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How NGR’s P:REACT Revolutionizes PET Plastic Recycling + Production

 

Bottle to Bottle recycling and PET fiber recycling are well known applications proving the excellent recyclability of PET. But what about PET sheet recycling?

A big challenge in PET sheet recycling is the material composition, as a PET sheet often consists of a PET/PE or G-PET structure.  Conventional Polycondensation Equipment CANNOT upcycle this product.

Next Generation Recycling (NGR) developed a revolutionary system called the P:REACT and the Liquid State Polycondensation (LSP), which uses PET’s inherent tendency to condense under vacuum in the melt phase. This condensation results in an extremely quick increase in the iV value.  The vacuum decontaminates the material by removing harmful chemicals.  This ensures that the material can be used downstream for 100% food-safe applications approved by the FDA and EFSA.

What kind of PET  materials can the NGR P:REACT recycle? 

An extremely wide range of PET materials and material shapes are fed into the system. Materials including bottle flakes, punch scrap or even PET fibers are all equally suitable.

  • PET fibers, fiber spinning
  • PET nonwoven, post industrial scrap
  • Purges
  • PET film, automotive airbag
  • PET bottle flakes, post washing line
  • PET bottles mixed color flakes, post washing line
  • PET preforms, injection molding and blow molding
  • PET wovens, post industrial scrap
  • PET trays, thermoforming
  • PET skeleton, thermoforming

NGR’s LSP method offsets fluctuations in mixture ratios of the fed materials, opening the door for flexible cost structuring depending on material availability.

How Does The Process Flow Work for the P:REACT?

  1. Feeding the Material
  2. Conveyor belt with metal detector
  3. Efficient size reduction with a shredder (optional depending on material)
  4. Extruder to melt or plasticize the material
  5. Venting to remove volatile components in the melt flow
  6. Filtration screen changer or melt filter
  7. Melt pump
  8. Gate
  9. High-efficiency vacuum container (melt reactor) to remove contamination raise iV levels
  10. Horizontal drum for perfect homogenization
  11. Discharge of decontaminated substances
  12. Melt discharge pump
  13. Filtration
  14. Ongoing viscosity measurement
  15. Transfer into downstream production

What Options Are Available For The Downstream Production?

As the reactor treats the material in the liquid phase, the result out of it is an iV upgraded, iV stabilized and decontaminated PET melt, ready to be used in different downstream technologies:

A. PET Film Production to produce clam shell containers.
B. PET Fibers for textile
C. PET Straps
D. rPellets with the amazing benefits to produce consistent high quality pellets despite varied post-consumer waste.  High quality rPET will command higher sell price.

This full turn key closed loop system will reduce production cost, time, and even virgin PET material makes it a win-win solution to meet strict plastic recycling initiatives.

 

 

Summary

  • Approved by FDA and EFSA for 100 % food safety.  LSP takes care of the contaminants in the melt phase, delivering a degree of rPET purity that is significantly higher than the current standards for food grade specified by EFSA and FDA.
  • Take PET recycling at the highest level, raises and controlling IV values with pinpoint accuracy
  • Melt phase eliminates issues with dust with PET bottle flake material.
  • Full flexibility of infeed input material to flexibility to create several different downstream production options.
  • Continuous process stability that takes a few minutes, not hours to transform contaminated PET to high-quality rPET.
  • Extremely low residence time inside the reactor equates to superb energy efficiency.
  • Output rate up to 2,200 kg/h (4,840 lbs/h) depending on type

 

 

NGR P:REACT makes it possible to revolutionize the PET recycling process. It transforms PET waste and PET bottle flakes into food-grade recycled PET in minutes.  The P:REACT continues it’s innovation with LSP technology to push PET recycling to a new dimensional boundaries that no other competitors can match.

If you have any questions regarding NGR or any plastic process equipment, please contact any of the Hirate America team members to provide a solution tailored to your requirements.

