There are many things to consider when you're building your own plastic film recycling washing line, such as choosing the right plastic film washing lines including shredder, washer and dryer, determining the most suitable cleaning agents, and creating a floor plan. This 5-step guide will help you navigate the process and determine exactly what you need.
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Some common types of plastic film include high-density polyethylene (HDPE), polyethylene (PE), polypropylene (PP), , and polyethylene terephthalate (PET). No matter what types of films, wraps, bags or packagings you will be processing, it is important to determine the dirty level of the plastic film and how you would like it to be processed.
Let’s take agricultural films as an example. Agricultural films are more contaminated. Recycling agricultural films is a complex process. The films are often delivered in bales and are a mixture of various polymers that must be separated. Additionally, the used films are typically damp or wet and heavily contaminated with substances such as soil, stones, and metals. It can be difficult to assess the level of contamination due to the film being transported in bale form. Organic matter that adheres to the film after silage or harvesting is often already decomposed, further hindering the recycling process. Therefore, you will need a customized plastic film washing line which could include more friction washers or floating tanks.
Upon the customer requirements GENIUS specialist team provides a flexible customized plastic recycling system for each customer starting from sorting units, feeding units, to degassing units , number or type of filters, storage and packing systems.Moreover, due to the various materials to recycle, GENIUS often helps customers with the unique screw design requirements and pelletizing units. Also, the force side feeding recycling machines are equipped with such as dual piston filters and auto self-cleaning filters upon customer’s request. Recently most of the customers prefer die face cutting pelletizing units to achieve more unique pellets for further manufacturing. Plant size has also become another consideration for many customers, the company has already received many customers’ appreciation with the custom-size machine manufacturing for various sizes of plants.
Some key pieces of equipment that you will need include a shredder, a wash tank, a drying system, and a granulator or pelletizer. You may also need additional equipment such as a pre-washer or a friction washer.
This is a machine that breaks down the film into smaller pieces so it can be washed more easily. They could be a single shaft plastic shredder or twin shaft plastic shredder for different demands.
This is where the washing process takes place, and it should have enough capacity to accommodate all of your incoming material. Floating tanks can be used to separate different types of plastics based on their density. This process relies on the sink-float principle, where denser plastics sink to the bottom of the tank while lighter plastics float to the surface. By using this method, it is possible to separate plastics based on their weight and density.
There are many different options available when it comes to film drying systems. Washed films typically retain about 30% moisture. High humidity will negatively impact the efficiency and production of the pelletizing process. Using a plastic squeeze dryer is essential to remove moisture from washed film, reduce the volume of recycled materials, and improve the quality of the final plastic pellets.
Friction washer is a type of machine that uses friction to remove contaminants from plastic film surfaces. They often consist of a cylindrical drum with an inner drum or impeller, which creates a scrubbing action when it comes into contact with the plastic films, wraps or bags being cleaned.
Finally, you'll need a granulator or pelletizer. This machine will turn your washed film into pellets or granules that can be used in manufacturing processes like packaging or recycling programs.
Read also: Plastic Film Recycling : Challenges & Solutions - Genius
Read also: How to Select Plastic Film Pelletizing Machine to Make Quality Pellet ?Consider the size and shape of your facility, as well as the flow of material through the line. The layout of the washing line is an important factor, as it will affect the flow of material through the line and the efficiency of the process. A well-designed layout will minimize the distance that the material needs to travel, which can help to reduce energy consumption and improve overall efficiency.
When selecting equipment for a plastic film washing line and plant, it is important to consider whether you can purchase all of the necessary equipment from the same supplier. There are several advantages to buying all of the equipment from the same supplier :
Purchasing all of the equipment from the same supplier simplifies the procurement process, as you only have to deal with one vendor rather than multiple. This can save time and effort, allowing you to focus on other aspects of your business.
Buying all of the equipment from the same supplier ensures that the various components are compatible with one another, which can improve the overall efficiency of the washing line.
A single supplier can provide a more comprehensive service and support package, as they are familiar with all of the equipment in your washing line. This can be especially useful if you encounter any issues or need technical support.
Buying all of the equipment from the same supplier may also result in cost savings, as you may be able to negotiate bulk discounts or other favorable terms.
