For its latest plastic regeneration systems, FAE selected Commander C300 and Unidrive M700 variable speed drives from Nidec Drives. The decision builds on an established technical cooperation and was driven by functional and operational requirements.
FAE has more than 40 years of experience in designing customised automated systems for industrial production. The company applies lean production principles to reduce waste, improve efficiency and optimise manufacturing processes in response to increasing global competition.
The project focuses on plastic granulation, also known as extrusion recycling. In this process, post-consumer and industrial plastic waste is sorted by polymer type, washed and shredded into flakes. Lightweight materials may be densified before entering the extruder, where the plastic is melted, formed into strands, cooled and cut into uniform pellets. These recycled granules are used as secondary raw materials in sectors including packaging, construction, consumer goods and automotive manufacturing.
From an industrial perspective, plastic recycling reduces dependence on virgin polymers and supports compliance with tightening environmental regulations. The growing availability of recycled granules also strengthens supply chain resilience and reduces reliance on fossil-based raw materials.
Within the system, Commander C300 drives control conveyors, pumps and screw conveyors to ensure stable material flow. For the extruders and densifiers, FAE installed three Unidrive M700 drives rated at 500 kW each. The drives were selected for their compact design, commissioning efficiency and low thermal losses, enabling a space-saving panel layout.
Commissioning was carried out using Connect software via Profinet, allowing configuration to be completed in approximately 15 minutes. In operation, the M700 drives reduced panel power dissipation by up to 2,800 W, resulting in estimated annual energy savings of around 24,500 kWh. Lower heat generation also reduced cooling requirements and contributed to improved system reliability.