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Plastic Recycling: How To Turn Your Plastic Scrap Into Reusable Pellets

Plastic Recyling: How To Turn Your Plastic Scrap Into Reusable Pellets

Not too long ago, many plastic processors were able to get rid of their scrap material selling them to local MRF (material recycling facilities).  Then these recycling facilities would reprocess the collected scrap to reusable plastic pellets and sell off the contaminated or difficult to recycle scrap to countries in South East Asia.   This however has changed and we are no longer able to sell our scrap to these countries and they simply don’t want our trash.  Our previous methods are no longer accepted and we need to take action and build a strong recycling infrastructure locally instead of land-filling and shipping our trash to other countries.

We work with many plastic processors and they are having trouble getting rid of their scrap.  Sometimes it’s difficult to even pay recyclers to haul them away.

Requirements on plastic recycling are becoming more stringent all the time.  California is one of the states on the forefront of initiating a clean environment and have been giving grants to many companies that are wanting to recycle plastics to reduce waste.

This seems like an almost impossible task to tackle, but we need to break it down and start with post industrial recycling (PIR).  Residual products left behind by the industrial production of plastic products are a high-quality and valuable raw material. To ensure that they can be fed back into production without losses would not only great for the environment to reduce waste, but will be beneficial to the company that will be saving money over time putting recycled material back into their products and reducing virgin consumption.

Does this sound too simple and easy?

Well it’s pretty simple, Next Generation Recycling (aka NGR) has an all-in-one DUMP & RUN machine called the S:GRAN and X:GRAN.  It’s a patented system that is a shredder, feeder, extruder and pelletizer.

NGR’s relentless and continuous innovation of their technology introduces the NXT:GRAN system the next iteration of the S:GRAN, which is their most popular model.

NXT:GRAN continues to combine size reduction, feeding and extruding into one extremely efficient process (ONE-STEP technology). In doing so, it draws upon the experience gained from having over 1000 patented shredder-feeder-extruder combination installations worldwide.

  1. Material feed (conveyor belt, roll feeder, air separator)

2. The shredder chops the material being fed to the extruder via the Duo-Direct feeder.

3. The heated material is melted and homogenized in the extruder. Single or double venting systems remove volatile components in the melt flow

4. The melt is cleaned, depending on the application with a standard screen changer or high-performance melt filter

5. A pelletization unit at the end of the recycling process produces uniform recycling pellets

THE WORKING PRINCIPLE

Using the material efficiently in each process: The patented shredder-feeder-extruder combination provides maximum performance for extremely high output and quality.

First, the materials being fed are pressed against the solid shredder shaft by the hydraulic pusher.

The shredded material is then conveyed into the extruder by the revolutionary Duo-Direct feeder. What this means is that the shredder is now decoupled from the extruder so cutting speed and extrusion speed can be controlled independently.  This method enables the system to optimize production and most importantly enables the system to be very reliable.

Both of these process components feature load-dependent and fully automatic control.

In the extruder, the polymer is efficiently melted and homogenized and if necessary, the melt is vacuum degassed at the same time.

The cutter outlet and extruder intake components are placed close together so the heat generated in pre-processing is transferred into the extruder. This design feature optimizes the energy balance and gives the NXT:GRAN extremely efficient operation.

Easy Operation

The system offers an extremely user-friendly large touchscreen that monitors the entire process flow.  When your recipe is dialed you can put it in autopilot and let it run automatically.

Malfunction-free Maintenance

Your maintenance manager will love how easy this system is to maintain.  Maintenance intervals and instructions are all embedded within the touch screen for easy step-by-step instructions.  Less downtime equals better efficiency equals more profit.

Summary

The NXT:GRAN offers improved maximum performance & reliability in all areas.

Zero-waste production between input and output guarantees that the full value of the material is realized.

At the same time, as with all NGR technologies, input of work and energy are reduced to an absolute minimum.

The chart below shows the different shredder and extruder screw diameters for each model within the NXT:GRAN line.

