Milestone Achieved: Aceretech’s rPET Food-Grade Sheet Line Successfully Commissioned for South American Customer
We’re proud to share that Aceretech has successfully launched a turnkey rPET food-grade sheet extrusion line for a customer in South America. The line is now running stably, producing crystal-clear, FDA-compliant sheets from 100% recycled PET flakes — a major step toward sustainable packaging in the region.
This project wasn’t just about installing machines. It was about integrating six core innovations and over a dozen precision-engineered components into a seamless, one-step process — from flake to food-grade sheet.
Let’s take a closer look at what made this line not just functional, but exceptional.
The Secret’s in the Pre-Treatment: Reaction Chamber & Vacuum Valve
Most lines start melting right away. Ours doesn’t.
Before the PET flakes even reach the extruder, they pass through a high-speed reaction chamber with a 5-layer cutter plate system. Friction heat rapidly heats the flakes to ~160°C, vaporizing moisture and small molecules — all under vacuum, which pulls out impurities instantly.
This pre-purification step is critical for food-grade output. And it’s paired with a specially designed vacuum-sealed valve that:
- Controls material level and residence time
- Ensures stable, continuous feeding
- Prevents air leakage — a common issue in high-vacuum systems
It’s a small component, but it makes a big difference in melt stability.
Gentle Melting, Maximum Purity: Single-Screw Extruder with Dual Degassing
The PET-optimized single-screw extruder uses a special barrel and screw design to achieve mild plasticization — minimizing degradation, especially with recycled content.
And it doesn’t stop there:
- Two vacuum degassing zones remove residual volatiles
- Powered by a liquid ring + Roots three-stage pump for deep purification
- Result: cleaner melt, higher clarity, and better thermoforming performance
Stable Flow, Zero Downtime: Backflush Screen Changer & Melt Pump
To keep the line running 24/7:
- The large-area backflush screen changer reduces screen changes by up to 70%, with a superior sealing system that eliminates polymer leakage.
- It’s paired with a ZB-B-315CC melt pump (600kg/h), ensuring constant pressure and flow — crucial for uniform thickness.
Real-Time Quality Control: Online Melt Viscosity Monitoring
One of the most advanced features? The online melt viscosity system.
- Uses torsional vibration technology (no moving parts, no wear)
- Measures viscosity in real time — independent of temperature or flow
- Helps operators adjust parameters instantly
This isn’t just monitoring — it’s intelligent process control.
Precision Sheet Formation: T-Die & 3-Roll Calender
The T-die (950mm width) features:
- Chrome-plated cavity (HV900–1000 hardness) for durability
5-zone temperature control
- Adjustable lower lip for fine-tuning thickness (0.15–1.5mm)
Then comes the servo-controlled 3-roll calender:
- Rolls can run synchronized or independently
- Hydraulic gap adjustment with dial meter
- Full-body movement (up/down, forward/backward) for easy setup
Result? Perfect cooling, maximum transparency, and excellent dimensional stability.
Smart Downstream Configuration: From Trimming to Winding
The finishing line is fully automated and built for efficiency:
- Edge Trimming Unit: Two sets of pneumatic round blades, adjustable for widths up to 830mm
- Silicone Oil Coating: Single or double-side application with infrared drying (12KW total) to prevent sticking
- Haul-Off Unit: Servo-controlled (3.5kW), with static remover for clean surface transport
- Accumulator: PLC-controlled, allows continuous operation during roll changes
- Heavy-Duty Winder: Dual-position, handles rolls up to Ø1200mm, with precise length tracking
Every component is designed to minimize downtime and maximize yield.
Technical Snapshot
| Donec nec varius | 100% recycled APET, rPET, PETG, PLA, PP, HIPS flakes |
| Output Capacity | Up to 600 kg/h |
| Sheet Thickness | 0.15 – 1.5 mm |
| Max Sheet Width | 830 mm (effective 800 mm) |
| Layer Options | 1-, 2-, or 3-layer co-extrusion capable |
| Power Supply | 380V / 3-phase / 50Hz |
| Cooling Water | 12 m³/h at 25°C |
| Compressed Air | 1 m³/h at 0.6–0.9 MPa |
Proving That Turnkey Solutions Work — Across Borders
This successful launch reflects what we stand for: reliable technology, global support, and real-world results.
Whether you’re building your first rPET line or scaling up production, Aceretech delivers end-to-end solutions that work — not just in theory, but on the factory floor.
👉 Want to see how this line could work for your operation?
Contact us today to discuss your next project — and let’s turn plastic waste into value, together.
Click the link below to view the factory trial video.
