China Wpa-3000 PET Bottle to Bottle Recycling Line

WPA-3000 PET Bottle to Bottle Recycling Line
There's a strong signal around the world about an ongoing trend among Global Consumer Goods brands and retailers of increasing the recycled content in their packaging to an average of 25% by 2025. These efforts of "closing the loop" initiative has become a real competition among by the International Brands these days.
Meanwhile, all major bottle preform companies are successfully the recycled PET combined in preform manufacturing sometimes in 100% ratio. Multiple feasibility studies show that this is not only environmentally right but it also brings significant economic benefits, which are vital for any business.
BoReTech is the leading supplier of post-consumer PET recycling solutions in Asia. We are proud with our 30 years of Polyester fiber manufacturing and plastic waste recycling. At present, we have over 150 plastics recycling lines successfully working in more than 30 countries across the Globe.
Our customers in the US, Japan, EU manufacture food grade rPET resin for such well-known brand owner's such as Niagara Bottling, Nestle, etc.
BoReTech offers a complete bottle to bottle recycling system for the conversion of post-consumer PET bottle bale into food grade rPET pellets. The resulting rPET pellets are suitable for applications in direct contact with food (FDA/EFSA approval).
The process is fully continuous and integrates extrusion as a first process section and solid-state polycondensation as a second process section into one integrated system. A fully advanced automatic and intelligent control system can be built in the line for easy and better operation. This system can be designed to have control optimization based on the each production line, what's more, we're able to develop customized modules , and so on, with functions mentioned above, we're capable of enhancing product operation, device monitoring, and production management.
Our Strengths:
- BoReTech washing process is the only technology designed in Asia which achieved USA FDA LNO (Letter of No Objection) standards.
- World-wide installation experience: USA, European Union, Asia, Africa, Latin America, India, etc.
- Primal focus on the sustainable R&D and cutting-edge engineering aimed to recover 100% of post-consumer PET waste.
- The shortest time for delivery, installation and start-up in the industry.
- Trust and confidence of the existing customers. 2/3 of our clients come for more machines to BoReTech to expand their production capacity.
- Experience in manufacturing food-grade rPET resin with significant economic benefits for our customers.
Estimated Plant Parameyers
Item/ModelWashing + Pelletizing + Patent + Chemical AddivitiveWashing + Pelletizing +SSPWPA-1000WPA-1500WPA-2000WPSCapacity(kg/h)900-11001200-18001900-2500800-2000Required Area(m2)1800230023002350-2550Installation Power(kW)1300155017001520-1820Required Water(m3/hr)22.529.529.522.25-29.5Chilling Water(m3/hr)20252550-75Steam Consumption(kg/h)70013001300700-1300Compressed Air(m3/min)70013001300700-1300Nitrogen Consumption(Nm3/hr)///40Manpower(Nos.)7997-10
PET Bottle to Bottle Recycling Process
Washing Line
De-baling - Dry Trommel - Iron Belt Separator - Label remover Unit - Bottle Pre-washing - Automatic Sorting (Optional) - Label Scrapping - Crushing - Drying - Floating - Hot washing& Turbo washing- Rinsing- Zig zag Separator- Eddy Current (Optional) - Automatic Sorting (Optional)
Pelletizing
Blending - Analysis - Pre-heating- Drying- Extruding- Pelletizer
Continuous SSP
Pre-crystallizing- Pre-heating- SSP Reactor- Pellet Cooling- Storage/Packing
Capacities
PropertyUnitDesignRangeOutput Design capacity
extrusionKg/hourMax.2200(based on 8000h/year)Output Design capacity
SSPKg/hour2000(based on 8424 h/year)Remarks to the difference in design capacities:
Due to the more frequent maintenance intervals of the extruder compared to the SSP plant the extrusion capacity is higher than the SSP plant.Minimal system capacity%60min
Utility consumption
Consumption PET Extruder Line
UtilityUnitExpected ConsumptionInstalledElectrical power[kW]578808Recirculation
Cooling Water (30/38°C)[m3/h]3040Process Water (70/90°C)[m3/h]3040Fresh Water/Treated water[m3/h]0.20.5Instrument air[Nm3/h]56
Consumption PET SSP Line
UtilityUnitExpected consumptionInstalledElectrical power[ kW]137190Nitrogen N2[Nm3/h]3550Natural Gas[Therms/h]7.922Instrument air[Nm3/h]1316Compressed air[Nm3/h]holdholdChilled water circulation flow rate[m3/h]2030

