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.
PERTANYAAN YANG SERING DIAJUKAN
Apa itu jalur ekstrusi lembaran PET ABA?
Lini ekstrusi lembaran PET tipe ABA melakukan proses koekstrusi tiga lapisan dalam satu tahap: dua lapisan luar (A) yang terbuat dari PET murni atau PET premium, serta satu lapisan inti (B) yang tebal dari PET daur ulang. Lapisan luar yang tipis menghasilkan permukaan yang halus dan aman untuk bersentuhan dengan makanan, sedangkan lapisan inti daur ulang menyumbang sebagian besar ketebalan dan biaya lembaran tersebut.
Apakah jalur produksi ABA dapat memproses serpihan PET daur ulang tipe 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 garis ekstrusi lembaran PET sekrup tunggal.
Mengapa menggunakan struktur ABA daripada lembaran PET satu lapis?
Tiga alasan: biaya bahan baku yang lebih rendah, kualitas permukaan yang lebih baik, dan kepatuhan terhadap standar kontak dengan makanan. Penggunaan serpihan daur ulang pada lapisan inti yang tebal dapat mengurangi pengeluaran bahan baku, lapisan luar yang terbuat dari bahan murni menyamarkan variasi warna kecil yang umumnya terdapat pada serpihan daur ulang, dan lapisan luar yang bersih mencegah kontak langsung antara makanan dengan bahan daur ulang.
Apa itu mesin thermoforming 4 stasiun?
Mesin thermoforming 4 stasiun menyelesaikan proses pembentukan, pemotongan, pengeboran, dan penumpukan dalam satu urutan in-line yang berkelanjutan. Pemotongan in-line menghilangkan satu tahap operasi terpisah, melindungi tepi produk, dan membuat kebutuhan tenaga kerja tetap pada satu hingga dua operator per shift.
Produk apa saja yang dapat dihasilkan oleh lini ekstrusi dan termoforming rPET ini?
Kombinasi antara lini produksi lembaran PET hasil koekstrusi dan mesin pembentuk multi-stasiun mencakup kotak buah segar, kemasan clamshell, nampan makanan, wadah makanan siap saji, serta kemasan PET kaku lainnya yang memenuhi standar makanan dan membutuhkan transparansi serta kemampuan untuk ditumpuk.
Peralatan pendukung apa saja yang melengkapi jalur produksi lembaran rPET menjadi baki?
Beyond the extrusion line and the thermoformer, most plants add edge-trim recovery. A penghancur online skrap tepi lembaran returns skeletal waste straight back into the process, which is the fastest way to raise recycled content and cut material cost per tray.