership with a future
The Markranstädt plant exemplifies the Morssinkhof-Rymoplast Group’s commitment to future-proof recycling using state-of-the-art technology. The decision to invest in a central, energy-efficient cooling supply directly supports the company’s sustainability strategy. For Langenhof, the investment has clearly paid off: “We produce quality products that close the loop. To do that, we need partners with the same quality standards. We have found that partner in technotrans. The system runs reliably and efficiently, and we would choose this path again at any time.”
Against a backdrop of rising energy costs and increasingly stringent environmental regulations, the project in Markranstädt serves as a blueprint for how industrial companies can successfully combine economic and environmental objectives through intelligent thermal management.
Further informationen under: www.technotrans.com