Indian preform and plastic packaging manufacturer, Magpet Polymer Pvt Ltd, has partnered with Coperion and Herbold Meckesheim to construct a cutting-edge plant for bottle-to-bottle recycling. This collaboration integrates technologies to ensure a seamless process from the mechanical processing of used PET bottles to extrusion with a ZSK twin screw extruder, including pelletizing and an SSP (Solid State Polycondensation) reactor.
This PET bottle recycling system has a throughput capacity of 5,500 kg/h and produces PET recyclate approved by the European Food Safety Administration (EFSA) and the U.S. Food and Drug Administration (FDA) for direct contact with food. Additionally, the PET pellets manufactured on this line are approved by brand owners.
Devendra Surana, Managing Director of Magpet, expressed their commitment to embracing new technology: “Magpet has always pursued the goal to be a first mover when it comes to embracing new technology. This PET recycling unit is a big step in that direction and aligns with our efforts to conduct business responsibly for a larger eco purpose. We are excited to partner with Herbold and Coperion to establish this state-of-the-art PET bottle recycling line in India.”
Efficient Collaboration from a Single Source
Magpet chose to work with Coperion and Herbold Meckesheim, part of Hillenbrand, for the entire system due to their streamlined technologies and reliable plastic recycling solutions. Coperion’s and Herbold Meckesheim’s bottle-to-bottle plants allow for the processing of all recyclates together, regardless of differences in IV (Intrinsic Viscosity) values or bulk densities. This collaborative solution not only reduces operating and logistics costs but also minimizes energy consumption compared to traditional PET recycling methods.
The bottle-to-bottle recycling system first converts PET bottles into flakes using Herbold’s granulators with forced feeding and washing system technologies, ensuring optimal material processing and maximum yield with minimal material loss.
Subsequently, the PET regrind undergoes melting and dispersion in the ZSK twin screw extruder, where it is processed into a uniform mass. Thanks to the extruder’s high torque, the PET’s residence time is minimal, preserving product quality with low polymer chain degradation. Volatile components are removed during this process.
After extrusion, the material is transferred to an underwater granulator and SSP reactor for condensation and decontamination, resulting in high-quality PET pellets suitable for various applications.
“In the bottle-to-bottle recycling plant for Magpet, we have combined Coperion and Herbold Meckesheim technologies to produce high-quality PET efficiently,” explains Jochen Schofer, Head of Sales Recycling at Coperion.
Mehmet Kaya, Sales Team Leader Asia for Herbold Meckesheim, added, “With this bottle-to-bottle recycling system, Magpet takes another step in their sustainability journey. We wish them success and anticipate further collaboration.”
