Developments in rPET preform production
A technological overview of a new beverage packaging plant
PET Solutions has recently completed the installation of a production line for a leading client in the beverage industry, designed specifically for the processing of rPET for preform manufacturing. With a throughput of approximately 6,000 kg/h, the facility incorporates technologies aimed at improving energy efficiency, material consistency, and operational reliability. The project reflects broader industry trends towards environmentally responsible packaging solutions.
Photo top: Complete drying solution installed on mezzanine level
Material handling: external silo loading system
The first stage of the plant’s operations involves the handling and loading of raw materials into four external silos, which are supplied by Ergomec, part of Pegaso Industries. These silos are equipped with pneumatic transport systems that securely transfer materials while maintaining strict standards for contamination control.
The system is designed to automate material flow, ensuring a continuous and steady supply of material to the downstream feeders. This is not only claimed to enhance the operational efficiency of the plant but also to minimise the risks associated with manual handling, reducing contamination risks and improving safety. The use of pneumatic transport ensures that the materials are transferred in a controlled and clean manner, which is especially critical when handling rPET.
Material blending: gravimetric dosing system
The production line features a gravimetric dosing system with an accuracy of ±0.1%. Capable of managing up to eight different components, the system offers throughput rates ranging from 50 kg/h to 3,000 kg/h.
Real-time monitoring and an adaptive recalibration feature help maintain consistent material quality. The system is operated via a Siemens S7 programmable logic controller (PLC) and a 7-inch touchscreen interface, allowing for precise monitoring and fine-tuning of material flow, contributing to product quality and reducing the chances of error during the production process.
Moisture removal: DRV vacuum drying technology
At the core of the plant’s operations lies the DRV technology, a continuous vacuum drying solution optimised for drying both rPET and virgin PET materials before injection moulding to produce preforms. Operating under low-pressure conditions, the system aims to reduce moisture content without causing overheating and degradation while improving energy efficiency.
Key features of the DRV system include:
- Material protection: The low-pressure operation prevents thermal degradation and preserves the quality of the material, preventing common issues such as yellowing.
- Energy efficiency: The DRV system operates with a reduced energy footprint compared to conventional systems, eliminating the need for oil condensers and providing energy savings.
- Fast and uniform drying: Four interconnected hoppers provide continuous and balanced drying.
- Quick material changeover: The system is claimed to reduce changeover times by up to 65%, enhancing the overall efficiency of the plant and reducing downtime between production runs.
- Minimal maintenance: The design of the DRV system has been designed for minimal maintenance, ensuring fewer interruptions and higher operational uptime.
Energy efficiency and sustainability considerations
Energy-efficient technologies and sustainability were key design priorities in the development of the plant. Technologies such as vacuum drying, gravimetric dosing, and automated transport systems contribute to lower energy usage and operational costs. The use of rPET in preform production reduces the reliance on virgin materials and aligns with broader regulatory and market pressures towards circular economy models and environmentally sustainable practices.
Integrated control systems
The plant’s operations are managed by a Siemens S7 PLC, which coordinates the various subsystems, ensuring seamless interaction between each component of the production line. This integration ensures that material handling, dosing, drying, and other processes are synchronised, reducing the potential for errors and optimising production efficiency.
The touchscreen interface provides operators with real-time access to all critical process parameters, allowing for any necessary rapid adjustments to be made. This real-time control enables operators to monitor and fine-tune operations, ensuring high production quality and minimal downtime. Additionally, the company states that the system’s data collection and diagnostics capabilities facilitate predictive maintenance, ensuring that any potential issues are addressed before they result in production stoppages.
Predictive maintenance
PET Solutions’ predictive maintenance system is engineered to reduce unplanned downtime and optimise the performance of production lines. By leveraging a network of advanced sensors, the system continuously collects real-time data on the operating conditions of each machine and plant component. This enables the early detection of anomalies and the identification of potential failures before they occur. Through predictive data analytics, maintenance activities can be scheduled in a targeted and efficient manner, minimising emergency interventions and extending the operational life of equipment. This approach is claimed to lower operating costs while enhancing system reliability and ensuring consistent production flow.
Traceability across the complete supply chain
The facility includes a traceability system that tracks raw materials through to final product delivery. This system provides digital documentation of each stage of production, enabling better inventory control, improved transparency, and compliance with quality and safety standards. This enhances transparency across the entire supply chain, effectively addressing the increase in customer demands for safety and sustainability.
Operational performance
The combination of automated material handling, precise dosing, energy-efficient drying, and integrated control systems contributes to a consistent production of rPET preforms. The facility is equipped to address the challenges associated with processing recycled materials, which can vary in quality, while maintaining stable output and cost efficiency.
The commissioning of this plant highlights ongoing efforts within the packaging and beverage industries to adopt more sustainable production methods. While PET Solutions implemented the system, the technologies and practices employed are indicative of a wider shift towards automation, traceability, and environmental responsibility in rPET processing.