collection & washing of pet bottlesincrease from austria’s starlinger to realize b-to-b...

Collection & Washing of PET Bottles

Steve Chen

Vice President

BU of Environmental Protection Equipment, Zhejiang Boretech Co., Ltd

49

6th China International Recycled Polyester Forum

Zhejiang Boretech Co., Ltd.Zhejiang Boretech Co., Ltd.ViceVice--presidentpresident

Steven ChenSteven Chen

Collection & Washing of PET Bottles

Status quo of Collection and Application of PET Bottles

Discussion about Difficulties in PET Bottles Recycling

Evolution of Bottles Washing Technologies

Boretech and Bottle Recycling Technology

Conclusion

Outline

50


Discarding post-consumer bottles at random contaminates our environments.

Hence, we should recycle them!

Status quo of Collection of PET Bottles

*Sources: Japan’s PET Bottles Recycling Promotion Council

Status quo of Collection of PET BottlesProduction of resins/ sales of bottles in JapanSales in the USASales in Europe

Collection rate in Japan Collection rate in USA Collection rate in Europe

(kt)

Collection rate

Sales/ P

roduction

51


R-PET Application: Textile

R-PET Application: Strapping

52


R-PET Application: Injection Molding

basket cosmetic container

R-PET Application: Packaging

53


1. High production cost2. Only suitable for

massive production3. Huge investment in

facilities4. Imbalance between

input and output

R-PET Application: B-to-B

washed PET flakes *This table is just assorted roughly, not absolutely

Quality Application Scope Added Value

High B-to-B High

film & flake

PFY

high-end PSF/ colored fiber/ monofilament

strapping tape

low-end PSF

Low paint Low

Application Scope of PET Recycling

Only 10 ppm of contaminants may affect the grade of flakes application.

Supported by reasonable hardware investment and production cost, the same feedstock (post-consumer PET bottles) should not be applied in low-end ways.

The final target is to realize

infinite B-to-B recycling with rational costs.

Classified by quality of flakes

54


“Label” issue also bothers Europe and the USA

Aluminum caps have nearly retired from the market. Now caps made from co-blended PP/PE can be easily separated by discrepancy in density.

European labels are mainly made fromBOPP and paper; hence European washing lines seem awkward in dealing with enormous PVC labels from Asia. Since density of PVC is close to that of PET, it is difficult to set them apart fully after broken.

Discussion about Difficulties in PET Bottles Recycling

Mexico-origin baled bottles:

With much sand and dirt, it is

tough for sorting. It’s also hard

to recycle a large amount of

waste water from the washing

lines that wash such bottles.

Baled Bottles from Different Countries

55



France-origin baled bottles:

W i t h high proportion of

colored bottles, and some

film plastics, it’s knotty to

sort.


China-origin baled bottles:

99% of them have been sorted

clearly. With manual sorting

of caps and labels, the sorting

model may be changed due to

increasing labor costs in the

future.

56


There is no universal washing process that can suit all

input materials with regional characteristics.

Each region owns typical washing lines designed based

on the features of local input materials, and troubles may

arise when the lines are used in other regions.

Modular designs are needed for washing lines.

Advanced processes should be in the manner of bottle washing.

Different Processes Suit Different Input Materials

PET Bottle Washing Process

input

output

bottles washing

unpacking

labels removal

wind sorting

bottles sorting

balingmixing & dedusting

dehydration

flakes rub-washing

grinding

57


Why we choose bottles washing?Contaminants can be more fully separated

from bottles before grinding than after

grinding.

How can we make perfect selection if

bottles unwashed?

Advanced bottle-washing process can

much lower water consumption in the

whole washing line.

Evolution of Bottles Washing Technologies

Traditionally, washing is carried out after bottles being grinded.

It will be more horrible to separate contaminants

from flakes without bottles washing.

To China locally collected bottles, most caps and labels have been manually removed; hence the bottles can be processed just by simple process. However, if input materials with caps and labels are fed into the washing line, terrible results will come along.

Traditional Process in China

58


Since BOPP or paper labels are stuck to bottles, they can be mostly removed through bottles washing.

With dirt, oil or sugar on the surface eliminated together, it does a lot of help for later automatic or manual sorting. To tackle with the tangled bottles due to too high pressure of baler, we can further loose such bottles through hot pharmacal washing.

Why bottles washing is needed?

1st Generation:

In small-volume batches

Introduced from the USA in late 1980s as inter-industrial application of large-scale washing machines;

Huge water consumption (5-tonwater/1-ton bottles);

Low capacity in each batch (300kg/batch, 1.5 batch/hour);

Need a great deal of civil engineering as assistant.