Once you have chosen the equipment, the next step is to install it. This will involve setting up the various pieces of equipment, connecting them to the necessary utilities, and ensuring that they are properly calibrated and functioning correctly.
To optimize a plastic film washing line, you can start by running small batches of material through the line to make necessary adjustments and fine-tune the process. It is also important to monitor and record key performance indicators, conduct experiments to test different variables, use simulation software, and consult with your equipment manufacturers. By following these steps, you can identify areas for improvement and make changes to the process as needed to ensure that the line is running efficiently and producing high-quality washed material.
It seems like a lot of work to build your own plastic film washing line or plant. But once you have it with effective and high-quality systems, you should see consistent improvements in the quality of your washed films, allowing you to increase production and generate greater profits.
If you're not an engineer or a plastics expert, do not worry, you can get a free consultant service from Genius. Contact us Now !
PET (polyethylene terephthalate) is a material widely used in the manufacture of plastic bottles. However, large quantities of discarded PET bottle flakes can cause serious pollution to the environment.
The use of PET recycling and cleaning lines has therefore become essential. With washing lines, waste PET bottle flakes can be transformed into high-quality recycled material, enabling recycling and reducing the need for new raw materials.
a.Determining capacity requirements: Determine the capacity requirements of the washing line based on the expected number of PET flakes to be processed
First, we need to determine your capacity requirements. Please let me know how many PET flakes you expect to process per hour in order to determine the capacity requirements for your cleaning line.
By accurately assessing your capacity requirements, we can select a washing line with sufficient capacity to ensure efficient production and meet market demand.
b.Consider washing efficiency: choose a machine with efficient cleaning and separation functions to improve the quality of the recovered material
A key step in the recycling of PET bottle flakes. Our washing line equipment uses process steps such as friction washing, rinsing, flotation and density separation to effectively remove contaminants, adherents, grease and other impurities.
In addition, our machines have the flexibility to handle a diverse range of PET bottle flakes to meet market demands.
c.Consider adaptability: ensure the line can handle different types and sizes of PET bottle flakes
When choosing a washing line, you should consider its adaptability.
Different types and sizes of PET bottle flakes may vary in size, shape and material. Ensure that the line is flexible and able to handle a wide range of PET flakes to meet market demands.
d.Ease of operation and level of automation: choose a PET bottle washing line that is easy to operate and maintain, with a high level of automation to increase productivity
Excellent washing line equipment is easy to operate and maintain, reducing operator training costs and equipment downtime.
In addition, the high level of automation of the equipment increases productivity and product consistency, further improving the quality of the recycled material.
a. Crushing and pre-washing: Selecting the right crushing equipment and pre-washing system to remove contaminants and adherents
In a PET bottle washing line, crushing and pre-cleaning are important steps in the start-up phase. you should select the appropriate shredding equipment and pre-washing system to ensure that contaminants and adhesions are thoroughly removed from the surface of the PET bottle flakes to provide a good basis for the subsequent process steps.
b. Cold and hot thermal washing: choosing the appropriate washing method and selecting different washing equipment and processes according to requirements
Cold washing and hot washing are the common cleaning methods used in PET bottle washing lines. They use different temperatures and chemical solvents in the cleaning process, with some equipment differences and differences in the final cleaning effect.
Cold washing: Cold washing is the process of using water or solvents at ambient temperature for cleaning. This type of cleaning is usually suitable for general contaminants and adherents and can be removed by steps such as friction washing and rinsing. Cold cleaning equipment usually includes water tanks, spray systems and filtration units.
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Thermal washing: Also called hot washing. Thermal washing is a process that uses heated water or steam for cleaning. By increasing the temperature of the cleaning medium, hot washing can be more effective in removing grease, colour and other difficult to remove contaminants. Thermal washing equipment usually includes heating systems, spray or immersion systems and heat exchange units.
c. Sorting and separation: PET bottle washing lines should use advanced bottle flake sorting technology to ensure efficient cleaning results.
For example, optical sorting systems allow for fast and accurate separation of different colours and types of PET bottle flakes.
Sorting is a key step in PET washing lines. By using efficient sorting equipment and separation technology, contaminants, foreign bodies and other non-compliant particles can be effectively removed from the PET flakes.
These sorting machines can screen and separate based on characteristics such as colour, shape and density, thereby improving the quality and purity of the recovered material.
d. Friction washing and rinsing: choose a quality friction washing and rinsing system to ensure thorough removal of residues and chemicals
Friction washing and rinsing are also important washing steps in a PET bottle washing line.
