
Fluff-Tec
Your solution for recycling soft materials
Optimal handling of fluffy materials
For rigid bulk materials made of PE, PET, PP, ABS, or PS, there are effective recycling solutions today. Fluffy materials, by contrast, are difficult to handle. ‘Fluffy materials’ refers to soft or thin films—sometimes multi‐layer packaging films—rigid films (e.g. from hard‐shell packaging), as well as foams, textile fibers, and even wool residues.
Films are often divided into two categories:
- Flexible (2D = Type A): lightweight agricultural films with very low bulk density and thickness
- Rigid (3D = Type B): for example, PET flakes
Other types include:
Solutions for the future

FLUFF-TEC – Always the right concept!
Zeppelin Systems boasts decades of experience in the plastics sector and in recycling processes—and has direct access to the corresponding plants. This expertise is integrated into our Fluff-Tec® concept. In close collaboration with the customer, we develop a bespoke solution concept, which, if required, includes trials at a Zeppelin technical center. We then select the appropriate technology or product for the application—and, if necessary, design new components. This ensures that your recovered materials are processed safely and economically at all times.

Handling is crucial
To ensure reliable handling, fluffy materials must be understood, examined, and characterized. The key factors are flowability, conveyability, storage behavior, and bulk density. Many fluffy materials readily alter their bulk shape under even slight external mechanical stress or their own weight, as air escapes from their voids. The entire bulk can be heavily compressed (1). Once the load or fill height is reduced, a pronounced elastic rebound occurs (2)
The optimal process for your bulk material
Together with you, we define the handling and processing method for your bulk material. If the material can be stored and conveyed normally, proven standard technologies from Zeppelin Systems are used in subsequent processing. Problematic, low-flow fluffy materials—such as film remnants—tend to bridge and consolidate over time, preventing discharge from silos. These materials can be processed by compacting, homogenizing, and further handling with specialized integrated solutions from Zeppelin Systems.
PROCESS EXPERTISE MEANS ZEPPELIN SYSTEMS The key to handling fluffy materials is mastering the entire process. It is not enough to adapt individual components to the process; the entire process engineering must be considered holistically—from filtration and separation to energy-optimized compaction and homogenization.
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