Evolution of Bottle Washing Machines

59


2nd Generation:

In big-volume batches

Developed independently and put into practice in Taiwan in 1990s and its prototype is concrete mixer;

Large amount of water consumption (4-ton water/1-ton bottles);

A bit higher capacity in each batch (1000kg/batch, 1.5 batch/hour);

Frequent technical issues; need a great deal of civil engineering as assistant.


3rd Generation:

Ccontinuous washing

Developed after 2000 with reference of European advanced technologies, mainly for waste plastics recycling;

Lower water consumption:

(1-ton water/1-ton bottles);

Higher capacity (4-6 tons/hour);

Much less technical issues; no need civil engineering as assistant.


60


We should improve online filtrating and

recycling system for process water to

further lower water consumption;

Since more plants will need have large-

scale capacity to process available input

materials in the future, single-line capacity

should be expanded further;

To realize online controls of temperature

and pharmaceuticals.

Developing Trend of Bottle Washing Machines

Currently, many washing processes in Europe still mainly wash flakes after grinding bottles. Only Italian producers such as Sorema and Amuthave bottle washing process, however, the prices for such washing linesare so expensive that common medium- and small-sized companies can’t afford it.

Taking advantage of European advanced technology, and modifying the structure and online filtrating and recycling system for process water, Boretech has developed its 3rd generation of continuous bottle washing system. Besides, with local characteristics in China, it can fully replace European facilities. Furthermore, with independent developing ability and investment, Boretech has been on the way to a higher-grade 4th recycling and washing system.

Can bottle washing units in China replace those in Europe and the USA?

61


BottleRecycleTechnology

Boretech and Bottle Recycling Technology

Meaning of our Logo:

With long-term experiences, Boretech possesses bottle-to-fiber technology through bottles washing and grinding. And then we use the recycled fiber to produce textile products. In a word, Boretech owns the whole set of PET recycling technology.

• With equipments quality and production process design similar to that in Europe and the USA, our facilities are offered at favorable prices.

• With mature technology with intellectual property right, we offer omnibearing services: production planning, plant design, equipments manufacture & installation & commissioning, after-sale services, and reserve of spare parts. Besides, we also help establish management process, flakes quality control system and cost analysis.

• We assist customers in obtaining information about feedstock purchasing and selling.

• Meanwhile, we provide you with complete replenishment of consumables and after-sale services to guarantee perfect operation of the equipments and production lines.

PET bottle recycling

Boretech Brand Orientation

62


According to environmental characters of different regions, coupled with customers’ budget, we offer customized, standard and modular designs.

Boretech Engineering Capability

• PET washing line in Chile– The plant uses 10% of virgin resin and 90% of flakes

to produce multilayer-films and then they are

thermally formed into fruit packing boxes.

Projects Example

63


• Modifying project in Beijing Incom– Beijing Incom purchases a full set of European equipment for

B-to-B recycling, but their washing line doesn’t suit Chinese input materials. Therefore, our company made a modification for the line, with all the labels removed before bottles put into the washing line.

Projects Example

• PET washing lines in a chemical fiber plan in India– The Indian producer has established one integrated complex

from post-consumer bottles to clothes, and it has purchased six washing lines from our company (1500kg/h each). Now it is carrying out one bottle-to-colored POY project with us.

30

Projects Example

64


• Feedstock pretreatment in B-to-B project in the UAE– The company uses B+B washing from Germany and palletizing & IV

increase from Austria’s Starlinger to realize B-to-B recycling. However, given excessive PVC labels in Middle East, the washing line can’t achieve the expected throughput, hence our company is asked to regulate the production line by labels removing.

Projects Example

• PET washing line in B-to-B project in Mexico– The company is conducting a B-to-B project by

chemical recycling, with capacity at 50 tons/day. Since they appreciate the quality of our flakes, the washing section is assigned to us.

– To save labors and improve sorting precision, the project is equipped with automatic sorting system from France’s PELLENC.

– The project is expected to start installation from late 2010.

Projects Example

65


• Bottle washing process is one indispensable sector in PET recycling in the future.

• The high growth in global PET bottle consumption is the solid basis of the eternal development of PET bottles collection &washing system.

• Taking account of both product quality and environment protection, the industry participants can build a favorable eco-friendly image for their corporations.

• With mature coordination between upstream and downstream industries, Zhejiang Boretech Corporation is convinced that we can be the guard in PET recycling market.

Thank You！

Conclusion

collection & washing of pet bottlesincrease from austria’s starlinger to realize b-to-b...

Documents