Description
The label separator, sometimes referred to as the “air classifier,” utilizes air pressure to effectively separate heavier materials from lighter ones in the PET recycling process. During the initial stages of PET bottle recycling, whole bottles are shredded into flakes, creating a material stream that contains both PET flakes and PP/PE film fragments from bottle labels. The label separator performs the critical function of separating these lighter PP/PE label fragments from the heavier PET flakes, ensuring a purer final product.
This separation process is essential for producing high-quality recycled PET (rPET) that meets industry standards for food-grade applications and other specialized uses. By efficiently removing label contaminants, the label separator helps recycling facilities maintain the value and integrity of their processed PET material.
How It Works
The label separator operates on a straightforward yet highly effective principle of air classification. The process begins when the mixture of PET flakes and PP/PE label fragments enters a specially designed sorting chamber. Within this chamber, a controlled column of upward-flowing air creates the ideal conditions for separation based on material density.
As the mixed materials are introduced into the air stream, the physics of aerodynamic separation take effect. The lighter PP/PE label films, having a significantly lower density than PET flakes, are carried upward by the air current. These lightweight materials are directed into a collection system where they can be properly contained and either recycled separately or disposed of according to facility protocols.
Meanwhile, the heavier PET flakes, unaffected by the upward air flow, descend through the chamber due to gravity. These cleaned PET flakes exit through the bottom of the separator and continue along the processing line to the next stage of the recycling operation.
This separation method is highly efficient, typically removing 95% or more of label contaminants from the PET flake stream. The system is designed to handle the high throughput requirements of commercial recycling operations while maintaining consistent separation performance.
The effectiveness of the label separator depends on several factors, including:
– Proper calibration of air flow velocity
– Consistent feed rate of material
– Appropriate moisture content of the input material
– Correct sizing of the PET flakes and label fragments
Models & Specifications
Our standard label separator is engineered for reliability and optimal performance in industrial PET recycling operations. Below are the technical specifications for our base model:
| Component | Specification |
|---|---|
| Blower Motor | 5.5 KW |
| Rotary Valve Motor | 1.5 KW |
| Rotary Valve Diameter | ⌀270mm |
| Rotary Valve Rotating Speed | 50 RPM |
| Cyclone Separator Volume | 600 L |
These specifications represent our standard model, which is suitable for medium to large-scale recycling operations. For facilities with specific requirements or space constraints, ASG Machine offers customization options to ensure optimal integration with your existing processing line.
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Operational Benefits
The label separator provides several key advantages for PET recycling operations:
Improved Product Purity: By effectively removing PP/PE label contaminants, the separator significantly enhances the purity of the final PET flake product, increasing its market value and suitability for high-end applications.
Reduced Manual Labor: Automated separation minimizes the need for manual sorting, reducing labor costs and improving workplace safety.
Energy Efficiency: The system is designed to maximize separation effectiveness while minimizing energy consumption, contributing to lower operational costs.
Minimal Maintenance: With few moving parts and robust construction, the label separator requires minimal maintenance, ensuring maximum uptime and productivity.
Scalability: The technology can be scaled to match the throughput requirements of various facility sizes, from small operations to large industrial plants.
Integration Considerations
When incorporating a label separator into your PET recycling line, several factors should be considered:
- Positioning in the Process Flow: The separator is typically installed after the granulator and before the washing and sorting stages.
- Material Handling Requirements: Proper conveying systems must be in place to transport material to and from the separator.
- Dust Collection: A dust collection system may be necessary to maintain air quality in the facility and capture any fine particles generated during the separation process.
- Control System Integration: The separator should be integrated with the overall plant control system for synchronized operation and monitoring.
Maintenance & Best Practices
To ensure optimal performance and longevity of your label separator, follow these maintenance guidelines:
- Regular Inspection: Check the blower system, rotary valve, and collection chambers daily for proper operation.
- Air Flow Calibration: Periodically verify and adjust air flow settings to maintain separation efficiency.
- Wear Component Replacement: Monitor wear parts such as valve seals and bearings, replacing them as needed.
- Cleaning Schedule: Establish a regular cleaning routine to prevent material buildup that could affect performance.
- Operator Training: Ensure operators are properly trained in the correct operation and troubleshooting of the equipment.
Place An Order
The general lead time for all single-piece, standard equipment orders is 30 days. For custom orders or complete washing lines, the lead time is between 60 – 90 days. The actual lead time will depend heavily on the complexity of the project as well as the amount of machinery we have in queue at the time of your order.
Contact us to discuss pricing and ordering details. Here is a brief summary of our ordering procedures:
- Initial Consultation: Our sales engineers will work with you to understand your specific requirements and facility constraints.
- Proposal & Quote: We’ll provide a detailed proposal including equipment specifications, pricing, and delivery timeline.
- Order Confirmation: Upon approval, we’ll issue a formal order confirmation with payment terms and production schedule.
- Manufacturing: Your equipment will be manufactured according to the agreed specifications.
- Quality Assurance: All equipment undergoes rigorous testing before shipment.
- Shipping & Installation: We coordinate shipping and provide installation support as needed.
- Training & Commissioning: Our technicians will train your operators and ensure the equipment is operating at peak performance.
Get Customized Solution & Quote
FAQ
Q: What types of materials can the label separator effectively process?
A: Our label separator is specifically designed for PET bottle recycling applications, efficiently separating PET flakes from PP/PE label materials. It can handle various bottle shapes and sizes, as long as the material is properly shredded to the recommended flake size.
Q: How often does the equipment require maintenance?
A: Routine daily inspections are recommended, with more comprehensive maintenance performed monthly. The actual frequency depends on your operating hours and material throughput. Our maintenance manual provides detailed guidance based on usage patterns.
Q: Can the separator be integrated with existing recycling lines?
A: Yes, our label separator is designed for flexible integration. We offer customization options to ensure compatibility with your existing equipment and can provide engineering support for seamless installation.
Q: What is the typical separation efficiency of the label separator?
A: Under optimal operating conditions, our label separator achieves 95% or higher separation efficiency, removing the majority of PP/PE label contaminants from the PET flake stream.
Q: Is technical support available after purchase?
A: Yes, ASG Machine provides comprehensive after-sales support, including technical assistance, spare parts availability, and operator training. We stand behind our equipment with a full warranty and responsive customer service.
Q: What safety features are included with the equipment?
A: Our label separator includes multiple safety features, such as emergency stop buttons, safety interlocks on access panels, and overload protection on motors. All equipment is designed to meet relevant industry safety standards.
Q: Can the separator handle materials with high moisture content?
A: While the separator can process materials with some moisture content, excessive moisture may reduce separation efficiency. We recommend consulting with our engineers to determine the optimal moisture range for your specific application.