Functional Section
Extrusion Process
The basic design concept for the system is: The moisture and organic small molecules can be removed after the pre-drying and screw extrusion with high performance vacuum system.
The Extruder is a co-rotating, conical, twin screw extruder. This new extrusion system brings together the familiar superior plasticization and homogenization of a parallel twin screw extruder with the specific advantages of the conical twin screw system. The screw is equipped with easy changeable shear and mixing elements which allow adjusting the plasticizing exactly to each demand. Effective degassing supported by a vacuum pump removes monomers in the front of the plasticising unit. Underwater pelletizing system, provides up to 35% crystallization of the product.
Solid State Polycondensation (SSP) process
The solid state polycondensation process (SSP) is required to up-grade the molecular weight of the amorphous PET pellets to high quality bottle grade resin, which meets the regulations of the authorities and requirements of the packaging industry.
SSP and decontamination from migrated substances are diffusion-controlled processes. The main design parameters are temperature and residence time.
Both, IV build-up as well as decontamination and AA removal, require process temperatures above 200° C and hold up times in the range of 10 to 16 hours, typically.
During the SSP process PET degradation products from previous heat histories and the decontamination process are re-polymerized. This reduces AA generation in injection moulding.
Typically, the resin is cooled down after the process in order to allow storage and shipping without any impact on product properties.
During the SSP process and molecular chain build-up, two main reactions will take place: the transesterification and esterification between polymer molecules.
Product Feature
Features of Extruder
This new extrusion system brings together the familiar superior plasticization and homogenization of a parallel twin screw extruder with the specific advantages of the conical twin screw system. The screw is equipped with easy changeable shear and mixing elements which allow adjusting the plasticizing exactly to each demand. Effective degassing supported by a vacuum pump removes monomers in the front of the plasticising unit
• Big intake section / very good in-feed behaviour
• Conical design ensures very good screw filling
• Therefore, high output per screw rotation (kg / rpm)
• High torque possible because of huge screw shaft diameter
• Very stable pressure behaviour
• Excellent homogenising offered by co rotating system
• Excellent feeding performance
• Small melt dwell time distribution inside the processing unit
• Therefore low melt temperature
• Therefore low energy consumption
Features of SSP
In the SSP process the PET pellets are further decontaminated and their molecular weight is increased to obtain high-quality bottle grade resin, which meets the regulations of the authorities and requirements of the packaging industry. SSP and decontamination of migrated substances are diffusion controlled processes. The main design parameters are product temperature and residence time.
The solid state polycondensation process (SSP) is required to up-grade the molecular weight of the amorphous PET pellets to high quality bottle grade resin, which meets the regulations of the FDA and requirements of the packaging industry.
• Especially suitable for small and medium enterprises in the third world countries which has no polymerization facility.
• High I.V. chip downstream users
• Stable performance, economic investment and high C/P value.
• Long-term experience and quality control method of washing line will provide excellent and stable quality of PET flakes for continuous and stabilized feeding of pelletizing and SSP.
• Energy-saving and environmental-friendly: reuse heat energy from pelletizing and SSP in washing process.

WARRANTY
Mechanical Parts: 12 months after commissioning.
Electric Motors & Electronic components: 6 months from delivery or manufacturer's warranty.
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.
PACKING&TRANSPORT
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.
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.
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.