Maximum of 1,760 pounds / hour can be achieved.

In our recycling test centers, we can prove the NGR reprocessing performance on your own scrap materials.

Please contact us if you would like to run a trial on your material, and we look forward to the opportunity to prove it to you in person.

They say the proof is in the pudding!

NGR NXT:GRAN continues to combine size reduction, feeding and extruding into one extremely efficient work step (ONE-STEP technology). In doing so, it draws upon the experience gained from having over 1,000 patented shredder-feeder-extruder combination installations worldwide.

If you have any questions regarding NGR or any plastic process equipment, please contact any of the Hirate America team members to provide a solution tailored to your requirements.

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India Plastic Scrap Ban In Effect

The Indian government announced it’s plan to ban plastic scrap imports earlier this year and will take effect on August 31st.  Since the China ban last year, India was the top importer of plastic scrap material, rough figures around 156 million pounds, for the first six months of 2019.  The ban is proposed to cover most plastics under the 3915 tariff code, including PET, PE, PP, PS and more.

For the time being, however, clean regrind is still going to the country, traders say, and it’s mostly the baled scrap plastic that has been impacted.

The influx of material has led to greater attention to contamination, particularly when the importing country does not have adequate infrastructure to dispose of that contamination.

These issues have built significant public pressure on governments to take action in thinking green and instill people to separate trash and recyclables so that we can preserve our planet we live on to better our children’s future here on this planet.

In the US, California is taking major initiative to drive new plastic recycling facilities by providing grants.

Hirate America has solutions to provide full turn key plastic recycling systems with a combination of full wash lines with shredders (Lindner Resource, specializing in waste management)  and all-in-one shredder + extruder + pelletizer by Next Generation Recycling (NGR).

Credit to Plastics Recycling Update, see full original article here.

 

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

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Push for Bag Manufacturers to Utilize Recycled Plastics

There continues to be a big push to increase recycled post-consumer plastics use in bag production especially in the state of California.

Garbage bags sold in California have been required to be made with 10% post-consumer plastic for nearly 30 years. And since 2016, concurrent with a single-use bag ban at retail stores, the state has required that all reusable plastic bags be made with 20% post-consumer plastic. That requirement increases to 40% next year.

There are several companies that have received grant funding to push plastic recycling in California.

If your company has been on the fence on turn key plastic recycling systems and processing to create product now is the time to move forward.

Hirate America has solutions to provide full turn key plastic recycling systems with a combination of full wash lines with shredders (Lindner Resource, specializing in waste management)  and all-in-one shredder + extruder + pelletizer by Next Generation Recycling (NGR).

Credit to Plastics Recycling Update, see full original article here.

 

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

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India to End Plastic Scrap Imports

The Indian government says it will ban scrap plastic imports, a move that threatens to further disrupt the U.S. recycling industry by closing a growing market.

“Solid plastic waste has been prohibited from import into the country,” the release stated, specifying that the ban closes exemptions to existing import restrictions. The Institute of Scrap Recycling Industries (ISRI) shared the information in an alert to members Wednesday March 6, 2019.

India has become a larger scrap plastic importer over the past two years and was among the top importers of U.S. plastic in 2018. The increase has been driven by the loss of China as a downstream outlet for U.S. plastic scrap went into effect at the start of 2018.

U.S. year-end trade figures for 2018, released this week, show India brought in 294 million pounds of scrap plastic last year. That was up from 271 million pounds in 2017 and 203 million pounds in 2016.

The release doesn’t specify a date of implementation and also doesn’t get into detail on resins (possibilities include PET, PE, PP, PE and PS) that will be covered by the new regulation.

California is a proven leader in environmental initiatives and policy and recyclers are now pushing to making substantial investments in mixed-plastics processing capacity, bringing positive news for a region hard hit by China’s ban.

The operations are installing lines for sorting mixed-plastic bales into discrete materials, some of which they’ll further process to clean and wash, shred, extrude and finally pelletize so you can put this material back into your products.

