PET GRANULES FROM PET BOTTLES

THEN MAKING PET PREFORM

[EIRI/EDPR/3659] J.C.: 1744XL

INTRODUCTION

Nowadays, PET bottles are the global number one in beverage packaging. More
than 400 billion plastic bottles come on the market every year and PET is
becoming increasingly valuable as a recyclable raw material used in the
production of beverage bottles. Thus, it is important that all of the production
steps applied for the manufacture of your PET bottles are made sustainable for
the future.

The gentle treatment of resources and economical use of materials are a must
when it comes to sustainable production. Valuable raw materials such as PET
must be processed as efficiently as possible while still tapping into every way of
saving costs. The PET manufacturing and production process allows for the
application of a sustainable approach which can optimally combine environmental
awareness and cost effectiveness: the bottle-to-bottle recycling concept.

Bottle-to-bottle recycling plant efficiently recycles used PET bottles - and the
recyclate is then reused in the food and beverage industry as recycled PET (rPET).
The complete process comprises the cleaning of the used PET bottles and the
treatment of the recyclate so that the end product - which could come in the form
of flakes, pellets or preforms - can meet the highest quality requirements after the
recycling process. European and American certificates (e.g. FDA), and a number of
different corporate approvals, all confirm the high quality of the recyclate for direct
use in containers which come into direct contact with foodstuffs.

www.eiriindia.org 1
  Food-grade PET flakes and pellets

Recycling plant produces food-grade PET. With it, returned PET bottles can
be reused to make new PET bottles. The use of recyclate has clear economic
and ecological benefits.

 Flakes, pellets or performs

The procedure gives you the freedom to decide which end product you wish
to create. The decontamination step required for the material's later contact
with foodstuffs is only ever performed with flakes. Afterwards, the flakes are
either used directly or are made into pellets. Another extremely energy-
efficient use for the decontaminated flakes is the direct feeding of the
material into an extrusion process –

Worldwide, PET-bottles more and more replace glass bottles in the beverage and
food sector. The success of PET in comparison to glass is based on several
economic (and environmental) advantages.

On the one hand, the production of PET is less expensive and energy consuming
than the production of glass. Secondly, the light weight of the PET-bottle makes it
easier for merchants and consumers to handle the bottles and crates. It saves
energy during transport, particularly on long distance haulage. Finally, PET offers
more or less the same material properties as glass regarding hygiene, taste and
gas impermeability.

www.eiriindia.org 2
The negative impacts of PET-bottles in recent years result from their use as
nonreturnable beverage containers leading to a dramatic increase of beverage
container waste. But even here, changes are on the move, particularly in
industrialized countries, where PET-bottles enter more and more the existing
returning and refilling schemes. Apart from returning and refilling, recycling of
used PET-bottles is also possible, and will be an interesting option especially for
developing countries, where refilling schemes are not in place or economically
unfavourable.

The material

PET is the abbreviation for polyethylene terephthalate. It is a polyester (chain of

individual “ester”) which is formed by polycondensation of two types of monomers
called ethylene glycol and purified terephthalic acid.

Principle of polycondensation

www.eiriindia.org 3
Polymerization of PET

It is important to note that during the process of polycondensation water is

released. Since the process is reversible, it is important to avoid contact with
water during the re-melting of PET (for instance during recycling) as this leads to
the decomposing or weakening of the polymer.

PET is produced from either crude oil or natural gas. Approximately 1.9 kg of
crude oil is needed to produce 1 kg of PET.

The overall energy consumption of the PET production is 23 kWh/kg PET.

www.eiriindia.org 4
 CONTENTS
INTRODUCTION
FOOD-GRADE PET FLAKES AND PELLETS
FLAKES, PELLETS OR PERFORMS
THE MATERIAL
PRINCIPLE OF POLYCONDENSATION
POLYMERIZATION OF PET
HISTORY OF PET
POLYESTER FIBRES
PET-BOTTLES
BOTTLE MANUFACTURING PROCESS
INJECTION MOULDED PREFORMS OF PET-BOTTLES
B) BLOW STRETCH FORMING OF BOTTLES FROM PERFORMS
BLOW STRETCH FORMING OF PET-BOTTLES
STRETCH FORMING MOULD FOR PETBOTTLES
PROPERTIES & CHARACTERISTICS
DIFFERENT TYPES OF POLYMER STRUCTURE
PET, AMORPHOUS
PET, PARTLY CRYSTALLINE
USES AND APPLICATION OF PET
RECYCLING OF PET BOTTLES
RECYCLING OF PET-BOTTLES
DEPENDING ON THE TYPE OF RAW MATERIAL THREE TYPES
OF RECYCLING ARE POSSIBLE:
TABLE DESCRIBES THE PRECONDITIONS FOR THE DIFFERENT
RECYCLING OPPORTUNITIES
PRECONDITIONS FOR THE DIFFERENT RECYCLING OPPORTUNITIES
OF PET-BOTTLE WASTE
CLEAR PET FLAKE – BOTTLE SPECIFICATION
PROPERTIES AND ADVANTAGE OF PET
CSD -- CARBONATED SOFT DRINKS
WATER -- THE CLEAR STORY
JUICE -- HOT FILL QUALITIES
BEER -- A NEW MARKET WITH NEW REQUIREMENTS
RECYCLING POLYETHYLENE TEREPHTHALATE (PET)
RPET IS EMPLOYED FOR NEW PRODUCTS SUCH AS:
PET COLLECTION AND SORTING
MARKET SURVEY
INDIA’S RECYCLING INDUSTRY
AN INNOVATIVE TECHNOLOGY
USD 80 BILLION WORLDWIDE AND IS GROWING BY 5% TO 6% EACH YEAR.
ACTIVELY IMPROVING THE VALUE CHAINS

