Method and apparatus for recycling R-PET and product produced thereby

• US 20040155374A1
• Filed: 12/17/2003
• Published: 08/12/2004
• Est. Priority Date: 12/18/2002
• Status: Abandoned Application

• Current Assignee: B & H Polymers, Ltd.
• Original Assignee: B & H Polymers, Ltd.
• Inventors: Hutchinson, Peter, Royall, Mark
• Application Number:
  US10/739,586
• Publication Number:
  US 20040155374A1
• Time in Patent Office: Days
• US Class Current: 264/40.1
• CPC Class Codes: B29B 17/0042 for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic
• CPC Class Codes: B29B 17/0412 to large particles, e.g. beads, granules, flakes, slices
• CPC Class Codes: B29C 48/09 Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
• CPC Class Codes: B29C 48/288 in solid form, e.g. powder or granules
• CPC Class Codes: B29C 48/29 in liquid form
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/0005 containing compounding ingredients releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26
• CPC Class Codes: B29K 2105/0032 Pigments, colouring agents or opacifiyng agents
• CPC Class Codes: B29K 2105/26 Scrap or recycled material
• CPC Class Codes: B29L 2031/7158 Bottles
• CPC Class Codes: C08J 11/06 without chemical reactions
• CPC Class Codes: C08J 2367/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds; C08J2367/06 takes precedence
• CPC Class Codes: Y02W 30/62 Plastics recycling; Rubber recycling
• CPC Class Codes: Y10T 428/1352 Polymer or resin containing [i.e., natural or synthetic]

Abstract

Preferred embodiments of the present invention comprise a method of manufacture utilizing significant amounts of R-PET and the preform and/or beverage bottle produced thereby. The method preferably comprises washing colored beverage bottles and substantially clear beverage bottles to remove any surface filth, forming colored R-PET flakes from the washed colored beverage bottles, and forming substantially clear R-PET flakes from the washed substantially clear beverage bottles. The colored R-PET flakes are preferably blended with the substantially clear R-PET flakes to form blended flakes having substantially homogenous color. The blended flakes are color corrected if so desired, and the blended flakes are then pelletized. The pelletized flakes are preferably combined with V-PET to form a preform which is then preferably shaped into a beverage bottle.

Claims

1. A method of manufacturing a color concentrate utilizing significant amounts of R-PET, comprising:

blending colored R-PET flakes with substantially clear PET flakes to form blended flakes having substantially homogenous color;

determining whether color correction of the blended flakes is desired, and if color correction is desired, color-correcting the blended flakes with pure color; and

pelletizing the blended flakes.

2. The method of claim 1, wherein blending comprises blending colored R-PET flakes with substantially clear R-PET flakes to form the blended flakes.

3. The method of claim 1, wherein blending comprises blending colored R-PET flakes with substantially clear R-PET flakes and post-industrial resin to form the blended flakes.

4. The method of claim 1, wherein blending comprises blending colored R-PET flakes with substantially clear PET flakes to form the blended flakes, the blended flakes being about seventy-percent (70%) by weight the colored R-PET flakes.

5. The method of claim 1, comprising calculating a blend ratio of colored R-PET flakes to substantially clear PET flakes, in accordance with a desired combination ratio of blended flakes to V-PET.

6. The method of claim 1, comprising:

washing colored after-market products to remove any surface filth;

forming the colored R-PET flakes from the washed colored after-market products;

washing substantially clear after-market products to remove any surface filth; and

forming the substantially clear PET flakes from the washed substantially clear after-market products.

7. The method of claim 6, wherein washing colored after-market products comprises washing colored beverage bottles, and wherein washing substantially clear after-market products comprises washing substantially clear beverage bottles.

8. The method of claim 1, wherein determining comprises determining whether a color depth correction of the blended flakes is desired, and if color depth correction is desired, color-correcting the color depth of the blended flakes with pure color.

9. A method of manufacturing a preform utilizing significant amounts of R-PET, comprising:

blending colored R-PET flakes with substantially clear PET flakes to form blended flakes having substantially homogenous color;

determining whether color correction of the blended flakes is desired, and if color correction is desired, color-correcting the blended flakes with pure color;

pelletizing the blended flakes; and

combining the pelletized blended flakes with V-PET to form the perform, the preform being at least about ten percent (10%) by weight pelletized flakes.

10. The method of claim 9, wherein blending comprises blending colored R-PET flakes with substantially clear R-PET flakes to form the blended flakes.

11. The method of claim 9, wherein blending comprises blending colored R-PET flakes with substantially clear R-PET flakes and post-industrial resin to form the blended flakes.

12. The method of claim 9, wherein blending comprises blending colored R-PET flakes with substantially clear PET flakes to form the blended flakes, the blended flakes being about seventy-percent (70%) by weight the colored R-PET flakes.