If your company has been on the fence on turn key plastic recycling systems and processing to create product now is the time to move forward.

Hirate America has solutions to provide full turn key plastic recycling systems with a combination of full wash lines with shredders (Lindner Resource, specializing in waste management)  and all-in-one shredder + extruder + pelletizer by Next Generation Recycling (NGR).

Credit to Plastics Recycling Update, see full original article here.

 

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

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An App That Will Help the Plastic Recycling Industry

Whenever there’s a problem, there’s going to someone that comes up with an idea to solve this issue. In our case with the China ban on plastic scrap, a Silicon Valley based technology company called Scrapo, who built a platform that connects suppliers & buyers of recyclable plastics.

It’s absolutely true that there’s an app for everything.

Fun facts:

  • Today there are over 10,000 buyers and sellers that are active users on the platform and this number is growing.
  • 75% of these users are outside the United Sates.
  • Scrapo does not take a fee for listings or sales
  • How platform makes money is with their enhanced services which they help the user with the sales, logistics and payment processes.
  • Listings on the marketplace cover loose or baled material, flakes and pellets.
  • 65% of plastic listed on the platform has been post-industrial material and 35% post-consumer plastic.

 

If your tired of selling your scrap and perhaps thought about having a turn key plastic recycling systems then we can help guide you through this journey.

Hirate America has solutions to provide full turn key plastic recycling systems with a combination of full wash lines with shredders (Lindner Resource, specializing in waste management)  and all-in-one shredder + extruder + pelletizer by Next Generation Recycling (NGR).

Credit to Plastics Recycling Update, see full original article here.

 

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

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China to enact tariffs on scrap and virgin plastics?!

There continues to be bad news on plastic recyclers and matters seem to worsen day-by-day.

The Chinese government plans to levy a 25% tariff on scrap plastic, as well as a number of virgin plastics and all recovered paper, in retaliation for the latest U.S. tariff proposals.

China’s Ministry of Commerce on Aug. 8 issued the latest list of tariffs the country is planning to implement on goods from the U.S. starting next week. The list identifies scrap PET, PE, PVC, PS and other plastics among the product codes that would be hit with the 25% duty.

The tariff codes named in the list would cover all scrap plastic, of which about 30.2 million pounds were exported from the U.S. to China during the first half of this year. In comparison to 2017, the U.S. sent 379.3 million pounds of scrap plastic to China.

The action also covers a handful of virgin resins, as well as recovered fiber.

Among the virgin plastics that will be hit with duties is high density polyethylene (HDPE). The U.S. shipped 300,000 metric tons of HDPE to China last year. The list also adds linear low density polyethylene (LLDPE), of which 130,000 metric tons were exported to China last year.

The virgin impact is important for the recycling industry because recycled plastic prices often follow virgin resin trends.

Although previous tariffs have affected the recycling industry through steel and aluminum pricing and availability, or by their impact on recycling equipment, the new proposal from China marks the first instance of recovered plastic and paper being targeted directly.

If your company has been on the fence on turn key plastic recycling systems now is the time to move forward.

Hirate America has solutions to provide full turn key plastic recycling systems with a combination of full wash lines with shredders (Lindner Resource, specializing in waste management)  and all-in-one shredder + extruder + pelletizer by Next Generation Recycling (NGR).

Credit to Plastics Recycling Update, see full original article here.

 

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

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Plastic Ban Expands to Other Southeast Asian Countries

“Thailand and a number of other Southeast Asian nations have seen substantially more scrap material flow into its ports this year because of China’s disappearance as a downstream destination. Census figures show U.S. exporters shipped 132.8 million pounds of scrap plastic to Thailand in the first four months of 2018, up from 4.6 million pounds shipped during the same period a year earlier.” – Resource Recycling

It is said that Chinese companies have set up factories around Southeast Asia, looking to stay in business by processing materials and shipping pellets back to China.  Other Southeast Asian countries like Vietnam is onboard with this as well.

