How Rymoplast Combines Process Reliability and Sustainability with Smart Refrigeration Technology
The recycling of plastics is a key component of a functioning circular economy. To turn used films into high-quality recycled materials, production processes must run reliably, efficiently, and consistently at all times. That is precisely why Rymoplast Deutschland GmbH relies on a customized cooling solution from technotrans at its Markranstädt facility. For the modern recycling plant, the thermal management specialist developed a central container cooling system with a capacity of 1.5 megawatts. The combination of intelligent free cooling, closed-loop system technology, and digital monitoring not only ensures maximum process stability but also significantly reduces energy consumption.
The result: approximately 650 megawatt-hours in electricity savings and about 480,000 kilograms less CO₂ per year.
Rymoplast Deutschland GmbH
High-Quality Recycling for a Functioning Circular Economy
The Morssinkhof-Rymoplast Group is one of Europe’s leading plastics recyclers. With more than 50 years of experience and approximately 800 employees, the family-owned company processes nearly 500,000 metric tons of plastic annually.
With the construction of the new plant in Markranstädt, the group invested approximately 30 million euros in expanding post-consumer recycling in Germany. The goal: to produce high-quality LDPE regranulate from used commercial and industrial films that is on par with virgin material in terms of quality.
Process Stability as a Key Success Factor// The recycling process involves numerous production steps—from shredding and washing to extrusion and pelletizing. Precise temperature control is crucial for product quality, particularly during extrusion.
"Compressed air, water, and a reliable supply of refrigerated air are the three pillars on which our process stability rests. If any one of them fails, production comes to a halt."
Mark Langenhof – Business Development & Application Engineer, Rymoplast Deutschland GmbH
A partnership of equals
The collaboration between Rymoplast and technotrans began even before the plant was built. Thanks to previous joint projects, there was already a high level of trust in technotrans’ technology and expertise.
Working together, the two companies developed a custom container solution that consolidates all refrigeration components outside the production hall. The system was designed with a modular layout from the outset and was easily expanded to include a third extrusion line in 2025.
"The connections and the control system were already set up. Integrating the additional pumps and adjusting the output went smoothly."
Mark Langenhof
The Technology
Centralized Container Cooling System with Smart Free Cooling
At the heart of the system is a central cooling solution with a total capacity of 1.5 megawatts. Pumps, tanks, chillers, and control cabinets are fully housed in a weatherproof container assembly. technotrans placed particular emphasis on energy efficiency and operational reliability. The system combines highly efficient chillers with an open-loop cooling unit and adiabatic cooling. If the outside temperature drops below the required return temperature of the process water, the outside air takes over the cooling. The compressors can then be shut down completely or significantly reduced in load.
Benefits at a Glance:
- Energy-efficient: Intelligent free cooling reduces electricity consumption by approximately 650 MWh per year.
- Reliable: Constant cooling water temperatures ensure stable and reproducible production.
- Hygienic: A closed cooling system prevents contamination and reduces maintenance requirements.
- Future-proof: The modular system design allows for easy expansion of production capacity.
Lower energy consumption, lower CO₂ emissions
Thanks to a combination of free cooling, efficient control technology, and a closed-loop system architecture, the plant reduces CO₂ emissions by approximately 480,000 kilograms per year. Its high efficiency levels also led to a grant from the Federal Office of Economics and Export Control (BAFA).
Efficiency Meets Sustainability
For Rymoplast, the cooling solution is much more than just a supply system. It is a key component of the company’s sustainability strategy and ensures that high-quality recycled products can be manufactured in a cost-effective and resource-efficient manner.
Langenhof emphasizes:
"We manufacture high-quality products here that close the loop. To do that, we need partners who share our commitment to quality. In technotrans, we've found that partner—the plant is running smoothly and efficiently, and we would choose this path again in a heartbeat."
Do you have any questions?
We have the answers.
Roger Schmidt
Contact Sales
T. +49 (0)2354 7060-126
roger.schmidt@technotrans.de