Introduction (Capacity 1500 kg/h) :
The Process is used to recycle big capacity and stable quality raw material, especially for PSF manufacturer and recycled POY manufacturer with big capacity.
The process flowchart :
A. De-baling
After the PET bottle bales are placed on the feeding belt conveyer, the baling wire should be cut and removed manually. The bottle bale will be loosed by powerful rolling paddles. And then all bottles will be conveyed to next machine.
B. Bottle Prewashing Section
Under powerful stirring, the continuous bottle washing machine which combined the power functions of machinery, chemistry and heat energy will separate and remove over 90% impurities (including environment polluted substances and labels, but thermal shrinkage PVC labels excluded). Afterwards process equipment will be protected properly due to purified bottle bodies. Especially the crusher will less suffer because of those hard solid substances were removed.
A dry trammel can be added to do try bottle prewashing to remove most of the solid objects from the bottles surface to reduce the chemical and water consumption.
C. Label Separating Section
There are many types of label used for covering bottles. Most labels will be removed in bottle prewashing process except the PVC labels which is formed by thermal shrinkage. The PVC label scrapping machine is used to tear PVC labels and other plastic labels, and broken labels will be separated from the PET bottles by pneumatic power in Label blower.
The bottles with PVC label will be separated by the PVC bottle sorting machine, People will pick out the PVC bottle by hand, and the PVC label bottles will go to the PVC label scrapper, and then the labels will be removed in the label blower.
D. Bottle Sorting Section
There are two kings of bottle sorting in the system.
One sorting is done by optical sorting. The NIR technology is used to do polymer sorting , color sorting can be processed by CCD or Visible light technology. The detected objected would be ejected by nuzzles with high press air.
The other is to do sorting manually as final bottle quality inspection before it goes to crusher. The requirement of the labors can be adjusted according to the input bottle quality.
E. Metal Separation Section
Metal separation can be processed in different process.
1. A strong magnetic separator can be hang over the belt conveyer, the ferrous metal would be adsorbed to the magnetic separator, it could be auto discharging for metal or manually.
2. The bottles would be lay on the moving belt conveyer with metal detector, the bottle and metal would be discharged by a three way flap. One more step on the sub-line would recover the bottles discharged with metal.
3. Metal detector would be installed on the sorting conveyer to prevent any metal going to the crusher. Sorting person can find the metal and pick it out if the conveyer is stopped by metal.
4. A Metal separator is installed to remove all metals before packing, the nuzzles with high press
Air would ejected the metal with some flakes when metal is detected by high sensitive metal detector.
F. Wet Crushing Section
This Section is specially designed for crushing PET bottles, which have following characteristics: input smoothly and output stably, low power consumption, low noise and vibration, strong structure, low maintenance cost. It's designed by a wet grinding way.
It can be designed for two steps grinding or one step grinding.
If need to 24hour non-stop running, one crusher would be designed for standby.
G. Flotation & Friction Washing Section
The crushed flakes are mixed with Polyolefins material; this section is using the gravity difference of PET(~1.3) and Polyolefins(~0.9), and water (gravity 1) as a media to let PET sink and Polyolefins float on the water. This effective will make PET more purified, and collected Polyolefins flakes can be sold as byproduct.
With chemical, friction and heat power, the glue will be entirely separated from flakes. The horizontal centrifugal dryer will remove the glue, mud from the flakes.
H. Rinsing Section
After the centrifugal drying, some chemical is residual on the flakes surface. The fresh water would be add to rinse the flakes to reduce the caustic content and give natural PH value of the flakes.
In the meanwhile, any floatable material would be removed with the overflowing water.
I. Drying, Mixing & Packing Section
High speed mechanical dryer is used to remove most of the moisture on the flakes surface, to achieve lower than 1% moisture, a hot air conveying system is required to remove the moisture.
To homogenize the impurities and get a higher acceptable product ratio, the mixing silo is to blend and store flakes. Mixing is done by an internal screw.
With a vibration system, 20% packing cost and transportation cost can be reduced.
J. Dust Separation & Optical Sorting Section
Because of weight difference, the air going up from the bottom would take away the dust, light material and an cyclone would collect the dust and light material. Flakes would go down because of gravity.
To achieve extremely low impurity content, optical sorting can be installed after drying section to eject color PET, non-PET as well as metals.
G. Process Water and Chemical Solution Circulation Section
Fresh water is applied at the final rinsing machine only. The water would be used to do second or more rinsing to remove the chemical residual and floatable material. Then water would be applied for floating separator and crusher.
Extra water can be used to prepare the chemical water for hot washing and bottle prewashing.
One set of sludge removal system each for bottle prewashing system and flakes washing system is configured to reduce to chemical consumption in the line.
The sludge and powder would be removed by machines which are discharged from the centrifugal machines.
Composition of PET Bottle Bale:
| Description |
Characteristic |
| PET Containers |
One-way bottles |
| Colors Fraction |
PET bottles should be pre-sorted by color. If the percentage of color bottles is higher than 30%, we suggest customer to install the automatic color bottle sorting machine to achieve efficiency. |
| Base Cups |
Included, if any, and should be PP or PE plastic. |
Labels
(shrunk or glued) |
The production line is designed for removing label mechanically. All type of labels will be removed by mechanical action. It includes paper, BOPP, PET, PVC, etc. |
| Caps |
PP, HDPE |
| Caps seals |
EVA, PP ( floatable material )
PVC or rubber seals are not separable. |
| Glue |
Hot melt, water borne. |
| Contamination |
Mixed with the bottles could be present contaminations coming from the collection and storage of the postconsumer bottles or made by consumer. These contaminations include mud, sand, soil, glass, organics, paper, residual liquid, etc.
Total contamination content should not exceed 10%. |
Total Non-PET
Containers |
Non-PET containers max 2% of which |
| PVC Container |
0.5 -1% max |
| Polyolefins Container |
3 % max. It will only affect the output volume but not quality of end product. |
Wrong PET Colors
and Opaque |
1-2% max |
| Glass and Ceramic (metals excluded) |
0.5 -1% max |
| Magnetic Metals |
0.5 - 1% max |
| Aluminum and Non Magnetic Metals |
0.5 - 1% max
All kind of metal will be separated before crushing |
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.
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