PET RECYCLING UNIT

(PET GRANULES FROM PET WASTE)

[EIRI/EDPR/3683] J.C. 1769

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.

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  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 materials 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.

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.

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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

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.

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 CONTENTS

INTRODUCTION
HISTORY OF PET
PROPERTIES & CHARACTERISTICS
USES AND APPLICATION OF PET
RECYCLING OF PET BOTTLES
MARKET SURVEY
US RECYCLED PLASTIC DEMAND, 2006-16
INDIA’S PET RECYCLING MARKET TO OUTGROW BY 2019
OVERVIEW OF PLASTIC RECYCLING
MANUFACTURERS/SUPPLIERS OF PET GRANULES
ADVANCEMENT AND PRACTICES IN PET RECYCLING
POST CONSUMER PET WASTE SORTING PROCESSING FOR SALE
FURTHER TREATMENT
PROCESS OF PET RECYCLING UNIT
SEQUENCES OF OPERATION INVOLVED IN PET RECYCLING UNIT
MANUFACTURING PROCESS IN DETAILS
PROCESS FLOW DIAGRAM
LOWERING THE COST OF PET RECYCLING THROUGH BETTER LABEL
TECHNOLOGY
PLANT LAYOUT
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
ADDRESSES OF CONSULTANT
SUPPLIERS OF PLANT AND MACINERIES
SUPPLIERS OF PLANT & MACHINERIES (IMPORTED)
SUPPLIERS OF RAW MATERIAL

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APPENDIX – A :

1. COST OF PLANT ECONOMICS

2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET

COST ESTIMATION

Plant Capacity 1.5 Ton/Day

Land & Building (1000 sq.mt.) Rs. 30 Lac
Plant & Machinery Rs. 33 Lac
Working Capital for 1 Month Rs. 16 Lac
Total Capital Investment Rs. 83 Lac
Rate of Return 40%
Break Even Point 60%

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