UM - 23103
Starlinger PET Recycling Line
Year Of Manufacture
Output Capacity: 1050 kg/h
Last Material Recycled: PET
Suitable Material Form: Flakes
Destination Of Product: Bottles
Working hours: 14.000 approx.
Output: 850 - 1050 kg/h
The unique combination of the predrying unit/extruder enables the optimal preparation of the PET pre-ground material before it is fed directly into the extruder, which is using the generated heat. The final product is melt-filtrated, uniform and dry pellets, with flow characteristics like virgin resin.
Solid State Polycondensation
The continuous Solid State Polycondensation increases the viscosity of PET depending an the chosen residence time in the reactor. Furthermore, decontamination takes place (letter of non-objection of the FDA authority issued in June 2004 and October 2007) as well as reduction of acetaldehyde. End product is crystalline pellet with virgin resin characteristics.
Material to be processed:
PET bottle flakes, washed post-consumer waste, clean (without PVC and paper, abrasive or metallic contamination), dry (max. 1.0 % surface moisture). Material pre-ground.
Recommendation for flake specification:
Surface moisture: max. 1.0
PVC (flake, label) content: max. 50 ppm
Glue content: max. 4.000 ppm (flakes included)
Yellow flakes (UV-degraded, blocker, oil bottles): max. 4.000 ppm
PA content max. 50 ppm
pH value: neutral (pH+/- 0,5)
HDPE / PP content: max. 20 ppm
PET dust (particle size < lmm): max. 1 %
Metal content: max. 50 ppm
Wood, paper, cellulose: max. 20 ppm
Silicone, rubber content: max. 20 ppm
Other contamination: max. 10 ppm
Flake size: 4 - 14 mm
Bulk density min. 290 g/I
PART 1 recoSTAR PET 125 HC IV+
FEEDING SCREW FOR HOT AIR DRYER HAD1500 INCL. METAL SEPARATION
Metal detector for all metallic materials (such as Fe, Ni, Co, stainless steel, Cu, Al, CuZn, Pb).
Detecting:Fe ball D 1.5 mm
HOT AIR DRYER HAD1500
This unit is recommend for higher moisture levels of the input material and/or for increased drying time and improved final material quality.
/ In the hot air dryer hot air heats up the material. This process dries the material and serves for optimum preparation of the material prior to extrusion.
Vessel diameter:1000 mm
Vessel volume:1500 L
Heating capacity:34/45 kW
Agitator speed:—6 rpm
EXHAUST AIR FILTRATION FOR HAD 1500
Continuous air filtration via cyclone including a dust collecting box which collects the separated dust. Manual emptying can be done without interruption of production.
FEEDING SCREW FOR PREDRYING UNIT PDU3700
The PET flakes are fed directly into the predrying unit by a feeding screw
PREDRYING UNIT PDU3700 FROM PIOVAN WITH DRIED AIR INCL. AIR FILTRATION AND CONDENSATE SEPARATOR
SURCHARGE FOR GAS HEATING FOR PREDRYING UNIT PDU3700
EXTRUDER EXP125 HC WITH HIGH VACUUM UNIT H-VAC
Including melt pressure sensor, melt temperature sensor, and control air conditioning for electronical components and control panel.
The extruder barrel is of a bimetallic design. The screw is nitride-hardened and armor-plated. The extruder screw plasticizes and homogenizes the material. The extruder screw is driven by V-belts and optionally speed-controlled. The extruder is equipped with a melt pressure display.
The material is fed into the extruder by a speed-controlled dosing screw.
Extruder screw:125 mm
Extruder power:160 kW AC
Screw speed:105 rpm (depending an material)
Melt pressure display & alarrn.Yes
Melt temperature display:Yes
UNDER WATER PELLETIZING UWP7OCC WITH INLINE CRYSTALLISATION (CLOSED WATER CIRCUIT)
FILLING STATION 1000 L AFTER EXP INCL. DIVERTER VALVE AND PIPING (PELLET TEMP.CM UP TO 150°C) 0
Storage silo volume: 1000 L
PART 2: viscoSTAR 120 (FoR 1050 KG/H— APPROX. 9.3 H
FEEDING SCREW (FROM UWP TO CRY1000)
The feeding screw serves for pellet transport between the UWP and the crystallizing unit. Execution in stainless steel and heat insulation proves a heat saving pellet transport.
CRYSTALLIZER CRY1000 INCL. AIR FILTRATION
Crystallization of the pellets by using the residual heat from the melt, including heating, optimized in energy consumption.
Feeding Parts for SSP
Incl. Outlet valve for CRY/PCU, suction box and lances.
viscoSTAR 120 BASE UNIT INCL. PREHEATING, COOLING UNIT, ETC.
The preheated, predryed pellets are transported via a vacuum transportation system to the preheater at the top of the reactor. The pellets get heated in the reactor preheater to reaction temperature, then set under vacuum and Ioaded to the reactor vessel.
Inside the electrical heated reactor vessel the reaction takes place and the iV of the pellets is increased according to the adjusted time in the reactor.
After the adjusted reaction time the batch is taken out of the reactor with a special designed outlet device to prevent mixing of pellets and vacuum.
In the cooling chamber the pellets are cooled down to a temperature which is lower than reaction temperature before being discharged to the piping system for transport to an intermediate storage silo.
Volume preheater:approx. 250 L
Preheating capacity:max. 600 kg/h
Number of preheaters:2
Compressor:2 x 30 kW
Air heater:2 x 75 kW
Volume SSP reactor:12000 L
Heating capacity reactor:12 x 6 kW
Vacuum pump:3 x 7.5 kW
ENLARGED MAINTENANCE PLATFORM FOR VISCOSTAR
Stairs with railings replace the standard ladders which enables easier and comfortable access for maintenance.
3 X WATER HEAT EXCHANGER FOR viscoSTAR 120 (REQUIRED FOR AMBIENT TEMPERATURE >35°C)
HIGH TEMPERATURE FEEDING SYSTEM INCL. FILLING STATION 1000 L FOR SSP FINAL MATERIAL
Storage silo and pipe in a soundproof design.
Frame provided with big bag holding facility.
Storage silo volume:1000 L
ENERGY RECOVERY KIT ERK1200
The system consists of a pellet-air heat exchange system which enables the reuse of the residual heat of pellets after an inline-crystallisation or after the SSP¬process. All components which are in contact with the food grade pellets are made of stainless steel or alloy.
PELLET WATER COOLER PWC1200 (PELLET TEMP. In case lower pellet temperature is required this unit is recommended. Water runs through coolings spirals that chill the surrounding pellets.
HIGH TEMPERATURE FEEDING SYSTEM (viscoSTAR120 -> FILLINGSTATION 1000L AFTER EXTRUDER)