PET Bottle to Cotton Fiber Line
This is a solution recycle post-consumer bottles to synthetic fiber. All the fiber from waste PET bottles is recycled and eco-friendly.
Normally, BoReTech provides the fiber production line design which can make two or three types of fiber, such as good hollow conjugated fiber and regular tenacity solid fiber, or hollow conjugated fiber, regular hollow fiber and normal tenacity solid fiber.
We recommend customer to produce customized regenerated polyester staple fiber (PSF) with minimum power consumption and waste discharge. And we also coordinate with our customer to develop innovative downstream products with special fibers.
Input material:
Post-consumed PET Bottles, RPET Flakes, RPET Chips, PET Lumps, PET Strap, Fiber Waste, Off-grade Chips
Specification and Capacity of Various Polyester Staple Fiber
| Fiber Type |
Specification |
Capacity |
Application |
| Filling Fiber |
6D,7D,15D
Length:32,64mm |
20-100T/D |
Pillows, Cushions,
Mattres etc |
| Cotton Fiber |
1.0D,1.2D,1.5D
Length:38,44,51mm |
20-100T/D |
Polyester yarn,
Make PC yarn with cotton |
| Non-woven Fiber |
2.5D,3D,4-15D
Length:32-102mm |
20-100T/D |
No-woven fabric for shoes, geo-textile, bags, carpets, liner, leathers etc |
| Dope-dyed Fiber |
1.4-20D
Length:38-102mm |
8-40T/D |
Spun yarn, non-woven fabric for automatic industries, carpets, textile etc |
Feature/Advantages
One-stage service from PET bottle to Polyester staple fiber (PSF) ensures the final quality.
With the highest optimization of proposal to reduce the cost of project and achieve the maximum benefits.
Fully integrate the market resource, production technology and engineering experience into practical production system, and implement the technology transfer. Various Products would conform to the requirement of the customers and increase the competitive of the product in the market.
Steel platform design of spinning building reduces the height and cost of construction.
Automatic design of flakes feeding and drying system saves manpower and conversion cost as well as increasing the drying efficiency and flake quality.
PET Flakes Quality Standard Reference Table
| Moisture(%) |
<=1.5 |
| Label(ppm) |
<=30 |
| PVC(ppm) |
<=100 |
| Glue(ppm) |
<=30 |
| PP/PE(ppm) |
<=20 |
| Metal(ppm) |
<=10 |
| Total Impurity(ppm) |
<=200 |
| Flake Size(mm) |
12 |
Spinning Fiber(White)
| Item |
Unit |
Fiber Specification
|
1.56dtex
(White)
|
1.33dtex
(White)
|
| Tenacity |
GPD |
≥6.2 |
≥6.7 |
| Break Elongation |
%
|
23±4.0 |
23±4.0 |
| Fitness Variation |
% |
±3.0 |
±3.0 |
Break Elongation
Variation |
% |
±3.0 |
±3.0 |
| Double Length |
% |
≤0.3 |
≤0.3 |
Double Length Fiber
Quantity |
mg/100g |
≤10.0 |
≤10.0 |
| Fuse Fiber |
mg/100g |
≤30.0 |
≤30.0 |
| Crimp Nos. |
n/25mm |
10±2.5 |
10±2.5 |
| Crimp Ratio |
% |
15±2.5 |
17±2.5 |
| Shrinkage at 180° |
% |
5±1.0 |
6±1.0 |
| Resistance |
Ωcm |
(1~10)10-8 |
(1~10)10-8 |
Strength Variable
Coefficient |
% |
<=12 |
<=12 |
Fiber Production Process Flowchart
Feeding-----Melting-----Extrusion------Spinning & Quenching-----Filtration-----Sunflower Feeding-----Creel-----Tow Guiding-----Drawing-----Draw Batch-----Drawing-----Draw Chest-----Drawing-----Tow Stacker-----Pre-heating-----Crimping-----Relaxing-----Cutting-----Baling
*Configuration are optimized due to different types of fiber and capacity
Process Intro
Drum Drying: drying input recycled PET flakes and remove dust. After vacuuming, PET flakes water content will reach the required index;
Melting, extrusion, metering: PET flakes are fed into screw extruder, and moves forward by screw rotation. They are experienced a series of complex changes such as temperature, pressure, viscosity, etc. during moving.
