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PET Bottle Flake and Pellet Handling System

Pelletron Pellbow installation
Pelletron Pellbow installation

Pelletron Corp., a global leader in providing custom solutions for pneumatic conveying and material handling systems to the plastics industry, was selected to supply the PET bottle flake and pellet handling systems for CarbonLITE’s newest post-consumer recycled PET plant in PA.

Pelletron is responsible for design, supply, and installation of the pneumatic transfer systems from and to multiple flake storage silos. The pneumatic conveying method applied for the pneumatic flake transfer system is the Strandphase technology in combination with the Pellbow, which assures the most gentle and economical handling of the flakes, even over distances as long as 400 ft.

For the PET pellet transfer systems, continuous slow motion dense phase technology is utilized, which is designed and operating with the lowest possible conveying velocities ranging from 400 ft/min at the pick-up point to a maximum of 1000 ft/min at the terminal point. This proven technology is especially suitable for handling plastic pellets in the gentlest way, with the main objective of keeping the end product as clean as possible, with “fines” levels well below the industry standard of 100 ppm.  

The entire Pelletron conveying and storage system is fully automated and driven by a central control system with HMI operator interface. Interlocks and PID loops provide efficient operation of the conveying system, based on constant conveying pressure settings, that automatically compensate for slight fluctuations of product bulk densities.      

All key components, such as rotary valves and diverter valves are equipped with speed switches and limit switches for constant feedback of operating condition and selected path confirmation, eliminating the danger of cross contamination. 

For the flake handling systems, the selected rotary valve type is the Pelletron medium pressure Model GRM, with a patented V-shape rotor and anti-shear inlets for minimizing cutting of product. For the pellet systems, the selected rotary valve type is the high-pressure Model GRH, with additional side plate seals to keep the leakage air volume as low as possible and ensure safe operation even at higher conveying pressure levels. 

All diverter valves selected for the PA plant (flakes and pellets) are the Model PDV, equipped with a positive mechanical seal package at each port. PDVs are Pelletron’s zero-leakage valve and are suitable for powder, flake, and pellet applications.

The new CarbonLITE plant will produce 80 million lb of rPET pellets annually and will be one of the largest in the world.

Pelletron also provided the entire conveying and storage system for CarbonLITE’s Riverside, CA and Dallas, TX facilities, which began production in 2017. CarbonLITE is one of the world’s largest producers of bottle grade rPET with the capability of recycling more than six billion plastic bottles per year, companywide.

For more information on Pelletron Corp. (Lancaster, PA), call 717-293-4008 or visit pelletroncorp.com.


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