This is more disappointing news on the plastic ban spreading like wildfire. The government of Thailand has banned all scrap plastic from entering its ports, amid a major increase in shipments to the country along with other Southeast Asia countries.   There is now an indefinite ban effective immediately imports of plastic scrap. Officials will begin inspecting recycling facilities across the countries.

Even the shipping and logistics companies responded swiftly to the Thai government announcement. Maersk, APL, Hapag-Lloyd, MCC Transport and  others have announced on June 23 that it would stop accepting shipments of recovered plastic bound for any port in Thailand.

Because of all of this, there has been significant activity with recyclers domestically and now really pushing to add new full turn key recycling systems in place.  It’s a race to see who will jump on this bandwagon of zero waste and zero carbon to clean up the environment and in the process capture business opportunities.

Hirate America has solutions to provide full turn key plastic recycling systems with a combination of full wash lines with shredders (Lindner Resource, specializing in waste management)  and all-in-one shredder + extruder + pelletizer by Next Generation Recycling (NGR).

Credit to Plastics Recycling Update, see original article here.

 

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

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China will Expand Ban to Post-Industrial Plastic

Quick update for those that haven’t heard already and if we already didn’t have enough bad news going on with the ban on post-consumer plastics ban into China.  Here’s more as China plans to prohibit imports of post-industrial scrap plastic by the end of the year.

The Chinese Ministry of Ecology and Environment announced that it is set to re-categorize post-industrial PE, PET, PS, PVC and other scrap plastic as materials banned from import, according to The Institute of Scrap Recycling Industries.

Post-industrial scrap plastics, including production scraps, off-cuts and regrind, were not named in the ban on post-consumer plastic that went into effect this year. Post-industrial loads, however, are subject to the sharp 0.5 percent contamination limits that went into effect March 1.

 

Chinese officials previously alluded to the country’s plans for further phased-in material import restrictions. The new announcement likely signals that the volume of scrap plastic shipped into China, which has dropped off substantially this year since the post-consumer ban took effect, will further decrease in 2019.

The market turbulence caused by China’s prohibitions over the last year have caused North American recycling stakeholders to scramble to determine the viability of markets in Southeast Asia and other parts of the world.

 

More focus has also been put on trying to quickly develop greater capacity to use recovered material in domestic applications.  So which path are you going to take?

Hirate America has solutions to provide full turn key plastic recycling systems with a combination of Lindner Resource for shredders and wash lines and Next Generation Recycling (NGR) for all-in-one shredder + extruder + pelletizer.

Credit to Plastics Recycling Update, see original article here.

 

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

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More on China Ban Causing FUD

With all this fear, uncertainty and doubt (FUD) on the China ban of plastic scrap materials, this topic continues to hit the headlines in the plastic recycling world.  China doesn’t want to continue taking in everyone’s waste. They are taking measures to clean up their environment and would like everyone else in the world to partake in being providers of clean recycling materials.  They recently stated a “0.5% contamination threshold for imports”.  The we shouldn’t be taking the easy solution road of putting waste into landfills as eventually there won’t be anymore land to fill with trash!  In term, we should be promoting recycling to the fullest and take care of the planet we live on and reduce waste.

Details on this topic can be found on the Plastics Recycling Resource How China fallout is shaking recycling in California.

 

The China ban FUD of plastic scrap materials has lead to a boom in plastic recycling opportunities here in California.  We have been getting more inquiries about plastic recycling technology solutions and businesses are trying to capitalize on this opportunity domestically.

 

 

Do you want to jump on the opportunity bandwagon or cheer on on the sidelines and pass up huge demands and opportunities along with making our world a better place live for our future children?

 

 

 

 

Hirate America has solutions to provide full turn key plastic recycling systems with a combination of Lindner Resource for shredders and wash lines and Next Generation Recycling (NGR) for all-in-one shredder + extruder + pelletizer.

 

 

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.