You should choose a good quality friction washing and rinsing system to ensure that residual contaminants and chemicals are completely removed from the surface of the PET flakes and to guarantee the quality and reusability of the recycled material.
e. Flotation and density separation: efficient flotation and density separation processes are used to remove grease, labels and other impurities
Flotation and density separation are key separation process steps in PET bottle washing lines.
By using efficient flotation and density separation technology, grease, labels and other impurities can be effectively removed from PET bottle flakes, improving the quality and purity of the recovered material.
f. Drying and sieving: consider efficient drying and sieving technology to ensure that the moisture content and particle distribution of the recovered material meets the requirements
Drying and screening are necessary steps in the final stage of a PET bottle washing line.
You should consider the use of efficient drying and screening technology to ensure that the moisture content and particle distribution of the recovered material meets the requirements of the market.
Flotation and density separation are the key separation process steps in a PET washing cleaning line.
By using highly efficient flotation and density separation technology, grease, colour and other impurities can be effectively removed from PET flakes, improving the quality and purity of the recovered material.
Summary:
By choosing the applicable washing method (cold or hot washing) and equipping it with the appropriate cleaning equipment and processes, you can achieve higher cleaning results and remove more contaminants and adherents, thus improving the quality and reusability of the PET bottle flake recycling material.
At the same time, you should also choose the right washing solution for your washing needs and objectives, taking into account equipment differences and cost effectiveness.
a. Using advanced quality control methods: ensuring that the washing line equipment is able to monitor key indicators such as particle size, colour and residue content
The use of advanced quality control methods in the production of PET washing lines is an important factor in ensuring consistent quality of recycled material.
We suggest you should choose washing line equipment with advanced technology that can monitor key indicators such as particle size, colour and residue content.
These indicators can be monitored and controlled in real time with equipment such as in-line sensors, optical inspection systems and colour analysers to ensure the production of high quality recycled material.
b. Implementing routine testing procedures: Establishing appropriate laboratory testing and quality inspection processes to carry out the necessary physical and chemical analysis of the recovered material
In addition to quality control of the equipment, you should also establish routine laboratory testing and quality assurance procedures.
These procedures can include the necessary physical and chemical analyses of the recovered material, such as tests for particle morphology, melt index, melt flow, etc.
Through these testing procedures, it can be ensured that the quality of the recycled material meets the customer’s requirements and market standards.
a. Equipment price and performance comparison: compare the price and performance of equipment from different suppliers to find the best value for money
When selecting PET bottle washing line equipment, you need to compare the price and performance of equipment between suppliers.
This can help customers find the best value for money equipment and ensure they meet your expectations in terms of return on investment.
Also, you should take into account factors such as price, features and quality of the equipment and communicate and consult fully with different suppliers.
b. Energy and maintenance costs: evaluate the energy consumption and maintenance requirements of the PET bottle washing line and select equipment that will provide long-term cost efficiency
In addition to the price of the equipment, you should also assess the energy consumption and maintenance requirements of the washing line equipment.
Choosing equipment that offers long-term cost effectiveness will reduce energy consumption and operating costs, as well as reducing the cost of maintenance and repair of the equipment.
You should request relevant data and information from the supplier to enable a full cost-benefit analysis to be carried out.
c. Service and support: consider the supplier’s level of service and support, including pre-sales service, in-sales support and after-sales service
In the procurement process of PET bottle washing recycling line equipment, the supplier’s service and support is a very important consideration.
Please consider the supplier’s pre-sales service, in-sales support and after-sales service levels. This includes the supplier’s capabilities in terms of equipment selection, installation and commissioning, operator training and after-sales maintenance.
It is worth highlighting that Nicety Machinery Co., Ltd is a highly respected manufacturer of PET recycling washing line equipment and is known for its excellent pre-sales, in-sales and after-sales services.
We offer professional pre-sales consultation to help customers select the right equipment for their needs. At the mid-sales stage, we provide comprehensive technical support and assistance to ensure smooth delivery and installation and commissioning of the equipment.
In addition, we offer a comprehensive after-sales service including training, equipment maintenance and spare parts supply to ensure that customers receive timely support and assistance during use.
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