Advancements in Mechanical Recycling: High-Quality rPET Resin Production by JB Ecotex - jbecotex

January 13, 2025

Advancements in Mechanical Recycling: Improving rPET Resin Quality

Although plastic waste has been a major worldwide problem, the growing use of recycled plastic is showing that there are workable alternatives. It’s time for us to shift our attention from discussing the issues to finding solutions. Over the years, mechanical recycling has emerged as one of the most effective methods for giving PET plastics a second chance. What’s particularly exciting is the progress this process has made—from a basic recycling technique to a sophisticated system that produces high-quality rPET resins that are suitable even for food-grade applications.

In addition to keeping plastics out of landfills, the development of mechanical recycling of post-consumer PET has addressed important concerns like efficiency, safety, and quality. It is crucial to remember that these elements have a significant influence on the environment and industries.

The Challenges of Early Mechanical Recycling of PET

Looking back a few decades, mechanical recycling was more of a promising start than a dependable solution. While it did help prevent a part of PET waste from ending up in landfills, the rPET produced during that time had notable drawbacks. Because sorting procedures were less sophisticated, recycled streams were frequently tainted by labels, non-PET materials, or food residues. Washing systems helped a little, but they couldn’t get rid of all the contaminants, so the recycled resin wasn’t perfect.

The outcome? rPET produced was cloudy, inconsistent in strength, and unsuitable for sensitive applications like food or beverage packaging. At that time, most recycled plastics found their way into products where quality was not a primary concern, such as textiles or strapping. rPET just could not meet the requirements for producers seeking a true substitute for virgin PET.

Thankfully, the industry identified these issues early on and started developing better solutions to address them.

Current Mechanically Recycled rPET Scenario

Today, this situation has undergone a significant change. Mechanical recycling has been transformed by technological developments, allowing for the creation of rPET that meets strict quality criteria and is comparable to virgin PET resins.

1. Precise Sorting and Superior Cleaning

Clean, superior materials are the foundation of any effective recycling operation. Only PET is included in the recycling stream thanks to modern sorting technology including optical sorters and near-infrared (NIR) systems. By doing this, pollution is effectively decreased right away.

In terms of cleaning, modern washing systems are far more sophisticated than those of the past. They give recyclers clean PET flakes that are prepared for processing by getting rid of food residues, adhesives, and tenacious labels. The quality of recycled PET (rPET) has significantly improved as a result of this development.

2. Preserving Strength with Advanced Processing

The potential for the recycling process to degrade the plastic’s quality is one of the primary obstacles. PET’s molecular structure may degrade when it melts, making the material weaker. Technologies such as EREMA’s VACUNITE® system are useful in this situation.

VACUNITE® protects PET during the solid-state polycondensation process by using nitrogen and vacuum conditions. This technique avoids oxidation, a typical issue with conventional recycling techniques, and helps preserve the integrity of the polymer chains. The result is rPET with outstanding clarity and robust mechanical qualities, making it a good choice for uses like beverage bottles.

3. Achieving Food-Grade Purity

Because of contamination problems, it was previously practically difficult to use rPET for food-contact applications. This scenario has changed, though, thanks to innovations like the VACUNITE® system. Recyclers may now create food-grade rPET that meets international safety requirements by using advanced cleaning procedures. The Food Safety and Standards (Packaging) Regulations 2018 were amended in 2022 by the Food Safety and Standards Authority of India (FSSAI) in India to permit the use of recycled plastics in food contact materials (FCM).

This development has made it possible for industry to use recycled materials much more widely, lowering their reliance on virgin plastics while still complying with health standards.

Where do start

4. Boosting Performance with Additives

Sometimes extra assistance is needed for even the most sophisticated recycling procedures. Chain extenders and other additions are useful in this situation. By repairing damaged polymer chains during processing, these materials can efficiently restore rPET’s strength and durability. As a result, in some circumstances, recycled resins can now function on par with or better than virgin PET.

EREMA VACUNITE® and its contribution to rPET

EREMA’s VACUNITE® system is a notable breakthrough in technologies in mechanical recycling. Its effectiveness lies in its innovative combination of techniques:

Enhanced Purity: The vacuum and nitrogen atmosphere work to eliminate impurities and prevent degradation, resulting in resins that are safe for food and beverage applications.

Improved Color: With minimized oxidation, the rPET produced using VACUNITE® has a clear, high-quality appearance, making it perfect for visible applications like bottles and other food packages.

Energy Efficiency: VACUREMA uses latent heat crystallisation to crystallise pellets without the need for an external energy source.

This system is setting new benchmarks for the industry, demonstrating that recycled materials can be just as good—if not better—than their virgin counterparts.

Where do start

At JB Ecotex Ltd., we take great pride in leading India’s recycling movement. Our journey is driven by a strong commitment to quality, innovation, and sustainability. Our advanced B2B plant features foodgrade washing line from “Boretech” with all latest sorting equipments and “Zerma” crusher to produce purest quality of rPET flakes required for food grade rPET resins. The state-of-the-art EREMA VACUNITE® technology, we use allows us to produce high-quality resins that meet the rigorous standards of industries needing durable and safe packaging solutions.

We are continually evolving, keeping pace with industry trends, and investing in cutting-edge technologies to ensure our products not only meet current expectations but are also ready to face future challenges. Beyond innovation, we are dedicated to building a legacy of responsibility—transforming PET waste into valuable resources and helping businesses create sustainable packaging that benefits both communities and the environment. Let’s create a legacy of responsibility, one choice at a time. Together!

Whatsapp Icon
Inquiry