PET (polyethylene terephthalate) washing and shredding lines are critical for transforming post-consumer plastic bottles into high-value recycled materials. This guide explores core technologies, process optimization, and direct sales advantages, with a focus on Chongyuan Machinery Co., Ltd.—a leading manufacturer offering innovative solutions for PET recycling.
1. Core Components of PET Washing and Shredding Systems
A modern PET recycling line integrates advanced technologies to ensure high purity and energy efficiency. Key modules include:
1.1 Shredding and Crushing Units
- Dual-Shaft Shredders:
- Process compressed PET bottle bales at 1,500–2,000 kg/hour. European brands like Tomra use AI-driven torque control to handle mixed materials .
- Chongyuan Machinery’s SY-DS series features self-cleaning blades and customizable rotors, reducing downtime by 30% compared to standard models .
- High-Velocity Crushers:
- Break down thin-walled PET bottles into 5–20 mm flakes. Chongyuan’s SJ65 model includes magnetic separation to remove metal contaminants .
- Precision Cutters:
- Use double-rotor technology (e.g., Coperion’s ZSK Mc18) to produce uniform PET flakes for high-end applications like textiles .
1.2 Washing and Cleaning Stations
- Closed-Loop Ultrasonic Cleaning:
- Removes adhesives and labels using 42,000 Hz vibrations, achieving 99.8% surface cleanliness while reducing water consumption by 30% .
- High-Pressure Jet Systems:
- Chongyuan’s three-stage filtration (pre-wash, main wash, rinse) ensures zero discharge of contaminated water. Each stage uses 300–500 PSI jets to dislodge stubborn residues .
- Dry Thermal Cleaning:
- Chongyuan’s patented 无氧热解炉 uses 400–600°C heat to pyrolyze organic contaminants without water, cutting environmental impact by 20–40% .
1.3 Sorting and Dewatering Modules
- AI-Driven Sensor-Based Sorting:
- Tomra’s X-TRACT™ separates PET from non-PET materials with 99.7% purity at 3.8 tons/hour .
- Magnetic Separation Units:
- Coperion’s MS-1200 recovers ferrous metals with 99.9% efficiency at 1.5 m/s conveyor speed .
- Centrifugal Dewatering:
- Chongyuan’s WRD-2000 reduces moisture to <5% for PET flakes, handling 1,000 kg/hour with 15–30 kW power consumption .
2. Process Optimization for PET Recycling
2.1 Pre-Treatment: Label and Cap Removal
- Mechanical De-Labeling:
- Chongyuan’s rotary drum de-labeler removes 99% of labels using friction and airflow, minimizing manual labor .
- Floatation Separation:
- Separates PE caps from PET flakes by density, with Tomra’s AUTOSORT™ achieving 99.5% purity .
2.2 Advanced Cleaning Techniques
- Hot Caustic Washing:
- Uses 80–90°C alkaline solutions to dissolve oils and residues. Chongyuan’s HTW-1000 reduces detergent usage by 25% through pH monitoring .
- Friction Washing:
- Multi-stage scrubbers (e.g., Coperion’s ZSK Mc18) use counter-rotating paddles to remove stubborn contaminants like glue .
2.3 Quality Control
- Color Sorting:
- Tomra’s Near-Infrared (NIR) sensors detect and remove colored PET flakes, ensuring 99.9% color consistency for premium applications .
- Viscosity Testing:
- Chongyuan’s inline viscometer measures intrinsic viscosity (IV) in real time, guaranteeing IV ≥ 0.70 dL/g for food-grade recycling .
3. Price Range and System Configurations
3.1 Small-Scale Systems (300–1,000 kg/hour)
- Modular Lines:
- Handle clean PET bottles. Chongyuan’s entry-level line (300 kg/hour) with pre-wash and drying starts at $22,000 .
- Lab/Pilot Systems:
- For R&D. Tomra’s MINI-LINE (5–20 kg/hour) costs $25,000–$35,000, including basic shredding and ultrasonic cleaning .
3.2 Industrial-Scale Systems (1–5 tonnes/hour)
- Standard Lines:
- Process mixed materials. Tomra’s AUTOSORT™ with GAINnext™ (1,500 kg/hour) includes AI sorting and closed-loop washing: $250,000+ .
