Description

 

Brand new production plant from china & overseas ,due to post covid & ongoing war impact reputed & famous sold oem brands in India  PET recycling pelletizing line-Twin screw extruder 1500 kgh capacity :

    PET granules

(All pictures are for reference only)

Main technical specifications

 

Process tasks

Recycle cleaned bottle flakes with the size less than 15mm (Moisture<1.5%).

 

Output and main extruder type

Output: 1500 kg/h (difference up to size of flakes and operation conditions).

Main extruder type: PTC95 co-rotating twin screw extruder.

 

Flow chart description

Storing and Loading －> volumetric feeding－> twin screw compounding－> melt filter－> die head－> cooling channel－> underwater strand pelletizer－> dewater－> classifier－> conveying and storing

 

Main features of extruder

Closely inter meshing screw profile with screws that are self-wiping at narrow clearance for easy product and color changing.

Special mixing and shearing elements is with varying effects for high process flexibility.

Modular building-block system for barrel.

Each barrel is with one temperature zone for optimal processing.

High reliable safety clutch and interlocking system for optimal protection against overload

High torque gear box ensure high output and long life time.

Variable screw speed from 100 to 800 rpm allows wide range of process technologies.

Large free volume due to outer/inner screw diameter ratio Do/Di ~ 1.75 for optimum processing.

Water manifold completely made of stainless steel.

 

5.Supply Scope

NO.-Description of goods-Specs-Quantity

1-Horizontal storage silo and screw feeder -3KW-1

2-Agglomerator dryer (with single screw feeder)-132+4KW-1

3- Parallel Twin Screw Extruder -315KW,40:1-1

4-Double piston type melt filter and Granulating Mould-3KW/6.3L-1

5-Extrusion die plate--1

6-Cooling channel-3000m,5.5KW-1

7-Underwater strand pelletizer-11kW-

8-Dewater-7.5kw-1

9-Classifier-2*0.55kw-1

-Convey and storing silo-2cbm-

10-Intelligent control system-3*380,50Hz-1

11-Free Spare Parts List---

 

Basis of FOB defined defined in accordance with the provisions of the International Rules for the Interpretation of the International Commercial Terms (INCOTERMS) 2000.

Validity of the Quotation

This quotation is open for acceptance with 60 days from the date of this offer, unless an extension of validity is agreed upon.

Delivery Time

Approx. 80 days required after receipt of down payment, and technical and commercial clarification.

The agreed delivery period is subject to the punctual receipt by us of all equipment, documents, approvals, releases and services to be furnished by Buyer for the performance of the order.

 

 

I  GENERAL TECHNICAL DATA

Equipment

Model: Twin Screw Extruder Line

Certification: CE

Application: PET Flakes Recycling

Capacity: 1500Kg/h (according to material)

Installation power: Approx. 486KW (working consumption: approx. 268KW/hr)

Dimension(LXWXH): Approx. 25m(L)X4m(W) X5.5m(H)

Layout: Installation on one floor

Labor requirement: 2-3 labors per shift

 

Technical Specifications

No.	Denomination of the delivery	Qty.
1.0	Raw materials dealing and feeding system
1.1	Screw loader	1 set

 

Storing volume: 5cbm Feeding method: by single screw. Interlock with the level sensor in the agglomerator.
1.2	Agglomerator Dryer and Auto feeder	1 set
	Motor power: 132Kw Effective volume: 1100L (inner diameter 1400mm) pot material: Stainless steel 304 The number of moving knives: 6 groups × 3 = 18 pcs The number of fixed tools: 7 pcs Temperature measurement point: 1 pcs Cooling fan: 4Kw Single screw feeder (connected to the agglomerator) Motor power: AC 4Kw (frequency control) Feeding screw: Single screw Reducer: Hardened gear reducer, cast iron housing Advantages: Double layer-blade agglomerator to pre-heat raw material to 140°C by high speed friction, Pre crystallization drying (On line drying, sustainable production) Efficient compaction and feeding to ensure production Austrian Technology, power saving (Comparing with pre crystallization drying + pelletizing seperately)
2.0	compounding system
2.1	co-rotating twin-screw extruder	1 set

 

Main motor:

Supplier: WN/ Huabin

AC motor, 315 kW

Speed controller: Siemens AC inverter.

