Company founded 1975 US-based machinery business experienced in worldwide sales.

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NovaStar, MM116, PSF Fiber Production Line, PET Bottle Recycling and Staple Fiber Plant (New)

Description

  1. 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
  2. Input Material Specifications
    1. Line capacity is designed for baled material; feeding loose material will decrease capacity accordingly
    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 percentage of color bottles is higher than 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): production line is designed for removing labels mechanically; all types of labels (paper, BOPP, PET, PVC, etc.) will be removed by mechanical action
    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, etc.; 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 (will only affect output volume, not quality of end product)
    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 kind of metal will be separated before crushing
  3. 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
  4. Process Description
    1. Key point of post-consumer pet bottle recycling is removal percentage of impurity mixed from beverage factory to recycling plant
    2. Design concept sets up best environment for separating impurities based on 20 years of practical pet bottle recycling experience
    3. Recycling line is designed on module basis for future expansion; can be improved to get higher capacity and more stable quality with minimum investment cost
  5. Functional Sections and Machinery
    1. De-baling and label separating section
      1. Pet bottle bales placed on feeding belt conveyor; baling wire cut and removed manually
      2. Bottle bale loosened by powerful rolling paddles; bottles conveyed to next machine
      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 from pet bottles by pneumatic power in label blower
      5. Bale breaker: breaks bales into loosened bottles for following processes; length of feeding belt conveyor: 5,000 mm; width of feeding belt conveyor: 1,200 mm; power: 13.2 kW; feeding speed is adjustable
      6. PVC label scrapping machine: tears PVC and other plastic labels; number of blades: 80 pcs; number of screws: 285 pcs; diameter of rotor: 800 mm; power: 30 kW; rubbing blades and screws are welded with high speed steel
      7. Label blower: separates labels and light membrane from bottles by pneumatic power; diameter of rotor: 2,000 mm; power: 2.95 kW; pneumatic force is adjustable by changing frequency of electrical fan
    2. Bottle prewashing section
      1. Under powerful stirring, continuous bottle washing machine combines machinery, chemistry and heat energy to separate and remove over 90% impurities (including environment polluted substances and labels, but thermal shrinkage PVC labels excluded)
      2. Purified bottle bodies protect subsequent process equipment; crusher suffers less due to removal of hard solid substances
      3. Bottle prewashing machine (patented): washes surface of bottles 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 is adjustable
    3. Bottle sorting section
      1. Final separation before bottles are crushed; sorts remaining other substances (non-PET bottles, color bottles, label ashes, metal, garbage, etc.)