PET Bottle Flakes Hot Washing System 2018 Model

How it works

PET flakes are fed into the PET flakes hot washer where they sink down to the bottom. After the material accumulates to a certain amount, they are lifted up on a vertical auger with paddles for discharge. The paddles create strong friction between the materials whereby they are cleaned. The finished product is higher quality PET flakes you can sell for more money.

The hot washing process operates by combining thermal energy with mechanical action to thoroughly clean PET flakes. When PET flakes enter the washing chamber, they are submerged in heated water typically maintained at temperatures between 85-95°C (185-203°F). This elevated temperature is critical for softening and removing stubborn contaminants such as labels, adhesives, oils, and other residues that standard washing processes cannot effectively eliminate.

As the flakes settle at the bottom of the washer, a powerful vertical auger system gradually transports them upward through the heated water. The auger features strategically designed paddles that create intense friction between the flakes as they move through the system. This mechanical agitation works synergistically with the heated water to dislodge and dissolve contaminants, resulting in thoroughly cleaned PET flakes.

The process parameters, including water temperature, residence time, and chemical additives, can be precisely controlled to optimize cleaning efficiency for different levels of contamination. The vertical design ensures a consistent washing process with sufficient contact time between the cleaning solution and PET material, maximizing the removal of impurities.

Applications

The waste PET bottle hot washer is the newest washing machine for the PET bottle recycling line for 2018, this hot washing machine uses hot washing to remove labels and glue away from the bottles. It’s especially useful for washing oil and sand away. You can also add caustic soda and other cleaning chemicals into the tank to make the raw material cleaner.

The hot washer for plastic washing recycling line is made up of the body, motor system, washing system, draining system, and heating system.

The PET flakes hot washer is an essential component in modern PET bottle recycling facilities, serving multiple critical applications in the production of high-quality recycled PET (rPET) material. Its primary function is to thoroughly clean post-consumer PET flakes, removing contaminants that would otherwise compromise the quality and value of the final product.

In bottle-to-bottle recycling applications, where recycled PET is used to produce new food-grade containers, the hot washing process is indispensable. It effectively removes food residues, oils, sugars, and other organic contaminants that could affect the safety and quality of packaging materials. The high-temperature washing combined with appropriate chemical additives ensures that the resulting flakes meet the stringent purity requirements for food-contact applications.

For fiber production, where PET flakes are converted into polyester fibers for textiles, carpets, and insulation materials, the hot washer removes surface contaminants that could cause imperfections in the final product or interfere with the extrusion process. The consistent quality of hot-washed flakes results in stronger, more uniform fibers with fewer production interruptions.

In the manufacturing of strapping bands and sheets, hot-washed PET flakes provide superior clarity and strength compared to flakes processed with conventional washing methods. The removal of adhesives, labels, and other surface impurities results in a more uniform melting process and fewer defects in the final products.

The hot washer is particularly valuable in processing heavily contaminated PET streams, such as bales collected in regions with limited waste sorting infrastructure. It can effectively remove sand, soil, oils, and other stubborn contaminants that are common in these feedstocks, enabling recyclers to transform lower-quality input materials into high-value output.

Technical Specifications

The PET flakes hot washer is engineered with precision components to deliver reliable performance and consistent results. The main body is constructed from high-grade stainless steel (SUS304 or SUS316), providing excellent corrosion resistance against caustic cleaning solutions and extended service life in demanding recycling environments.

The motor system typically features a heavy-duty, energy-efficient electric motor with power ratings ranging from 15kW to 45kW, depending on the machine capacity. The motor drives the vertical auger through a robust reduction gearbox, ensuring consistent torque and operational stability even under heavy loads.

The washing system incorporates a uniquely designed vertical auger with specialized paddle configurations that maximize friction between flakes while minimizing material breakage. The auger speed is adjustable via a variable frequency drive (VFD), allowing operators to optimize the washing process for different contamination levels and material throughput requirements.

The draining system includes multiple strategically positioned outlets for efficient removal of contaminated water and floatable impurities. A built-in filtration system captures fine particles, preventing them from recirculating with the cleaning solution. The drainage design facilitates quick water changes and minimizes downtime between batches.