 

The clutch is used to transmit the power from the motor to the gearbox.

High safety coupling with torque limit from Polytec.

With cover for safety.

High torque gearbox:

 

Precise balancing principle applied to increase torque level.

Torque level up to 10.3 defined by Torque/center line distance.

High safety factor design.

Latest steel alloy material for gears applied with special heat treatment and manufactured at high precision level.

NSK bearings and imported seals applied,

 

Special lubricating for gearbox:

Fin-plate heat exchanger configured to provide best cooling.

With one temperature sensor: if the oil temperature more than 60 degree, the extruder will stop automatically.

With one pressure sensor: if the oil pressure less than 0.2 MPA, the extruder will stop automatically.

With one pressure indicator meter for the operator to see the pressure easily.

With magnetic filter to remove the metal power from the gear.

With one vane pump with much less noise compare to the traditional gear pump.

 

Screw element & shaft:

The intermeshing screws co-rotate and wipe each other with narrow clearance so that no residues are left in the screw flights and cleaning effort is thus reduced.

The screw shaft system is characterized by the following:

Through-going solid shafts

Screw elements with various pitches and lengths

Kneading blocks with various angles of stagger, numbers of kneading disks and disk widths

Screw tips to fix the screw set axially

Gear teeth connection to ensure power flow between the screw shaft and screw elements

 

Screw Diameter: 95mm. L/D = 40:1.

Maximum Screw speed: 300rpm.

Screw configuration: with modular structure, torque transmission by spline.

Material of screw: 38CrMoAlA.

Nitrify treatment: with nitrify depth 0.4～0.6mm.

Surface hardness: HV740～940.

Roughness: Ra≤1.6µm.

Structure feature: modular fixed on shafts.

Direction of screw: co-rotating.

Screw shaft material: 40CrNiMoA.

 

The flexible modular principle is realized with barrel sections from the wide range of different designs possible. Fast, intensive and uniform heating of the barrel sections is ensured by electrical heaters. The barrel sections are cooled with water, by means of an internal bore system, with bores arranged close to the inside barrel wall.

Barrel sections are available as:

Closed barrel section

Barrel section with opening for material feed or devolatilization

Barrel section with top and lateral opening for top venting .

The processing section is provided with stainless steel plates as a protection against accidental contact.

 

Barrel configuration: with modular structure, each one with length of 4L/D, and the barrels connected together by bolts and pins.

Material: 38CrMoAlA.

Nitrify treatment:

Nitrify depth of screw: 0.5～0.7mm.

Surface hardness: >HV940.

Roughness: Ra≤3.2µm.

 

Temperature control system:

Temperature controller: PLC.

All of barrel with heating and cooling both, except No.1 barrel without heating, only with cooling channel.

Heating system: infrared heater, total heating power with about 90KW.

 

 

The system consists of:

1water-pump (3KW)

1 stainless steel water-box (with water Temp. gauge)

1 fin-plate heat exchanger

1 water pressure indicator

1 solenoid valve for each barrel

1 manual valve for each barrel

1 bypass

 

Steel base:

Welding base with 6 pieces of special pads which can adjust the height and reduce the vibration.

 

Connect with the second and the third vacuum port.

The compact vacuum system is used for the removal of volatile matter and moisture from the product. The system is completely assembled and internally tubed.

 

Consisting of following main components:

Motor:11 kw*2, Pumping speed:150L/m

2 force vacuum exhaust port

Rotating speed:2900, rpm Pressure :133Pa.

1 manual valve

1 air pressure indicator

1 bypass

With independent PLC and HMI control.