13. The method of claim 9, comprising calculating a blend ratio of colored R-PET flakes to substantially clear PET flakes, in accordance with a desired combination ratio of blended flakes to V-PET.

14. The method of claim 9, comprising:

washing colored after-market products to remove any surface filth;

forming the colored R-PET flakes from the washed colored after-market products;

washing substantially clear after-market products to remove any surface filth; and

forming the substantially clear PET flakes from the washed substantially clear after-market products.

15. The method of claim 14, wherein washing colored after-market products comprises washing colored beverage bottles, and wherein washing substantially clear after-market products comprises washing substantially clear beverage bottles.

16. The method of claim 9, wherein determining comprises determining whether a color depth correction of the blended flakes is desired, and if color depth correction is desired, color-correcting the color depth of the blended flakes with pure color.

17. The method of claim 9, wherein combining comprises combining the pelletized blended flakes with V-PET to form the preform, the preform being about twenty percent (20%) by weight pelletized flakes.

18. The preform produced according to the method of claim 9.

19. A method of manufacturing a shaped preform utilizing significant amounts of R-PET, comprising:

blending colored R-PET flakes with substantially clear PET flakes to form blended flakes having substantially homogenous color;

determining whether color correction of the blended flakes is desired, and if color correction is desired, color-correcting the blended flakes with pure color;

pelletizing the blended flakes;

combining the pelletized blended flakes with V-PET to form the perform, the preform being at least about ten percent (10%) by weight pelletized flakes; and

shaping the preform into the shaped preform.

20. The method of claim 19, wherein blending comprises blending colored R-PET flakes with substantially clear R-PET flakes to form the blended flakes.

21. The method of claim 19, wherein blending comprises blending colored R-PET flakes with substantially clear R-PET flakes and post-industrial resin to form the blended flakes.

22. The method of claim 19, wherein blending comprises blending colored R-PET flakes with substantially clear PET flakes to form the blended flakes, the blended flakes being about seventy-percent (70%) by weight the colored R-PET flakes.

23. The method of claim 19, comprising calculating a blend ratio of colored R-PET flakes to substantially clear PET flakes, in accordance with a desired combination ratio of blended flakes to V-PET.

24. The method of claim 19, comprising:

washing colored after-market products to remove any surface filth;

forming the colored R-PET flakes from the washed colored after-market products;

washing substantially clear after-market products to remove any surface filth; and

forming the substantially clear PET flakes from the washed substantially clear after-market products.

25. The method of claim 24, wherein washing colored after-market products comprises washing colored beverage bottles, and wherein washing substantially clear after-market products comprises washing substantially clear beverage bottles.

26. The method of claim 19, wherein determining comprises determining whether a color depth correction of the blended flakes is desired, and if color depth correction is desired, color-correcting the color depth of the blended flakes with pure color.

27. The method of claim 19, wherein combining comprises combining the pelletized blended flakes with V-PET to form the preform, the preform being about twenty percent (20%) by weight pelletized flakes.

28. The shaped preform produced according to the method of claim 19.

29. The method of claim 19, wherein shaping comprises shaping the preform into a second preform.

30. The method of claim 19, wherein shaping comprises shaping the preform into a beverage bottle.

31. A method of manufacturing a color concentrate utilizing significant amounts of R-PET, comprising:

forming blended flakes from washed green beverage bottles having significant amounts of green R-PET flakes and from washed substantially clear beverage bottles having significant amounts of substantially R-PET flakes, the blended flakes being about seventy (70) percent green R-PET flakes by weight;

determining whether depth correction of the blended flakes is desired, and if depth correction is desired, color-correcting color depth of the blended flakes with pure color; and

pelletizing the blended flakes.

32. The method of claim 31, wherein color-correcting comprises color-correcting the color depth of the blended flakes at an addition rate equal to about five (5) times typical addition rates.

33. The method of claim 31, wherein color-correcting comprises color-correcting color depth of the blended flakes at an addition rate equal to at least one of about 0.225%, about 0.275% and about 0.300%.

34. A method of manufacturing a green preform utilizing significant amounts of R-PET, comprising:

forming blended flakes from washed green beverage bottles and washed substantially clear R-PET beverage bottles, the blended flakes being about seventy-percent (70%) by weight the green R-PET flakes;

determining whether a color depth correction of the blended flakes is desired, and if color depth correction is desired, color-correcting the color depth of the blended flakes with pure color;

pelletizing the blended flakes;

combining the pelletized blended flakes with V-PET to form the perform, the preform being at least about ten percent (10%) by weight pelletized flakes.

35. The method of claim 34, and wherein color-correcting comprises color-correcting the color depth of the blended flakes at an addition rate equal to about five (5) times typical addition rates.