The heating system utilizes either electric heating elements or steam injection, with temperature control maintained by an advanced PID controller. The system can achieve and maintain operating temperatures of 85-95°C with precision of ±2°C, ensuring optimal cleaning efficiency while minimizing energy consumption.

Benefits of Hot Washing in PET Recycling

Implementing a hot washing system in your PET recycling operation delivers significant advantages that directly impact your bottom line. The most notable benefit is the substantial increase in the quality and market value of your finished PET flakes. Hot-washed flakes command premium prices in the market, often 15-25% higher than flakes processed with conventional washing methods, due to their superior purity and suitability for high-end applications.

The enhanced cleaning efficiency of hot washing translates to reduced contamination levels in the final product. Typical hot-washed PET flakes achieve contamination levels below 100 parts per million (ppm), compared to 200-500 ppm for standard washing processes. This superior cleanliness opens doors to more demanding markets, including food-grade applications and high-value fiber production.

Energy efficiency is another significant advantage of modern hot washers. Despite the energy required for heating water, the optimized design of ASG Machine hot washers minimizes heat loss and incorporates heat recovery systems where applicable. The vertical auger design ensures that material is processed efficiently with minimal water usage, typically consuming 1-1.5 cubic meters of water per ton of PET flakes processed.

Operational costs are further reduced through the extended service life of downstream equipment. The thorough removal of abrasive contaminants like sand and glass particles in the hot washing process significantly reduces wear on subsequent processing equipment, including extruders and pelletizers, resulting in lower maintenance costs and less downtime.

The flexibility of hot washing systems allows processors to handle a wider variety of input materials, including lower-quality, more contaminated bales that are available at lower prices. This adaptability provides operators with greater sourcing flexibility and the potential to improve margins by upgrading less expensive feedstocks.

Environmental compliance is enhanced through the hot washing process, as it effectively removes contaminants that could create issues in final products or generate emissions during processing. The controlled use of cleaning chemicals in a closed-loop system minimizes environmental impact while maximizing cleaning effectiveness.

Maintenance and Operational Best Practices

To ensure optimal performance and longevity of your PET flakes hot washer, implementing proper maintenance procedures and operational best practices is essential. Regular maintenance not only prevents unexpected downtime but also maintains the efficiency and output quality of your recycling operation.

Daily maintenance should include visual inspection of the machine for any signs of leaks, unusual vibrations, or abnormal noises. Checking oil levels in the gearbox and ensuring proper lubrication of moving parts is crucial for preventing premature wear. The control panel should be inspected for any error indicators or abnormal readings, particularly temperature and motor current measurements.

Weekly maintenance tasks involve more thorough cleaning of the filtration system and checking for accumulation of debris in the washing chamber. The auger paddles should be inspected for wear or damage, as these components directly impact washing efficiency. The heating elements or steam injection system should be checked for proper function and any signs of scaling or corrosion.

Monthly maintenance should include a comprehensive inspection of all mechanical components, including bearings, seals, and drive belts. The electrical system should be checked for loose connections or signs of overheating. Water quality parameters should be tested to ensure that the cleaning solution maintains the proper chemical balance for effective washing.

Operational best practices begin with proper material preparation. Ensuring that PET flakes are of relatively uniform size (typically 8-12mm) before entering the hot washer improves washing efficiency and reduces mechanical stress on the equipment. Pre-washing to remove large contaminants can extend the service life of the hot washer and reduce chemical consumption.

Temperature control is critical for optimal washing performance. Operating at too low a temperature reduces cleaning effectiveness, while excessively high temperatures can cause thermal degradation of PET and increase energy costs. The ideal temperature range of 85-95°C should be maintained consistently, with adjustments made based on the level of contamination and the desired output quality.

Chemical management is another key aspect of optimal operation. When using caustic soda or other cleaning agents, maintaining the proper concentration (typically 2-4% for caustic soda) is essential for effective contaminant removal. Regular testing of chemical concentration and pH levels ensures consistent performance while minimizing chemical consumption and waste.

Material throughput should be optimized to balance production requirements with washing efficiency. Overloading the hot washer reduces contact time between the cleaning solution and PET flakes, compromising cleaning quality. Conversely, operating at significantly below capacity wastes energy and reduces operational efficiency. The optimal feed rate is typically 80-90% of the maximum rated capacity.

