PET Bottle Recycling via Enhanced Extrusion Techniques

Device to efficiently recycle waste plastic into new synthetic threads using a pretreatment, melting, and spinning process. The device has a pretreatment section for preparing waste like shredded fabric, a melting section to turn the pretreated waste into a plastic melt, and a spinning section to extrude threads from the melt. This allows recycling of textile plastics like PET bottles into new threads without the complex and costly steps of granulation and filtration.

Source

Producing thin-walled containers for food storage that can be easily demolded and won't shatter when dropped, using recycled PET (rPET) produced via a specific process. The process involves blending virgin PET with a low viscosity (0.5-0.7 dl/g) and recycled PET (rPET) with higher viscosity (0.01-0.4 dl/g) in a reactive extrusion step. The blended material is then injection molded into thin-walled containers. The reactive extrusion lowers the viscosity of the recycled PET to match the virgin PET for injection molding. The containers have a wall thickness of 0.1-0.5 mm and a smaller bottom area than the opening.

Source

Method to produce polyester starting material for extrusion blow molding of hollow articles like PET bottles from recycled post-consumer PET. The method involves melting and reactively extruding the recycled PET with chain extenders to increase viscosity for blow molding. The chain extenders can be dianhydrides like pyromellitic dianhydride. The extruded melt is filtered and granulated. This provides a recycled PET with higher viscosity suitable for blow molding without needing additives or long condensation times.

Source

A process for producing high barrier and crystallinity PET and rPET containers using injection stretch blow molding. The process involves adding a nucleating agent to the PET during granulation. This improves barrier properties against oxygen and crystallinity of the blown containers compared to regular PET. The nucleating agent quantity is optimized between 0.1-1.5% by weight. The containers have preferably >35% crystalline fraction and can be used for sensitive foods without additional oxygen scavengers. The nucleating agent helps achieve these properties in single-layer containers without needing multilayer or coating techniques.

Source

Using waste plastics containing PET, like colored plastics, PET-containing mixtures, and PET-containing byproducts from recycling facilities, as feedstock for chemical recycling processes like solvolysis. This allows recycling of plastics that cannot be efficiently recycled mechanically, like mixed waste plastics, by extracting the PET. The PET-containing waste is fed directly to the chemical recycling facility without preprocessing, and depolymerization converts the PET back to monomers. This enables closing the loop on hard-to-recycle waste plastics by extracting valuable PET for recycling.

Source

Recycling post-consumer PET bottles into carpet yarn using a multi-rotating screw (MRS) extruder. The PET bottles are sorted, ground, washed, and dried to remove impurities. The ground flakes are melted and purified in the MRS extruder, which has multiple satellite screws to expand the melt area and remove volatiles. The purified melt is extruded directly into the carpet spinning machine to make recycled carpet yarn. This allows making 100% recycled carpet yarn from bottles without using virgin PET.

Source

A process for making clear PET plastic parts for refrigerators that avoids defects like scars, white spots, and opaqueness. The process involves injecting dehumidified PET into a mold from the side instead of the top to prevent scars. The mold has a heated nozzle and heating rod to maintain consistent temperature during injection. After molding, the part is removed using a robot. This prevents cooling issues during ejection. The molded part is then blown stretched to shape.

Source

A method to produce PET material with higher viscosity suitable for extrusion blow molding of plastic bottles, using recycled PET as the starting material. The method involves increasing the intrinsic viscosity of recycled PET by solid state polycondensation (SSP) after extrusion. The extruded PET is first mixed with a chain extender, then extruded again. This extruded PET is then subjected to SSP at temperatures below the melting point to further increase viscosity. This allows producing PET with higher viscosity suitable for blow molding from recycled material without requiring high temperatures or long times.

Source

A production line for making multi-layer twin-screw co-extruded PET sheets with uniform distribution of different resin pellets for composite production. The line has a feeding device, mixing device, and discharging device connected in sequence. The mixing device has a horizontal conveying pipe with a screw for conveying pellets. It also has a heating mechanism to melt the pellets and an agitating mechanism to mix the molten resins. This allows gradual feeding of mixed pellets from the feeding device into the conveying pipe, where they are melted and mixed before extrusion into the sheet.

Source

Manufacturing 100% recycled carpet yarn from post-consumer PET bottles using a specialized extrusion process. The method involves preparing the PET flakes from bottles, melting and purifying them in an extruder, and spinning them into carpet filaments. The extruder uses a multi-stage screw design and pressure control to remove impurities and water from the recycled PET. The flakes are first crystallized to remove moisture before extrusion. This allows making high-quality recycled PET filaments for carpet without using virgin PET.