www.eiriindia.org 5
INDIA’S PET RECYCLING MARKET TO OUTGROW BY 2019
PLASTIC BOTTLE RECYCLING ESCALATES BY 4.3% IN 2013
INDIAN SOLID WASTE MARKET TO GROW AT 7.14% CAGR BY 2025
PET RECYCLING IN INDIA
STEP 1. REACHING THE WASTE STREAM, GETTING COLLECTED
STEP 2. SORTING AT THE KABADIWALLAHS
STEP 3: AT THE PET RECYCLERS—SORTING (ONCE AGAIN),
CLEANING, FLAKING
OVERVIEW OF PACKAGING INDUSTRY
STATUS & PROSPECT OF PET IN FOOD PACKAGING
PET-INDIAN SCENARIO
CARBONATED SOFT DRINKS (CSD)
MINERAL WATER
ALCOHOLIC BEVERAGE
TEA
FOOD APPLICATIONS-JARS
EDIBLE OIL
OPPORTUNITIES IN THE PET PERFORMS MARKET
BEVERAGES INDUSTRY REMAINS THE KEY END-USER
WITH MAXIMUM REVENUE SHARE
GROWING USE OF READY-TO-USE AND SINGLE-SERVE BEVERAGES
TO BE WITNESSED IN THE PET PREFORMS MARKET
ADVANCEMENT AND PRACTICES IN PET RECYCLING
POST CONSUMER PET WASTE
SORTING
PROCESSING FOR SALE
FURTHER TREATMENT
SEQUENCES IN PET RECYCLING
PROCESS OF PET RECYCLING UNIT
SEQUENCES OF OPERATION INVOLVED
IN PET RECYCLING UNIT
MANUFACTURING PROCESS IN DETAILS
METHOD OF OPERATION
PRE-SORTING
DRY LABEL SEPARATION
SIZE REDUCTION
THE WASHING MODULE
WATER CASCADE
PARCIVAL FILTRATION SYSTEM
THE DECONTAMINATION MODULE CLOSE
AUTOMATIC PROCESSES AND QUALITY SURVEILLANCE CLOSE
QUALITY "TRAFFIC LIGHT"
PROCESS FLOW DIAGRAM
LOWERING THE COST OF PET RECYCLING THROUGH BETTER

www.eiriindia.org 6
 LABEL TECHNOLOGY
DETAILS OF PET PREFORM
PRODUCT FEATURES
MARUFACTURING PROCESES OF PET PREFORM
PROCESS IN DETAILS
TWO WAYS OF MANUFACTURING PERFORMS ARE POPULAR:
DRYING PROCESS
PET PREFORM INJECTION MOLDING PROCESS
PET PREFRMS MOLDING PROCESS
PROCESS FLOW SHEET
THE INJECTION MOULDING OF PET PREFORMS CONSISTS
OF FIVE PROCESS STEPS.
PET PREFORM AND BOTTLE BLOWING
PET CONTAINER APPLICATIONS:
POPULAR APPLICATIONS ARE:
PURE: PRODUCTS TASTE GOOD
MANUFACTURING PROCESSES:
QUALITY REQUIREMENTS:
SINGLE STAGE PROCESS
ON-STEP AND TWO STEP SYSTEMS COMPARED
TOW STAGE PROCESS:
INJECTION MOULDING MACHINE.
MACHINES TO GIVE
MOULDS
DEHUMIDIFICATION
HENCE DEHUMIDIFIER IS A MUST.
CHILLERS
HIGH PRESSURE COMPRESSOR:
PROCESSING DETAILS OF PET PREFORM
1) FUNDAMENTALS
2) PROCESSING METHOD
GRANULATE TO PREFORM AND BOTTLE
PRE-DRYING
INJECTION MOLDING
COOLING
FROM THE PREFORM TO THE BOTTLE
PLANT LAYOUT
ADDRESSES OF CONSULTANT
SUPPLIERS OF PLANT AND MACINERIES
SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)
SUPPLIERS OF RAW MATERIAL
PET BOTTLES WASTE

www.eiriindia.org 7
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

COST ESTIMATION
Plant Capacity 900 Ton/Day
Land & Building (3900 sq.mt.) Rs. 1.81 Cr
Plant & Machinery Rs. 4 Cr
Working Capital for 2 Months Rs. 98 Lac
Total Capital Investment Rs. 7.02 Cr
Rate of Return 30%
Break Even Point 56%

www.eiriindia.org 8