6000kg/h Food Grade PET Bottle Washing Line
PET bottle recycling system is used to recycle from PET bottles bales to PET flakes, which with big capacity from 500 kg/h to 9000 kg/h.This process of washing and crushing is consist of different function units. The final product rPET flakes has a stable quality and various grade applications, especially for PSF ,POY manufacturer with big capacity. Recent year, BoReTech develop new technology, rPET can be achieved Bottle-to Bottle grade application with FDA approval.
B-to-B Grade PET Bottle Recycling Line
| Estimated Plant Parameters |
Input Capacity
(kg/h) |
Required Area
(m2) |
Installed Power
(Kw) |
Required Water
(kg/h) |
Required Steam
(kg/h) |
Requied Compressed Air(m3/min) |
Manpower |
| 1500 |
1500 |
600 |
2.25 |
700 |
3.5 |
5 |
| 3000 |
2000 |
900 |
4.5 |
1300 |
6.5 |
7 |
| 6000 |
3000 |
1000 |
9 |
2300 |
12 |
11 |
| 9000 |
4500 |
1600 |
14 |
3200 |
20 |
16 |
The above parameters are calculated based on the standard contiguartion;PET bottle material composition and factory management level will affect consumption.
Water consumption parameters are calculated based on using wastewater reuse system.
| Production Consumprion Table-Average Energy Consumption per ton Flakes |
Capacity
(kg/h) |
Electricity Consumption
(KWh) |
Steam
(kg) |
Washing Detergent
(kg) |
Water Consumption
(ton) |
| 1500 |
170 |
550 |
12 |
1.5 |
| 3000 |
160 |
500 |
12 |
1.5 |
| 6000 |
150 |
450 |
12 |
1.5 |
| 9000 |
145 |
400 |
10 |
1.5 |
Process Flowchart:
De-baling----- Label Scrapping------ Label Separation------- Bottle Pre-washing--------Manual Sorting and Metal Detecting-----Wet Grinding-------Gravity Separation-------Chemical Washing for PET Flakes-------Rinsing--------Drying--------Packing
De-baling Section
De-baling unit adopts weighing-connected feeding device by high automation technology and break up bottle bales and remove mixed metal. The special knife structure can avoid any unexpected mechanical clogging.
Sieving Section
Sieving unit including dry trommel, disk screener and metal removal device to separate some big impurities such as mud, sands and metals from PET bottles and flakes. Meanwhile, through digital technology likes metal detector, pipe-type metal separator, metals can be separated automatically by flapping device to reduce inline manpower. Besides, belt-type metal separator can reach the same function.
Label Separation Section
This label separation unit is mainly designed for heat shrinkage label removal.
Label separation unit from BoReTech has two types. One consists of patented label scrapping machine and label blowing machine which wind-force is adjustable. When facing limited space, the new design of compact label remover is also a good choice to scrap heat shrinkage labels and separate them by one machine.
Bottle Pre-washing Section
The primary features of this process are the automated water circulation system, continuous feeding and washing. This system uses special designed inner structure to cause friction for PET bottles inside the machine to remove most of adhesive labels, and uses the high-temperature chemical water to remove dirt, sands, glues, rubbers, metal and other impurities on the surface of bottles.
Batch pre-washing for the recycling of oil bottles can be adopted to ensure the sufficient contact time between bottles and chemical water, so that the oil can thoroughly dissolved, and finally achieving the cleaning performance.
Optical Bottle Sorting Section
BoReTech provides optical sorting machine and integration solution by cooperating with well-known sorting device manufacturers across the world. On one hand, automatic optical sorting machine can reduce the management cost and manpower requirement, and on the other hand guaranteeing the stability of sorting.
Non-PET, color bottles and metals can be detected and sorted out by NIR, optical sensor, optical camera and metal detector in this section. It provides guarantee the PET material's purity.
Manual Sorting & Crushing Section
Although automatic sorting can achieve high sorting efficiency, but it cannot guarantee 100% sorting precision. For high-grade downstream application of PET flakes, manual sorting is still required at present. Especially for areas with relatively lower labor cost.
Crushing unit grind PET bottles into flakes by relative mechanical motion of blades. BoReTech grinder adopts the wet crushing which achieves the washing effect through water added; on one hand, it can reduce the temperature due to generated friction and reduce the abrasion of the blades too; and moreover, it reduces the loss of the powder. BoReTech also provide sound-proof solution to protect operation labor from noise damage.
Floatation Section
Secondary washing of PET flakes after crushing is very important. Floatation unit separates PO& PP/PE caps which density is below 1 by using water as the separation media. This unit is comprised by floatation washing and packing silo. It's good to remove caps, rings to keep flakes with stable quality. And impurities of final products can be reduced to 100 ppm or even to 50 ppm.
Hot Washing & Friction Washing Section
This unit is comprised by hot washing with chemical water, turbo friction washing and automatic detergent dosing system. Closed-loop connection and reasonable collocation of the functions can effectively remove oil, glue and other impurities attached to flakes. All above control is automatic which reducing production costs and achieve high efficiency of the production process.