Filtration: Filter impurities of PET flakes to prolong the service life of the components.
Spinning: Spinning is the most core section of polyester staple fiber production. rPET material are melted and extruded, under the action of pressure and heating, which are sprayed out through spinning holes, then cooled to form primary fibers.
Spinning Beam & Spinning Pack: it is mainly composed of metering pump and spinning pack, PET melt is fed into spinning pack through metering pump.
The spin pack has the function of filtering and pressurizing, removing impurities in the melt and evenly conveying the melt to the spinneret.
Quenching: The quenching device is the most important device in the spinning and cooling process. It can cool the yarn flowing out of each spinning hole uniformly, and reduce the sway and bonding to ensure a good spinning condition.
Take up: Take up bringing the tow together, drawing and fed into tow cans by sunflower feeding machine.
Creel: According to the process requirements, the polyester primary fibers are drawn out of the yarn head, and passed through tow guide, it is assembled into a bunch of fiber, which are be drawing later.
Crimper: Crimper can improve fiber friction coefficient, elasticity, feel, and thermal performance.
Oiling (anti-static) System: Add antistatic fluid to the oil tank to remove static electricity.
Drawing: Through drawing, the fibers have the fineness, strength and elongation required for textile processing.
Folding Machine: transform the original left and right chemical fibers into upper and lower distribution and reintegrate.
Relaxer: remove the fiber moisture, so that the fiber meets the required moisture content of the finished product, at the same time to avoid fiber becoming yellow as oil with moisture.
Baler: make PET fiber baled into baler.
BoReTech Brief
BoReTech is a resource environmental enterprise which integrates manufacturing, engineering and equipment supply. BoReTech is devoted to develop large input capacity of smart PET bottle recycling system with full automation and intelligence. Meanwhile, BoReTech as resources and technology integrator of recycled polyester industrial chain supply turnkey service of PET bottle washing line, bottle-to-fiber and bottle-to-bottle engineering.
Started as a post-consumer PET bottle recycling factory in Taiwan in 1991, BoReTech began to enter the field of recycled polyester fibers production in 1994. BoReTech possess of more than 20 years' manufacture experience of PET bottle washing and recycled polyester staple fiber and is well acquainted with PET material characteristics and have abundant experience for PET flakes downstream applications and technological knowhow, which promotes the evolution and upgrade of PET bottle washing system constantly.
BoReTech has obtained ISO9000, ISO14000, CE certificate and carry out long-term technical and cooperation with the internationally well-known manufacturers of automation equipment and is an international leading manufacturer in the manufacturing of PET bottle recycling system.
The target of enterprise's establishment is to promote resource recycling in the world and support customer stepping into this booming industry effectively with our long-term engineering capability, create the best commercial value, encourage energy saving and carbon reduction for a cleaner and healthier earth.
INSTALLATION AND COMMISSIONING SERVICE
Technicians from BORETECH are available to supervise customer's skilled staff for installation, commissioning, train customer's technical and production staff and help the staff to produce qualified end product.
DELIVERY TIME
180 days from the receipt date of the L/C or shall be finalized according to the project status. Partial shipment is allowed.
PACKING
The machines are wrapped by plastic film.
The electrical panels are wrapped by plastic film or in wooden cages.
The connection chutes and pipes are not packed.
The spare parts and loose material are contained in boxes or cases or on pallets.
TRANSPORT
The machines will be prepared, disassembled into the primary components for loading into container as full as possible. The customer has the right to request Boretech to load the assembled machines by extra expenses for changing container type and quantity.
WARRANTY
Mechanical Parts: 18 months from delivery.
Electric Motors & Electronic components: 12 months from delivery or manufacturer's warranty.
This warranty shall not apply in the case of:
Normal wear and tear on the machines and in particular on the blades and other parts subject to stress
during use of the machine.
In the case of processing materials other than those contracted and materials which may cause
damage and breakage caused from anomalous stress, wear or corrosion.
Non observance of the norms in the instruction and operation manual and in any case from incorrect
use, maintenance or storage other than that indicated by Boretech.
Execution of alterations or repairs without the prior written consent of Boretech.
The use of non-original spare parts supplied or recommended by Boretech.
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