Recycling line - recoSTAR PET (non food)

The decisive criterion for all PET applications is that the use of repelletised material may not influence either extrusion or any following process, nor may it prejudice the quality of the end product. The Starlinger recoSTAR product line offers the ideal solution for PET recycling, as it fulfils both conditions with optimal pre-drying of the PET flakes and optional solid stating.

The recoSTAR PET line is state-of-the-art recycling technology for the in-house recycling of PET flakes from bottles, preforms, strapping bands and sheets as well as for the recycling of post-consumer bottle flakes after the washing process. The end product is melt-filtrated, uniform granulate that can be used for a wide range of applications (containers, sheets, fibers and nonwovens, strapping).

recoSTAR PET features the following advantages:

  • Modular design ensures flexibility and adaptability to different input material and the changing requirements of rPET users.
  • High automation and userfriendliness leads to highest efficiency and consequently fast ROI.
  • Careful treatment of flakes, avoiding dust, high IV loss and degradation. FIFO ensures uniform treatment of the input material.
  • Direct material flow at the melt filtration reduces stress of material. Finest filtration is available on request.
  • The inline viscosimeter optionally measures the IV for immediate quality control.
  • Pellets size and bulk density are adjustable for all pelletising systems available.
  • The optional inline crystallisation after underwater pelletising ensures optimised foot-print, energy saving and high crystallinity.
  • Increased energy efficiency by using gas, steam, or the residual heat of previous process steps.
  • The visualisation panel features archiving, maintenance list, alarm list, etc.

The recoSTAR PET and recoSTAR PET HC (High Capacity) series comprises five different machine sizes which together cover an output range of 150 – 3.600 kg/h. By adding SSP reactors, the number of which will depend on the requirements of the application, the machine concept meets even the most stringent demands as to IV.

PET flakes are heated and dried in a two-stage process by means of hot air and optional dry air or under vacuum. The special design of the dryer outlet results in center flow prevention, consistent residence time and FIFO processing. This ensures ideal preparation for the extrusion process with maintained IV level or with IV increase. Once installed, the unit can be equipped with an SSP reactor before or after extrusion to increase the viscosity.

Technical Data - recoSTAR PET

Output* 150 - 2900 kg/h
Energy consumption 0.25 - 0.35 kWh/kg
Extruder screw diameter (L/D) 65(40) - 2x165(40) mm
Extruder AC drive 45 - 500 kW
High-vacuum ≤ 10 mbar
* depends on extruder dimensions and the material to be processed

Technical Data - recoSTAR PET HC

Output* 150 - 3600 kg/h
Energy consumption 0.25 - 0.35 kWh/kg
Extruder screw diameter (L/D) 65(40) - 2x165(40) mm
Extruder AC drive 45 - 630 kW
High-vacuum ≤ 10 mbar
* depends on extruder dimensions and the material to be processed

Process description

The recycling line recoSTAR PET comprises the following process steps:

  1. Conveyor screw
  2. Hot air drying unit
  3. Pre-drying unit
  4. Extruder
  5. High-vacuum degassing extruder
  6. Melt filter without backflushing
  7. Melt filter with backflushing
  8. Strand pelletiser
  9. Automatic strand pelletiser
  10. Underwater pelletiser
  11. Underwater pelletiser with inline crystallisation

    Optional: Crystallisation and solid state polycondensation (12-18):

  12. Crystalliser / post-crystallisation unit
  13. Vacuum transport
  14. Preheating unit
  15. SSP reactor
  16. Cooling unit / vacuum sluice
  17. Energy recovery kit
  18. Storage silo

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Additional information