Project Background

In 2025, a leading recycling factory in Kosovo reached out to us to upgrade their rPET (recycled polyethylene terephthalate) value chain. Specializing in collecting and processing post-consumer PET bottles into high-purity rPET flakes, the client sought an integrated manufacturing solution to convert these recycled flakes into food-grade PET packaging, such as fresh fruit boxes, clamshells, and food trays.

Client Challenges & Requirements

To meet European sustainable packaging standards and maintain cost competitiveness, the client required:

• Direct rPET Flake Processing: An extrusion system capable of handling 100% rPET flakes without sacrificing clarity or mechanical strength.
• Cost-Efficient Layer Structure: An ABA layer configuration to use recycled core materials while sandwiching them between virgin PET outer layers for flawless food-contact safety.
• High-Speed Automated Forming: A versatile 4-station thermoforming machine (forming, cutting, punching, stacking) to produce various PET fruit boxes and trays at maximum output.

Caption: Watch our ABA PET Sheet Extrusion Line processing rPET flakes into high-clarity PET sheet rolls at the Kosovo plant.

Our Tailored Machinery Solution

1. ABA PET Sheet Extrusion Machine

We customized an advanced ABA Co-Extrusion PET Sheet Line. Equipped with a specialized degassing vacuum system and precise melt pumps, it directly processes rPET flakes into uniform, high-rigidity PET sheets, significantly reducing raw material costs for the client.

[Image: ABA PET sheet extrusion line processing 100% rPET flakes at the Kosovo plant – TZ Machinery]

2. High-Precision 4-Station Thermoforming Machine

To handle complex container shapes, we integrated a high-speed 4-station PET thermoforming machine. Featuring servo-driven mold technology and precise temperature control, this unit produces clean-cut, easily stackable fruit boxes and food trays with ultra-short cycle times.

[Image: 4-station PET thermoforming machine producing clear food trays – TZ Machinery]

Caption: See our 4-station thermoforming machine forming, cutting, and stacking PET food containers and fruit boxes automatically.

Results & Industry Impact

By implementing our complete extrusion and thermoforming solution, the Kosovo client successfully bridged the gap between recycled PET flakes and high-value packaging products. Today, their factory efficiently supplies eco-friendly PET food trays across the regional market, achieving both operational sustainability and higher profitability.

PREGUNTAS FRECUENTES

¿Qué es una línea de extrusión de láminas de PET ABA?

Una línea de extrusión de láminas de PET tipo ABA coextruye tres capas en una sola pasada: dos capas externas A de PET virgen o de alta calidad y una capa central B gruesa de PET reciclado. Las finas capas externas proporcionan una superficie lisa y apta para el contacto con alimentos, mientras que el núcleo reciclado aporta la mayor parte del grosor y del coste de la lámina.

¿Puede una línea ABA procesar escamas de PET reciclado 100%?

Yes. In an ABA configuration the core layer can run 100% rPET flakes, which is why this structure suits recycling plants that already produce high-purity flakes. Degassing and vacuum venting remove moisture and volatiles during extrusion, so the material does not need the long crystallization and pre-drying cycle required by a Línea de extrusión de lámina de PET de un solo tornillo.

¿Por qué utilizar una estructura ABA en lugar de una lámina de PET de una sola capa?

Tres razones: menor coste de la materia prima, mejor calidad de la superficie y cumplimiento de la normativa sobre contacto con alimentos. El uso de escamas recicladas en una capa central gruesa reduce el gasto en material; las capas exteriores de material virgen ocultan las ligeras variaciones de color típicas de las escamas recicladas; y las capas exteriores limpias evitan el contacto directo de los alimentos con el material reciclado.

¿Qué es una máquina de termoformado de 4 estaciones?

Una máquina de termoformado de 4 estaciones realiza el conformado, el corte, el troquelado y el apilado en una secuencia continua en línea. El recorte en línea elimina una operación independiente, protege el borde del producto y mantiene la mano de obra en uno o dos operarios por turno.

What products can this rPET extrusion and thermoforming line produce?

The combination of a co-extruded PET sheet line and a multi-station former covers fresh fruit boxes, clamshells, food trays, deli containers, and other rigid food-grade PET packaging that needs transparency and stackability.

What supporting equipment completes an rPET sheet-to-tray production line?

Beyond the extrusion line and the thermoformer, most plants add edge-trim recovery. A chatarra de cantos de chapa trituradora en línea returns skeletal waste straight back into the process, which is the fastest way to raise recycled content and cut material cost per tray.