GenesysNext now manufactured in the USA by Piovan UnaDyn: A Game-Changer in Sustainable rPET Drying Solutions
Piovan UnaDyn
U.S. leader in plastics automation with specific solutions for recyclers and manufacturers using recycled polymers
Fredericksburg, Virginia, November 12, 2024 - Piovan UnaDyn, a global leader in the plastics processing industry, is pleased to announce the local manufacturing of GenesysNext, the innovative drying solution for rPET, now made in its 90,000 square foot facility in Fredericksburg, VA, in the United States. As your North American Partner for Plastic Production Automation, Piovan UnaDyn continues to lead the way in sustainable solutions that meet the evolving needs of the industry.
GenesysNext is the Piovan's proven drying solution specifically designed and developed to optimize PET and rPET preform production. Designed on these premises, it is ready to process recycled PET, enhancing productivity and process stability while ensuring complete control over operations.
The Increased Use of Recycled Material
The remarkable increase in the use of recycled materials introduces new variables in the processing of PET for preform production. These include variable humidity content, the presence of contaminants, lower intrinsic viscosity values, and differing rheology or bulk density of raw materials. As a result, the preform production process demands consistent quality, flexibility, and speed in achieving stable operations while minimizing scrap rates.
GenesysNext is Piovan’s new generation dryer specifically designed and developed to optimize PET and rPET preform production. Built on these premises, it is ready to process recycled PET, enhancing productivity and process stability while ensuring complete control over operations.
For the first time, GenesysNext synchronizes the drying and injection processes, allowing the Piovan dryer to regulate key process variables to maintain stable injection pressure. Furthermore, the GenesysNext algorithm serves as a powerful tool, predicting system evolution by analyzing trends in key variables and proactively stabilizing the process. These advancements significantly reduce scrap rates while maintaining high and consistent quality in the produced preforms.
“Our goal is to provide innovative solutions that not only enhance productivity but also support environmental stewardship,” added Angelo Suar, President of Piovan UnaDyn, Piovan Canada and Piovan Mexico “With GenesysNext, we are offering our customers a tool that can adapt to their needs while driving down costs and promoting sustainable practices.”
GenesysNext Evolution for Perfection
GenesysNext represents the evolution of the first generation of Genesys dryers. Known in the marketplace for its energy efficiency in the drying process, Genesys has set the stage for GenesysNext to enhance overall efficiency in the preform production process. By synchronizing drying and injection processes, it aims to achieve the highest quality levels in the final product at the lowest cost per preform produced.
Key features of GenesysNext include:
- A completely new, intuitive, user-friendly HMI with a color 12” touch panel.
- PLC control that increases computing power and enables comprehensive process control and traceability.
This powerful control system can now manage the entire bay, including a second dryer for increased drying capacity or as a backup unit, alongside the mold dryer, hopper, split hopper, condensing unit, smart mold dehumidifier, and gas burner (if included).
Maximum Process Stability
GenesysNext is designed to ensure a stable process with minimal scrap. Material IV (Intrinsic Viscosity), a critical parameter in PET preform production, is effectively monitored through hydraulic injection pressure control. This value is integrated into the dryer control system, which, aided by a patented algorithm, adjusts all relevant parameters (including dew point, flow rate, and temperature of the process air) to maintain injection pressure stability at the desired set point.
The control algorithm not only reacts to current conditions but also predicts future developments by analyzing key variable trends. This proactive approach enables the system to achieve stability in the shortest time possible.
The tangible benefits of this system include increased productivity, reduced scrap materials, consistent quality in terms of IV and Acetaldehyde values, potential decreases in actual injection pressure (resulting in reduced stress on the melt resin), and lower energy consumption for the injection molding machine.
Pure-Tech: The State-of-the-Art Activated Carbon Filtering System
The Pure-Tech filtering system is a cornerstone of the new concept embodied by GenesysNext. Its objective now includes not only mechanical dust filtration but also the chemical absorption of contaminants. With the intensive use of recycled materials, the presence of VOCs (volatile organic compounds) has become more common, and GenesysNext is fully prepared to process any kind of rPET without compromising the quality of the final product. Pure-Tech is a proprietary technology protected by a pending patent.
Additional enhancements include a novel system for detecting the dew point of process air, which collects multiple samples to ensure a more reliable and stable measurement. Additionally, the design of the desiccant towers has been upgraded to boost absorption capacity.
“GenesysNext represents a significant leap forward in our commitment to sustainability,” said Ernesto Fonseca, Commercial NA Director at Piovan UnaDyn. “By integrating advanced injection pressure control with an optional PureTech filtration system, we empower our customers to meet their production needs while also contributing to a circular economy. This dryer is not just about efficiency; it's about responsible manufacturing.”
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Revolutionizing Industry 4.0 Standards in Drying Technology
Equipped with a comprehensive sensor kit for performance monitoring and predictive maintenance, GenesysNext incorporates temperature probes on the desiccant tower and pressure transducers on the filter. Advanced control capabilities allow for extensive data analysis, delivering only the most relevant information to users. Key features include:
- Integration of frequency converters on process blowers for real-time diagnostics and proactive maintenance scheduling.
- Unique control algorithm for managing process airflow, eliminating the need for airflow meters in the field and enhancing accuracy without periodic calibration.
- Monitoring of filters using pressure transducers to estimate the remaining lifespan of filtering cartridges.
- Utilization of new temperature probes on desiccant towers to prevent thermal stress on molecular sieves, ensuring consistent performance over time.
The local manufacturing of GenesysNext at the Fredericksburg facility marks a significant milestone in Piovan UnaDyn's commitment to the North American market. By bringing this proven technology closer to customers, Piovan UnaDyn is not just shortening delivery times and improving service support – it's strengthening its position as a leading partner in sustainable plastics processing solutions. This strategic move reinforces the company's dedication to supporting the region's transition towards a more sustainable and efficient plastics industry, while maintaining the high-quality standards that have made Piovan a global leader in the sector.
For further information, please contact:
Cathy Weise
Marketing Specialist
T: 703.490.7000 | D: 703.490.7076
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Note for the Press
Established in 1957, Piovan UnaDyn is one of the leading companies in the United States specializing in providing complete automation systems, showcasing high engineering skills to develop customized plant solutions with innovative features that satisfies diverse requirements across various industry sectors. Moreover, Piovan UnaDyn assists customers from initial planning through start-up, with a commitment to follow-up support.
Since 2008, Piovan UnaDyn has been part of the PiovanGroup.
The PiovanGroup is a world leader in the design and manufacture of process automation systems for the storage, transport and handling of polymers, bio resins, recycled plastics, food liquids, food and non-food powders. In recent years, the Group has also been particularly active in the development and production of systems related to the bioeconomy and circular economy for the recycling and reuse of plastics and the production of plastics that are naturally compostable in the environment, taking advantage of cross-selling opportunities. Since October 2018, Piovan S.p.A. has been listed on the Italian stock exchange in the STAR segment. With 90 years of experience, more than 2,000 employees in 14 production plants and 43 subsidiaries/service and sales offices around the world, the Group is close to its customers on a global scale, also thanks to the continuous innovation of the solutions developed and the constant support, from the design phase of the plants to their installation, commissioning, and operation. Sales in 2023 exceeded 570 million euros.
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