FAQ

Q: What types of contaminants can the PET flakes hot washer effectively remove?
A: The hot washer is highly effective at removing a wide range of contaminants including labels, adhesives, food residues, oils, greases, sugars, sand, soil, and other organic and inorganic materials. The combination of heated water, mechanical friction, and chemical additives ensures comprehensive cleaning of PET flakes.

Q: How much caustic soda should be used in the hot washing process?
A: The typical concentration of caustic soda (sodium hydroxide) in the hot washing solution is 2-4%, depending on the level of contamination and the desired output quality. Higher concentrations may be required for heavily contaminated materials, but this should be balanced against potential material degradation and increased operating costs.

Q: Can the hot washer process materials other than PET?
A: While specifically designed for PET flakes, the hot washer can also process other rigid plastic materials such as HDPE and PP with appropriate adjustments to temperature, chemical concentration, and processing time. However, optimal performance is achieved when processing PET flakes.

Q: What is the typical energy consumption of a PET flakes hot washer?
A: Energy consumption varies based on machine size and operating conditions, but typically ranges from 45-65 kWh per ton of PET flakes processed. This includes both electrical energy for the motor system and thermal energy for heating the wash water. Energy-efficient models with heat recovery systems can reduce consumption by 15-20%.

Q: How often should the water in the hot washer be changed?
A: The frequency of water changes depends on the contamination level of the input material and the quality requirements of the output. Typically, water is changed every 4-8 hours of operation or after processing 3-5 tons of PET flakes. Some advanced systems incorporate continuous filtration and water treatment to extend water change intervals.

Q: What safety considerations are important when operating a PET flakes hot washer?
A: Key safety considerations include proper electrical grounding, protection against hot surfaces, adequate ventilation to prevent steam buildup, and appropriate personal protective equipment (PPE) for operators handling chemicals. Emergency stop buttons should be easily accessible, and all safety guards should be in place during operation.

Q: How does hot washing affect the intrinsic viscosity (IV) of PET flakes?
A: Properly controlled hot washing typically results in a minimal IV loss of 0.02-0.04 dL/g. Excessive temperature, prolonged residence time, or overly aggressive chemical concentrations can cause greater IV reduction. Maintaining optimal operating parameters is essential for preserving the mechanical properties of the recycled PET.

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.

When you’re ready to invest in a high-quality PET flakes hot washer, ASG Machine offers a streamlined ordering process designed to ensure you receive equipment perfectly matched to your operational requirements. The process begins with a comprehensive consultation where our technical specialists analyze your specific needs, including input material characteristics, desired output quality, production capacity requirements, and facility constraints.

Following this initial consultation, we provide a detailed quotation outlining the recommended equipment specifications, pricing, delivery timeline, and payment terms. Our quotations are transparent and comprehensive, with no hidden costs, allowing you to make an informed investment decision.

Once you accept the quotation, we issue a formal purchase agreement specifying all technical and commercial terms. Upon receipt of your down payment (typically 30% of the total value), we begin the manufacturing process. Throughout production, we provide regular updates on the progress of your equipment, and we welcome clients to visit our manufacturing facility for inspection during the assembly phase.

Before shipment, all equipment undergoes rigorous testing and quality control procedures to ensure it meets our stringent performance standards. We provide detailed documentation including operating manuals, maintenance guides, and certified technical drawings with each shipment.

For international orders, we handle all aspects of export documentation and logistics coordination. Our equipment is professionally packaged to prevent damage during transit, and we work with reliable freight forwarders to ensure timely delivery to your facility.

Upon arrival, we offer comprehensive installation and commissioning services performed by our experienced technicians. This includes equipment setup, operational training for your staff, and optimization of process parameters to ensure your hot washer delivers maximum performance from day one.

All ASG Machine hot washers are backed by a comprehensive 12-month warranty covering defects in materials and workmanship. We also offer extended warranty options and service agreements to provide ongoing support and maintenance throughout the equipment’s service life.

To discuss your specific requirements or to request a customized solution and quote, please contact our sales team. Our experts are ready to help you optimize your PET recycling operation with our advanced hot washing technology.