Continuous Rinsing & Flushing Section
The main idea of the process lies in the further separation of impurities and remove the detergent in chemical hot washing process. Fresh water is added to remove the detergent residual on flake surface during the previous hot washing and some separated suspended substance after the friction. It ensures the sufficient time of flakes washing.
This unit is consisting of continuous rinsing machine, rinsing tank and salt-separation tank if necessary. Flush washing is supplemented to separate impurities in maximum and make sure the cleanness and transparency of flakes.
There are two options for reference.
Dewatering Section
De-watering process is running by high-speed mechanical centrifugal force, the moisture content of the flakes will be reduced to be less than 1%. If the heat-exchange air drying is supplemented later, the moisture rate of the flakes will be further reduced to be less than 0.7%.
Dust-removal Section
Combined with the years of experience in the production of PET industry, PET dust has potential negative impact on the downstream product process, especially the production process of POY and PET sheet.
Zig-zag separator can effectively separate the dust in the flakes, small plastic labels or film by taking advantage of the gravity and the special internal structure design.
The label aspirator separates the label and fine impurities from the flakes by the negative pressure which generated by blower, and can be used by multiple assembly.
Flakes Sorting, Blending & Packing Section
For high-grade PET flakes applications, automatic optical flake sorting unit is an indispensable module. The unit including automatic flake sorting, eddy current, and pipe-type metal separator. These devices would maximize the removal of impurities before packing to ensure the stability of flakes quality.
Flake with low impurity content and stable quality is a standard to measure PET recycling process. For the various quality factors during PET recycling process, blending equipment and on-line detection device especially designed can ensure the various quality indicators to meet criteria and to make sure no single parameter exceeding the requirement, so that the quality of the flakes will be guaranteed. On-line weighing device can monitor real-time production flow.
Packing unit, by taking advantage of the shaking system specially designed, can make the packing of the flakes reach the fix weight and maximize bulk density, which greatly reduce the packing and transportation costs.
Advantage of PET Bottle Washing Line by BoReTech
- Food grade PET bottle washing line supplier in Asia;
- Greater capacity - Greater than 6t/hr input capacity of PET bottle recycling system with full automation and intelligentialize;
- Water saving -provide waste water treatment to decrease water consumption to be lower than 1 liter for each ton of PET flake;
-Optional Functional Unit for your choice:
1.Automatic Detergent Dosing System:In-line real-time monitoring,save manpower.
2.Online Water Saving System:Save water consumption.
3.PET Fines Purification:High speed centrifugation,multi-step separation,capacity:500 KG/H.
4.Tntegrated Automation:Monitor all machine running statuses and conditions,
fix any equipment problem in a timely manner and enhances plant safety and control stability.
1,pre-sale support:
Normally we suggest you paint our standard color , but we can supply customization paint service by paid.
2,after-sale service:
Warranty:1 year for machinery,6 months for electrical.
For mechanical parts, our guarantee duration is 12 months. If the part is broken within this period, we will send the spare parts immediately to the client for repairing.
3,technical support:
Normally, we send our engineer(s) to supervise the installation and commissioning. The buyer need to prepare the operation staff to implement it. BORETECH is able to send mechanical engineer, electrical engineer and operation engineer. The operation engineer is to help the buyer's labors to know how to operate the washing line and get the best efficiency.
BoReTech is one of the major supplier of PET bottle recycling system in Asia . We uses the around 30 years of fiber making and bottle recycling experiences to manufacture PET Bottle recycling machine and configure Pelletizing line, Polyester Staple Fiber line, POY line and Bottle to Bottle Line. At present, we have supplied about 170 sets plant for more than 30 countries. Our customers in the US, Japan, EU manufacture food grade rPET resin for such well-known brand owner's such as Coca Cola, Niagara Bottling, Nestle, etc.
Boretech can help our customers to make right configuration of the machinery, and find the right position in the industries. The most important value is that we can help our customers to minimize the learning cost and to avoid making any mistake during investment.
FAQ
Q:How do you assistant to install the machine on worksite?
A: Normally, we send our engineer(s) to supervise the installation and commissioning. The buyer need to prepare the operation staff to implement it. BORETECH is able to send mechanical engineer, electrical engineer and operation engineer. The operation engineer is to help the buyer's labors to know how to operate the washing line and get the best efficiency.
Q:What do you guarantee on China local brand for bearing and gearbox?
A:For mechanical parts, our guarantee duration is 12 months. If the part is broken within this period, we will send the spare parts immediately to the client for repairing.
Q:Can I use machine with different color?
A: Normally we suggest you paint our standard color , but we can supply customization paint service by paid.
Q:What about packaging and transshipment?
A: It depends on capacity and equipment selection. For example, the line with 3 ton/h input capacity, there will be 15x40'HQ containers from China, and 1x40'HQ container from Taiwan. The crusher and crusher blade are made in Taiwan with excellent quality. For some special case, if the client requests the batch type bottle prewashing machine, we will need one flat rack for loading that.
Q:What is the delivery of the line?
A: 3~4 months after receipt of the down payment and L/C.
Q: How far is your factory from Shanghai?
A: It takes 1~1.5 hours from Shanghai airport to Boretech according to traffic situation.
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