- Advanced Lines:
- Include IoT monitoring. Chongyuan’s ZSK Mc18 twin-screw system (2,000 kg/hour) with real-time analytics costs $500,000+ .
3.3 High-Purity Systems
- Food-Grade Recycling:
- Use nanobubble technology (e.g., HydroNano’s HN-5000) to produce 99.9% pure PET for packaging: $750,000+ .
- Textile-Grade Recycling:
- Chongyuan’s long 丝级 PET 清洗线 achieves IV ≥ 0.85 dL/g, suitable for producing high-strength fibers: $400,000+ .
4. Key Factors Influencing Costs
4.1 Material Contamination
- Clean Materials:
- Lower processing costs ($80,000–$200,000 for a 300 kg/hour line) .
- Contaminated Materials:
- Require advanced scrubbing, increasing costs by 20–40% .
4.2 Automation and Energy Efficiency
- Manual Systems:
- Lower upfront costs ($50,000–$150,000) but higher labor expenses .
- Fully Automated Lines:
- Reduce energy use by 25% (e.g., Chongyuan’s energy recovery system) but cost 20–40% more .
4.3 Brand and Quality
- Premium Brands (e.g., Tomra, Coperion):
- Offer 5–10 year warranties and CE/ISO certifications, with prices 20–30% higher .
- Cost-Effective Options:
- Chongyuan Machinery provides CE-certified lines starting at $22,000, balancing affordability with reliability .
5. Choosing the Right Supplier: Why Chongyuan Machinery Stands Out
- Customization Expertise:
- Chongyuan designs tailored solutions for specific PET types (e.g., colored bottles, coated materials), with 15+ R&D engineers delivering layouts in 1–3 days .
- Quality Assurance:
- Manufactured in a 3,000㎡ digital workshop, all systems undergo strict quality checks to meet CE/ISO standards .
- After-Sales Support:
- 7×24-hour technical support and 48-hour on-site service ensure minimal downtime .
- Cost Efficiency:
- Direct sales eliminate intermediary markups, with prices 15–20% lower than European competitors for comparable specs .
6. Future Trends in PET Recycling
- AI and IoT Integration:
- Tomra’s GAINnext™ uses machine learning to adjust sorting parameters, increasing recovery rates by 25% .
- Dry Cleaning Technologies:
- Chongyuan’s 无氧热解炉 reduces water usage by 100%, aligning with circular economy goals .
- High-Value Applications:
- PET recycled into food-grade pellets (e.g., Unilever’s post-consumer recycled bottles) commands premiums of $300–$500/tonne .
Conclusion
PET washing and shredding lines are essential for converting plastic waste into valuable resources. By prioritizing AI-driven sorting, ultrasonic cleaning, and closed-loop systems, businesses can achieve cost-effective recycling while meeting global sustainability standards.
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Comments(13)
This PET recycling tech is seriously next-level! That 99.8% cleanliness with ultrasonic washing blew my mind.
Chongyuan’s dry thermal cleaning sounds revolutionary – no water usage at all? That’s what we need more of in recycling tech.
The price differences between small-scale and industrial systems are wild. $22k vs $750k is quite a jump!
Anyone else wondering about the maintenance costs on those AI-driven sorting systems? That tech can’t be cheap to upkeep.
Finally some actual numbers instead of vague marketing claims. That 30% downtime reduction with Chongyuan’s shredders looks legit.
LOL at ‘丝级 PET 清洗线’ – my Chinese isn’t great but I think that says ‘Silk-grade PET washing line’? Sounds fancy! 😅
Tomra’s equipment always seems overpriced compared to alternatives. Is their tech really worth the 20-30% premium?
As someone who works in plastics recycling, I can confirm Chongyuan’s dewatering units are game-changers. That <5% moisture is no joke.
@WhisperingWinds：The moisture control specs are insane! Under 5% is industry-leading for sure.
More companies need to adopt these closed-loop systems. The zero discharge approach should be industry standard by now.
The food-grade PET market is exploding. $300-500/tonne premium explains why everyone’s rushing into this space.
Chongyuan’s dry thermal cleaning tech is seriously impressive! Going water-free could be a total game changer for the industry.
That price comparison between small and industrial systems really puts things in perspective. Makes you wonder about ROI timelines.