x

Technology of

PET BOTTLES,
PREFORM AND
PET RECYCLING

Technology of

PET BOTTLES,
PREFORM AND
PET RECYCLING
Written By :
EIRI Board of Consultants & Engineers

4449, Nai Sarak, Main Road, Delhi-110 006 (India)

Ph.: 91-11-23918117, 23916431, 45120361, 23947058, 64727385
E-Mail: eiribooks@yahoo.com & eiriprojects@gmail.com
Website: www.eiriindia.org, www.eiribooksandprojectreports.com

Printed and Published by :

4449, Nai Sarak, Main Road, Delhi-110 006 (India)

Ph.: 91-11-23918117, 23916431, 45120361, 23947058, 64727385
E-Mail: eiribooks@yahoo.com & eiriprojects@gmail.com
Website: www.eiriindia.org, www.eiribooksandprojectreports.com

Marketed By:
EIRI PROJECT CONSULTANTS & PUBLISHERS
Roop Nagar, Delhi110007
Copy Reserved by Sudhir Gupta,
ISBN : 9789380772080
Printed in New Delhi (India)

The book is sold subject to the condition that it shall not, by way or
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without the publishers prior written consent, in any form of binding
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regarding this book are Subject to Delhi Jurisdiction only

Printed and Published by Sudhir Gupta for

Engineers India Research Institute, 4449, Nai Sarak, Main Road,
Delhi-110 006 and Printed at Swastik Offset, Delhi

Preface
The Book Technology of PET Bottles, Preform & PET Recycling
covers almost all the basic and advanced details to setup own Unit. The
Book Covers Details of PET Plastic Packaging, Properties of PET, Recycling
of PET, Aseptic Filling of PET Bottles, Flexo Inks For The Printing of Nontreated Polyester Films (PET) on Central Impression Flexo Presses,
Production and Filling Process of A PET-bottle, PET Bottle Recycling, PET
Preform and Bottle Blowing, Advantages of Coextruded PET-films in Flexible
Packaging, Thermoforming of Apet Sheet, Project Profiles, PET Pre-form
PET Resin, PET Bottle From Pre-form (Capsules), PET Bottles/Containers
From PET Grains, Project Profile on PET Bottles, Advanced Recycling,
Class Aseptic Filling of PET Bottles, Reprocessing of PET Bottles Waste,
Polycarbonate (PC) Blends With Recycled Polyethylene Terepthalate (RPET), PET Recycling, PET Plastic Reclamation Processes, Opportunities,
Coding Solutions Pet Brow Molders, PET Barrier Capabilities & Design
Flexibilities, Auxiliary Equipments in PET Processing, Masterbatches, PET
Bottle Manufacturing.
The book has been written for the benefit and to prove an asset and a
handy reference guide in the hands of new entrepreneurs & well established
industrialists.

4449, Nai Sarak, Main Road, Delhi-110 006 (INDIA)

E-mail : eiribooks@yahoo.com
www.eiriindia.org

Contents
1.
PET PLASTIC PACKAGING.......1-2
2.
PROPERTIES OF PET..........3-4
PET Properties ............................... 3
PET Characteristics ....................... 4
Use of PET ..................................... 4
3.
RECYCLING OF PET..........5-38
Virgin PET ...................................... 5
PET synthesis ................................ 6
Virgin PET thermal transitions
and crystallisation .................... 6
PET applications and processing ... 8
Extrusion ........................................ 9
Extrusion moulding ......................... 9
Extrusion to produce foam ............. 9
Inject ion moulding ....................... 10
Blow moulding .............................. 10
Recycled PET .............................. 10
Contamination .............................. 12
Acid producing contaminants ....... 12
Water ............................................ 13
Colouring contaminants ............... 13
Acetaldehyde ............................... 13
Other contaminants ...................... 13
POSTC-PET conventional
recycling processes ............... 13
Chemical recycling ....................... 13
Mechanical recycling .................... 14
Contaminants removal ................. 14

