NovaStar, SY109, Staple Fiber Plant with Bottle Washing and Reprocessing, 1500 kg/h (New)

Description

Overview
1. Pet bottle washing line with 1,500 kg/h input capacity
2. Dry pet flakes output: ~1,200 kg/h or depends on raw material composition
3. Recovery rate is normally around 70-80%
4. Precise data can only be supplied when customer’s bottles are defined
Input Material Specifications
1. Line capacity is designed for baled material; loose material will decrease capacity
2. Minimal bale size: 700 x 800 x 700 mm
3. Maximum bale size: 1,200 x 1,400 x 1,200 mm
4. Bale density: 150-350 kg/m³
5. Pet containers: one-way bottles
6. Colors fraction: pet bottles should be pre-sorted by color; if color bottles exceed 30%, automatic color bottle sorting machine is suggested
7. Base cups: included if any, should be PP or PE plastic
8. Labels (shrunk or glued): all types removed mechanically, including paper, BOPP, PET, PVC
9. Caps: PP, HDPE
10. Caps seals: EVA, PP (floatable material); PVC or rubber seals are not separable
11. Glue: hot melt, water borne
12. Contamination: mud, sand, soil, glass, organics, paper, residual liquid; total contamination content should not exceed 10%
13. Total non-pet containers: max 2%
14. PVC container: 0.5-1% max
15. Polyolefins container: 3% max (affects output volume but not quality)
16. Wrong pet colors and opaque: 1-2% max
17. Glass and ceramic (metals excluded): 0.5-1% max
18. Magnetic metals: 0.5-1% max
19. Aluminum and non-magnetic metals: 0.5-1% max; all metal separated before crushing
Final Product Quality Criteria
1. Intrinsic viscosity: 0.71-0.78 dl/g, depends on bottle’s I.V.
2. Bulk density (min/avg/max): 400/500/600 kg/m³
3. Flake size: 1-12 mm; fraction ≤ 1 mm: < 1%; fraction ≥ 12 mm: < 5%
4. Humidity: ≤ 1.5%
5. PE, PP: ≤ 20 ppm
6. Paper: ≤ 20 ppm
7. Glues/hot melts: ≤ 20 ppm
8. Organics: ≤ 20 ppm
9. Metals: ≤ 20 ppm*
10. In-organics: ≤ 20 ppm
11. PVC: ≤ 25 ppm*
12. Total impurity: ≤ 100 ppm
13. *Depends on efficiency of manual sorting section and input material quality
Process Description
1. Key point is removal percentage of impurity mixed from beverage factory to recycling plant
2. Design concept sets best environment for separating impurities based on 20 years of practical experience
3. Line is designed on module basis for future expansion with minimum investment cost
Functional Sections and Machinery
1. De-baling and label separating section
  1. Bales placed on feeding belt conveyor; baling wire cut and removed manually
  2. Bottle bale loosened by powerful rolling paddles
  3. Most labels removed in bottle prewashing process except PVC labels formed by thermal shrinkage
  4. PVC label scrapping machine tears PVC and other plastic labels; broken labels separated by pneumatic power in label blower
  5. Bale breaker: breaks bales into loose bottles; feeding belt conveyor length 5,000 mm, width 1,200 mm, power 13.2 kW; feeding speed adjustable
  6. PVC label scrapping machine: 80 blades, 285 screws, rotor diameter 800 mm, power 30 kW; rubbing blades and screws welded with high speed steel
  7. Label blower: separates labels and light membrane from bottles by pneumatic power; rotor diameter 2,000 mm, power 2.95 kW; pneumatic force adjustable by changing frequency of electrical fan
2. Bottle prewashing section
  1. Continuous bottle washing machine combines machinery, chemistry and heat energy to remove over 90% impurities (including environmental pollutants and labels, except thermal shrinkage PVC labels)
  2. Purified bottle bodies protect downstream equipment; crusher suffers less due to removal of hard solid substances
  3. Bottle prewashing machine (patented): washes bottle surface to remove sand, oil, mud and other contaminations; makes PVC bottles turn milky for easier sorting; diameter 2,000 mm, length approx. 15,000 mm, power 16 kW; feeding speed adjustable
3. Bottle sorting section
  1. Final separation before bottles are crushed; sorts remaining non-pet bottles, color bottles, label ashes, metal, garbage
  2. In areas where recycled bottles are over 75% single material and color, or at relatively lower labor manual sorting may be sufficient

Maximum Bale Size	1200 x 1400 x 1200 mm
Minimal Bale Size	700 x 800 x 700 mm