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.

SSS

ABA PET levha ekstrüzyon hattı nedir?

Bir ABA PET levha ekstrüzyon hattı, tek geçişte üç katmanı birlikte ekstrüde eder: saf veya birinci sınıf PET’ten oluşan iki dış A katmanı ve geri dönüştürülmüş PET’ten oluşan tek bir kalın B çekirdek katmanı. İnce dış katmanlar, pürüzsüz ve gıda ile temasa uygun bir yüzey sağlarken, geri dönüştürülmüş çekirdek katmanı levhanın kalınlığının ve maliyetinin büyük bir kısmını oluşturur.

Bir ABA hattı, 100% geri dönüştürülmüş PET pullarını işleyebilir mi?

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 tek vidalı PET levha ekstrüzyon hattı.

Neden tek katmanlı PET levha yerine ABA yapısı kullanılmalı?

Üç neden: daha düşük hammadde maliyeti, daha iyi yüzey kalitesi ve gıda ile temasa uygunluk. Kalın bir çekirdek katmanında geri dönüştürülmüş pulların kullanılması malzeme maliyetini düşürür; işlenmemiş dış katmanlar, geri dönüştürülmüş pullarda tipik olarak görülen küçük renk farklılıklarını gizler; temiz dış yüzeyler ise geri dönüştürülmüş malzemenin gıda ile doğrudan temas etmesini engeller.

4 istasyonlu termoform makinesi nedir?

4 istasyonlu bir termoform makinesi, şekillendirme, kesme, delme ve istifleme işlemlerini tek bir kesintisiz hat içi işlem dizisi halinde gerçekleştirir. Hat içi kesme işlemi, ayrı bir adımı ortadan kaldırır, ürünün kenarlarını korur ve vardiya başına işgücü sayısını bir ila iki operatörle sınırlar.

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 sac kenar hurdası çevrimiçi kırıcı returns skeletal waste straight back into the process, which is the fastest way to raise recycled content and cut material cost per tray.