Drying ........................................... 15
Melt processing ............................ 15
Increasing recycled PET intrinsic
viscosity ................................. 17
Reprocessing under vacuum ........ 17
Stabilizers ..................................... 18
Solid sidle polymerisation ............. 18
Chain extension ........................... 19
Chain extension process .............. 19
End groups effect ......................... 20
Cross-linking reaction ................... 21
Chain extenders ........................... 21
Chain extension process
experimental variables ........... 24
Chain extension process
equipment .............................. 25
Reactive extrusion process .......... 25
Single-screw extruder ................... 27
Twin-screw extruder ...................... 27
Stability of reactive extrusion
system ................................... 28
The effect of chain extension
on PET crystallinity and
thermal transitions ................. 29
Thermal Transitions and
Crystallinity ............................ 30
Multiple melting peaks
phenomena ........................... 31
ISBM process ............................... 31
Preform moulding ......................... 32
Bottle stretch blow moulding ........ 32
ISBM of RER-PET ........................ 32
Bottle physical properties ............. 34

Orientation and conformation of

molecules of PET bottle ........ 36
Trans Gauche-Conformational
Changes ................................ 37
Dichroism ..................................... 38
4.
ASEPTIC FILLING OF
PET BOTTLES ........................ 39-41
Concept ........................................ 40
5.
FLEXO INKS FOR THE
PRINTING OF NON-TREATED
POLYESTER FILMS (PET)
ON CENTRAL IMPRESSION
FLEXO PRESSES .................. 42-44
Flexo printing of non-treated polyester films (PET) ....................... 42
Printing and lamination of PET
films ....................................... 42
6.
PRODUCTION AND FILLING PROCESS OF A PET-BOTTLE ......... 45-49
Handling of empty PET Bottles .... 45
Tray Loader .................................. 46
Tray Loop ...................................... 46
Pelletizer ....................................... 47
Installation of a Tray Storage ........ 47
Discharge at several
production lines ..................... 47
Separation of Blow moulder
and Filling Line ...................... 49
Application of commercially
available Plastic Trays as
means of Transportation ........ 49
Summary ...................................... 49
7.
PET BOTTLE RECYCLING .... 50-53
8.
PET PREFORM AND
BOTTLE BLOWING ................ 54-72
PET Container Applications: ........ 54

Popular applications ..................... 54

Manufacturing Processes: ............ 57
Quality Requirements: .................. 57
Single Stage Process: .................. 57
Two Stage Process: ...................... 59
Two Stage System: ....................... 59
Injection Moulding Machine .......... 59
Machines to give: ......................... 59
Dehumidification: .......................... 59
Chillers: ........................................ 60
High pressure compressor: .......... 60
How are the physical
properties of PET
improved by stretching? ......... 60
International trends: ..................... 60
Indian Scene ................................ 61
Future Scene Expected: ............... 64
The Future is Big and Good. ........ 64
PET Resin Industry Structure ....... 64
9.
ADVANTAGES OF COEXTRUDED
PET-FILMS IN FLEXIBLE
PACKAGING ........................... 73-80
Introduction .................................. 73
Properties of PET films ................ 74
Advantages of three layer
co-ex PET films ..................... 75
Hostaphan RD .............................. 76
Hostaphan RHB ........................... 76
Hostaphan RHS ........................... 78
Hostaphan MPK ........................... 79
Summary ...................................... 80
10.
THERMOFORMING OF
APET SHEET .......................... 81-88
Introduction .................................. 81
Why A PET ................................... 81
Thermoforming ............................. 82
Preparation ................................... 82
Heating ......................................... 82
Thermal Diffusivity: ....................... 83
Thermoforming ............................. 84
Cooling ......................................... 84

