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.
FAQ
O que é uma linha de extrusão de chapas PET ABA?
Uma linha de extrusão de chapas de PET do tipo ABA coextrude três camadas numa única passagem: duas camadas exteriores A de PET virgem ou de alta qualidade e uma camada central B espessa de PET reciclado. As finas camadas exteriores proporcionam uma superfície lisa e segura para o contacto com alimentos, enquanto o núcleo reciclado é responsável pela maior parte da espessura e do custo da chapa.
Uma linha ABA consegue processar flocos 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 linha de extrusão de folha PET de parafuso único.
Por que razão se deve utilizar uma estrutura ABA em vez de uma folha de PET de camada única?
Três razões: menor custo da matéria-prima, melhor qualidade da superfície e conformidade com os requisitos de contacto com alimentos. A utilização de flocos reciclados numa camada central espessa reduz os custos com a matéria-prima; as camadas exteriores de material virgem ocultam as pequenas variações de cor típicas dos flocos reciclados; e as camadas exteriores limpas impedem o contacto direto dos alimentos com o material reciclado.
What is a 4-station thermoforming machine?
A 4-station thermoforming machine completes forming, cutting, punching, and stacking in one continuous in-line sequence. In-line trimming removes a separate operation, protects the product rim, and keeps labor at one to two operators per shift.
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 triturador online de sucata de chapa returns skeletal waste straight back into the process, which is the fastest way to raise recycled content and cut material cost per tray.