Source

Twin-screw extruder for efficiently melting and drying polyester chips without pre-drying and steam requirements. The extruder has two parallel screws in a horizontal housing with rhombus-shaped extrusion protrusions on the screw blades. The screw sections have gradually decreasing blade pitches from feed to discharge to increase shearing and extrusion force. This improves melting and drying of the chips. The feeding mechanism conveys chips into a silo that connects to the extruder inlet. The extruder has a drive motor, reducer, and cooling system. The conveyor and silo allow feeding chips without a rotary drum.

Source

Twin-screw extruder for processing TPO elastomer particles that allows cutting the extruded TPO into uniform-sized pellets. The extruder has a discharging tube with mold holes to shape the TPO into long cylinders. A rotating rod driven by a dual-axis motor moves a pallet that contacts the cylinders to cut them into pellets. A return spring resets the rod to discharge the pellets. A conveying screw transports the pellets to a collection tube. The extruder also has a tapered tube for concentrated pellet output. This allows cutting and pelletizing TPO directly from extrusion.

Source

A process for making carpet yarn from 100% recycled polyethylene terephthalate (PET) bottles using a specialized extrusion system. The process involves: grinding and washing recycled PET flakes, melting and purifying the flakes using a multi-screw extruder with low pressure regulation, and pelletizing the purified PET into nurdles. The low pressure extrusion removes impurities without melting and cooling multiple times. This allows using lower quality recycled PET like curbside bottles to produce high-quality yarn for carpets.

Source

Ultra-high intrinsic viscosity (IV) polyester resin suitable for extrusion blow molding applications that can be produced using a novel method. The resin has a final IV of at least 0.9 dL/g, achieved by melting and extruding the resin at a temperature below its crystallization point, followed by solidifying and pelletizing. This avoids the long solid-state polymerization step needed for conventional high IV resins. The lower processing temperature prevents crystallization and results in a clear, amorphous resin. The method provides a faster, energy-efficient, and more cost-effective way to make high IV polyesters for applications like handleware containers.

Source

PET waste recycling device that allows simple recycling of PET waste without pre-degradation steps. The device includes steps to clean, crush, and melt the waste PET, then filter, dry, and finally polymerize it into new PET. The recycling process involves extruding waste PET into a melt state, filtering it before final polymerization, drying it in a tower, and pre-drying it before final drying. This allows recycling of dirty, contaminated PET waste without the need for pre-degradation. The recycled PET is obtained by melting, filtering, drying, and polymerizing the waste PET.

Source

Method to manufacture high-quality recycled PET chips from low-grade PET bottles with low intrinsic viscosity for producing high-strength polyester fibers. The process involves pulverizing low-grade PET flakes, sorting transparent flakes, crystallizing them, preheating, solid-state polymerization, melting extrusion, and cutting to make high-IV, high-purity recycled PET chips. This enables upcycling low-value PET into valuable fibers with improved recyclability.

Source

A process to make recycled carpet yarn from post-consumer PET bottles that enables producing bulked continuous filament carpet from 100% recycled PET. The process involves grinding the bottles, washing the flakes, removing impurities, melting the PET, and extruding it through multiple screws at reduced pressures. This purifies the recycled PET to high quality for carpet production. The process can also use colored bottle flakes and dye concentrates to match carpet color. Automated color adjustment and dye enhancers further optimize color. The system enables making recycled carpet yarn with better quality and color compared to melt-and-cool processes.

Source

Manufacturing 100% recycled PET carpet yarn using a processing system that effectively removes contaminants and water from recycled PET flakes without melting and cooling multiple times. The system involves steps like sorting, washing, identifying impurities, and crystallization of recycled PET flakes before extrusion. This improves the quality of recycled PET suitable for making carpets without needing pure virgin PET.

Source

Extrusion blow molding (EBM) method and system to produce containers using high and low intrinsic viscosity (IV) PET resins. The method involves co-extruding PET resins with different IVs to form the parison, then blow molding it into a container. The higher IV PET forms an inner layer and the lower IV PET forms an outer layer. This allows using lower IV extrusion grade PET in the outer layer for recycling compatibility while maintaining container strength and quality. The higher IV inner layer provides capturability and melting properties. The co-extruded parison is then blow molded into the container.

Source

A process for extruding plastic compositions using a multi-screw extruder with specific screw profiles to reduce temperature rise and avoid polymer degradation. The screw profiles have continuously differentiable cross-sections made of multiple circular arcs that merge tangentially. This reduces energy dissipation in the tip zone compared to conventional screws with pure shear flow. The self-cleaning screws have clearances between them and the barrel. The cross-section profiles can have 4 or more arcs.

Source