Removal From Mould ................... 85

Cutting .......................................... 85
Sealing ......................................... 85
Productivity ................................... 86
Advantages Over PVC: ................ 86
Manufacture of Buster Paching: ... 87
General Guidelines For Part
Design in APET ..................... 87
Recycling ...................................... 88
11.
PROJECT PROFILES ............. 89-95
Pet Bottles from Pre-Form PET .... 89
Properties ..................................... 89
Food Grade : ................................ 90
Aesthetics : ................................... 90
Strength : ...................................... 90
Weight : ........................................ 90
Airtight & Leak Proof : .................. 90
Space Utility : ............................... 90
Chemical resistance : ................... 90
Environment Friendly. ................... 91
PET (Polyethyleneterephthalate) : ................................ 91
Plant Economics of
Pet Bottles from
Pre-Form PET ....................... 94
Plant & Machinery ........................ 94
Fixed Capital ................................ 94
Working Capital
Requirement/Month ............... 94
Raw Materials .............................. 94
Total Working Capital/Month ........ 94
Total Capital Investment ............... 95
12.
PET PRE-FORM PET RESIN .. 96-100
Introduction .................................. 96
Injection Moulding machines :- ..... 96
Blow Moulding : ............................ 96
Uses ............................................. 96
Properties ..................................... 97
Manufacturing Process ................. 97
Manufacturing Processes of PET
Preform .................................. 97

Process Flow Sheet ..................... 98

Plant Economics .......................... 99
Plant & Machinery ........................ 99
Fixed Capital ................................ 99
Raw Material ................................ 99
Total Working Capital/Month ........ 99
Total Capital Investment ............. 100
Turn Over/Annum ....................... 100
13.
PET BOTTLE FROM
PRE-FORM (CAPSULES) .. 101-103
Plant Economics ........................ 101
PET Containers .......................... 101
Plant & Machinery ...................... 101
Fixed Capital .............................. 101
Working Capital
Requirement/Month ............. 103
Raw Materials ............................ 103
Total Working Capital/Month ...... 103
Total Capital Investment ............. 103
Turn Over/Annum ....................... 103
14.
PET BOTTLES/CONTAINERS
FROM PET GRAINS ........... 104-109
Manufacturing Process ............... 104
Formulation for PET
Containers ........................... 105
HDPE, PVC and PET
Bottles ................................. 105
Coloured Mellnar PET ............... 107
Process Flow Sheet
(For Plastic (PET)
Containers ........................... 108
Plant Economics ........................ 108
PET Containers .......................... 108
Plant & Machinery ...................... 108
Fixed Capital .............................. 108
Working Capital
Requirement/Annum ........... 109
Raw Materials ............................ 109
Total Working Capital/Annum ..... 109
Total Capital Investment ............. 109
Turn Over/Annum ....................... 109

15.
PROJECT PROFILE ON
PET BOTTLES .................... 110-113
Introduction ................................ 110
Market ........................................ 110
Raw Material .............................. 110
Manufacturing Process &
Technology .......................... 110
Technology ................................. 112
Investment .................................. 112
Means of Finance ....................... 113
Profitability Assumptions ............ 113
16.
ADVANCED RECYCLING .. 114-125
Introduction ................................ 114
Extrusion process ....................... 115
Mixing ......................................... 116
Degassing .................................. 118
Flexibility .................................... 119
Specific examples ...................... 120
rPET ........................................... 121
Low Bulk Density Scraps
Such as Agricultural
Films or Payarn .................... 124
17.
CLASS 0 ASEPTIC FILLING
OF PET BOTTLES .............. 126-128
18.
REPROCESSING OF
PET BOTTLES WASTE ...... 129-137
Status today ............................... 130
Current scenario of PET usage .. 130
Recycled PET bottles wasteproducts thereof .................. 131
MISC: ......................................... 131
Sub: PET bottles recycling
-some important points ........ 132
Caution ....................................... 133
Current scenario ......................... 134
Chemical recycling

(Bottle to Bottle) ................... 134

Food safety evaluation of
recycled material ................. 134
Chemical Recycling .................... 136
Chemical Recycling
(Bottle to Bottle) ................... 136
Methanolysis .............................. 136
AWRAP-UP ................................ 136
19.
POLYCARBONATE (PC)
BLENDS WITH RECYCLED
POLYETHYLENE
TEREPTHALATE (R-PET) .. 138-142
Introduction ................................ 138
Results and Discussion .............. 139
Mechanical Properties ............... 139
Electrical Properties ................... 140
Optical Properties ...................... 140
Physical Properties .................... 141
Thermal Properties .................... 141
Effect of Process Variable Injection pressure ................ 141
Cost Reduction and
Applications ......................... 142
20.
PET RECYCLING ............... 143-147
The process ............................... 143
Virgin vs used PET ..................... 144
Use for reclaimed PET ............... 145
Challenges involved ................... 146
Expanding scope ........................ 146
Developing Indian market ........... 147
21.
PET PLASTIC RECLAMATION
PROCESSES ...................... 148-150
Sorting and Granulation ............. 148
Cleaning ..................................... 149
Material Separation .................... 149
Drying and Filtering .................... 149