 

Double Position Type Melt filter

Structure: two piston type (filter rotating on the piston). Filtering position number: 2. Filtering area: 2000cm2; Driven by hydraulic station: Motor for hydraulic system: 1.5kW, Max. pressure 20Mpa, and safety valve, condenser equipped. Pressure and Temp. gauge: one melt pressure and temperature transducer respectively before and after the screen.
3.0	Underwater strand pelletizing system
3.1	Extrusion die plate	1 set
	Material: 40Cr, with nitrify heat-treatment. The strand outgoing hole diameter: 6mm, 32 holes. With heating.
3.2	Cooling channel	1 set

 

Body material: stainless steel. Water pump:4kW; Cooling water supplied by User, flow:15-20m3/h, tem.:20-30℃；
3.3		Underwater strand pelletizer						1 set
Capacity: 1200kg/hr. Driving power: 11KW. RPM controller: Schneider/SCIYON AC inverter. With water supply.
3.4						Dewater		1 set
Type: centrifugal dryer Capacity: 1500kg/hr. Motor: 7.5KW. Material: all the material touched polymer is stainless steel.
3.5			Classifier					1 set
Capacity: 1500kg/h. With two vibrating motor. Screen material: stainless steel. Screen layer: 3pcs (each with oversize, regular size and small size hole). Material: all the material touched polymer is stainless steel.
3.6				Convey and storing Silo				1 set
Convery blower: 5.5kW, With Vent tube.   Silo Vol.: 2m3. Material: stainless steel. Disassemble frame equipped.
4.0					Intelligent Control system			1 set
Intelligent Control System: Polytec develop and launch the New Intelligent Control System based on the many years experience of manufacturing of Extruder, and always be devoted to make the User’s experience more personal and efficient.   Reducing the cable in control cabinet approx. 70% and greatly reducing the error rate and troubleshooting time; all the wire connecting every control modular by the special communication line except the power line, so the cabinet looks more neatly. The program written in the special PLC, it is easy to modify and check the error. All the driving ,heating ,and cooling controlled by the special modular, it is more convenient to install and replace. The software special designed based on Windows system, the operation screen is more personal. Built-in Wifi, easier to connect to internet or hotspot by phone, The engineer from oem can remote control the machine ,monitor and modify the parameter. Formula function, User can set up the optimized formula in program to assure the quality of product. The historical data of process parameters can be preserved and reflected in the form of curves. It includes each temp. of every zone, speed, ampere, pressure etc. Intelligent assist system(IAS), when the loading ampere or melt pressure is more than setting value, IAS will reduce the screw and feeder speed automatically. Alarm diagnosis function, the system is equipped with intelligent equipment alarm modular and remote service system to monitor the running state of the machine. The system will automatically report the cause of the failure and guide the operator how to eliminate the alarm. Polytec can connect to this extruder by remote control. Maintenance remind, The system automatically count the effective running time , then give the information of inspection to avoid the false check or miss detection. All the devices have industrial Ethernet which is very convenient to connect with other intelligent products such as Loss-in –weight feeding system and underwater cutting system. One button start/stop. All electric parts and design of control panel meet with the standards of CE.
Spare parts
	Free spare parts Screw elements 600mm. Each type of heater 1 pcs. O seal for vacuum ports 4pcs. Solid state relay 3 pcs. Tool part to draw screws 2 pcs. Oil sealing for input and output shafts for gearbox 3sets. Standard tools 1 set. Rotating cutter and fixed cutter for the pelletizer, 1set.

 

- After all machines are delivered to customer’s factory; Buyer is responsible for all preparation work, e.g. electricity supply, water supply, labors and cranes, etc.

 

- oem will prepare for visa application for their engineers, who are responsible for guide of machine installation and testing at the Buyer’s factory to meet normal operation requirements.

 

- The Buyer will buy the round-trip air ticket for Engineer if visa application is approved. The buyer is also responsible to bear expenses generated, e.g. visa formalities, meals, accommodation, and allowance of USD200 per day for each engineer from the date of departure to the end of the trip (including round trip time).

 

- Engineer will give free training lessons to labors in buyer’s factory.