22.
DEVELOPING
NEW OPPORTUNITIES ...... 151-167
The shape of things to
come PET ............................ 155
Barrier solutions ......................... 156
Beer best before ......................... 157
Glass Ceiling .............................. 158
Increased PET production .......... 159
Future factors ............................. 160
Emergence of PET Beer
Bottles ................................. 162
Improving Barrier Properties
and Shelf Life ...................... 162
Recent Developments in PET .... 163
Has Customer Perception
Changed? ............................ 163
Future of PET Beer Bottles ........ 164
23.
CODING SOLUTIONS FOR
PET BLOW MOLDERS ....... 168-173
Commercial Director,
Domino Laser, Inc. .............. 168
PET Manufacturing Process ....... 168
Product Types ............................. 168
Key Drivers: ................................ 168
Coding Need Summary .............. 169
PET Marking Solution ................ 169
PET Solution - Blue Laser
Tubes ................................... 169
PET Solution - Through-beam
photocell .............................. 169
PET Solution - Motion sensor .... 172
PET Installations Motion
sensor .................................. 172
PET Installations Adjustable
laser head stand .................. 172
PET Solution - Anti-static
device .................................. 172
PET Solution - Fume
Extraction system ................ 173
PET Marking Solution ................ 173
PET Solution - The Domino
Difference ............................ 173

24.
PET BARRIER
CAPABILITIES &
DESIGN FLEXIBILITIES ..... 174-176
Design flexibility ......................... 175
25.
AUXILIARY EQUIPMENTS
IN PET PROCESSING ........ 177-186
Drying-Chilling-Air Conditioning . 177
Dont Try Without Dry ................. 177
Drying Systems .......................... 177
Why to Dry PET Before
Processing ? ........................ 177
(A) Oven Drying ......................... 178
(B) Hopper Dryer ........................ 178
Container - Reverse
Conical Flow ........................ 178
Dehumidified Air Dryer ............... 178
Dehumidified Air Dryerworks
on dew-point principle ......... 179
Key Components ........................ 180
Drying Agent .............................. 180
Heater ........................................ 180
Air Shut-Off Valve ....................... 180
Switching Valve .......................... 180
Suction Container
[Exhaust Valve] .................... 181
Return Line Air Cooler ................ 181
Selection of Dryer /
Dehumidified Air
Dryer (DAD) and
Drying Bins .......................... 181
(A) Dryer / DAD .......................... 181
(B) Drying Container .................. 181
Important Parameters to
achieve efficient drying.
Air Temperature: .................. 182
Air dew point: ............................. 182
Air Flow: ..................................... 182
Chilling Plant / Mould Dehumidifier
Cooling and Heating
Plays Important Role in
Plastics Processing Air
Cooled Chiller ...................... 183

Advantages ................................ 182

Disadvantages ........................... 183
Water Cooled Chiller .................. 183
Advantages ................................ 183
Disadvantages ........................... 183
Precaution Requeued for
Air Cooled Unit .................... 183
Application of Chiller in Injection
Moulding Machines ............. 183
Machine Cooling ........................ 184
Selection Criteria ........................ 184
Working Principle ....................... 184
Key Components ........................ 184
Compressor ................................ 184
Condenser .................................. 185
Water Pump ............................... 185
Water Tank ................................. 185
Microprocessor Based Control ... 185
Purpose: ..................................... 186

Requirement of Process: ............ 186

26.
MASTERBATCHES ................... 187
Inorganic Pigments .................... 187
Organic Pigments ....................... 187
Dyestuffs .................................... 187
The additives .............................. 188
Performance Additives: .............. 188
Processing Additives: ................. 188
27.
PET BOTTLE
MANUFACTURING ............. 189-193
Pellets ........................................ 189
Preforms ..................................... 191
Bottles ........................................ 192
Caps ........................................... 193