36. The green preform produced according to the method of claim 35.

37. A method of manufacturing a green beverage bottle utilizing significant amounts of R-PET, comprising:

collecting green beverage bottles and substantially clear beverage bottles

washing the green beverage bottles and the substantially clear beverage bottles to remove any surface filth;

forming green R-PET flakes from the washed green beverage bottles and substantially clear R-PET flakes from the washed substantially clear beverage bottles;

blending green R-PET flakes with substantially clear R-PET flakes to form blended flakes having substantially homogenous green color, the blended flakes being about seventy-percent (70%) by weight the green R-PET flakes;

determining whether a color depth correction of the blended flakes is desired, and if color depth correction is desired, color-correcting the color depth of the blended flakes with pure color;

pelletizing the blended flakes;

combining the pelletized blended flakes with V-PET to form the perform, the preform being about twenty percent (20%) by weight pelletized flakes; and

shaping the preform into the green beverage bottle.

38. The green beverage bottle produced according to the method of claim 37.

39. A system for manufacturing a color concentrate utilizing significant amounts of R-PET, comprising:

a first extruder for blending colored R-PET flakes with substantially clear PET flakes to form blended flakes having substantially homogenous color;

a weigh scale blender for measuring pure color;

a pump for dosing the blended flakes with pure color; and

a pelletizer for pelletizing the blended flakes.

40. The system of claim 39, comprising a shredder for forming colored R-PET flakes from colored beverage bottles and for forming substantially clear R-PET flakes from substantially clear beverage bottles.

41. The system of claim 39, comprising a dryer for drying the pelletized flakes.

42. The system of claim 41, wherein the dryer comprises:

a first chamber for drying the pelletized flakes, thereby transferring pellet moisture to the chamber air;

a second chamber for vacuum evacuation of the moist chamber air; and

a third chamber for storing the pelletized flakes in a vacuum condition.

43. The system of claim 39, wherein the first extruder comprises a twin screw extruder having co- and contra-rotation, ring extruders

44. The system of claim 39, wherein the pelletizer comprises a strand-cut pelletizer.

45. The system of claim 39, wherein the first extruder and the pelletizer form an integrated machine.

46. The system of claim 45, wherein the first extruder comprises a twin screw extruder having co- and contra-rotation, ring extruders

47. The system of claim 45, wherein the pelletizer comprises a strand-cut pelletizer

48. The system of claim 39, wherein the pump comprises a peristaltic pump.

49. The system of claim 39, wherein the first extruder is adapted to blend the colored R-PET flakes with the substantially clear PET flakes to form the blended flakes, the blended flakes being about seventy-percent (70%) by weight the colored R-PET flakes.

50. The system of claim 39, wherein the pump doses the blended flakes with pure color to implement a color depth correction.

51. A system for manufacturing a preform utilizing significant amounts of R-PET, comprising:

a first extruder for blending colored R-PET flakes with substantially clear PET flakes to form blended flakes having substantially homogenous color;

a weigh scale blender for measuring pure color;

a pump for dosing the blended flakes with pure color;

a pelletizer for pelletizing the blended flakes; and

a second extruder for combining the pelletized blended flakes with V-PET to form the perform, the preform being at least about ten percent (10%) by weight pelletized flakes.

52. The system of claim 51, wherein the second extruder forms the preform, the preform being about twenty percent (20%) by weight palletized flakes.

53. The system of claim 52, the first extruder being adapted to blend the colored R-PET flakes with the substantially clear PET flakes to form the blended flakes, the blended flakes being about seventy-percent (70%) by weight the colored R-PET flakes.

54. The system of claim 51, comprising a shredder for forming colored R-PET flakes from colored beverage bottles and for forming substantially clear R-PET flakes from substantially clear beverage bottles.

55. The system of claim 51, comprising a dryer for drying the pelletized flakes.

56. The system of claim 55, wherein the dryer comprises:

a first chamber for drying the pelletized flakes, thereby transferring pellet moisture to the chamber air;

a second chamber for vacuum evacuation of the moist chamber air; and

a third chamber for storing the pelletized flakes in a vacuum condition.

57. The system of claim 51, wherein the first extruder comprises a twin screw extruder having co- and contra-rotation, ring extruders

58. The system of claim 51, wherein the pelletizer comprises a strand-cut pelletizer.

59. The system of claim 51, wherein the first extruder and the pelletizer form an integrated machine.

60. The system of claim 59, wherein the first extruder comprises a twin screw extruder having co- and contra-rotation, ring extruders

61. The system of claim 59, wherein the pelletizer comprises a strand-cut pelletizer

62. The system of claim 51, wherein the pump comprises a peristaltic pump.

63. The system of claim 51, wherein the pump doses the blended flakes with pure color to implement a color depth correction.

64. A system for manufacturing a beverage bottle utilizing significant amounts of R-PET, comprising:

a first extruder for blending colored R-PET flakes with substantially clear PET flakes to form blended flakes having substantially homogenous color;

a weigh scale blender for measuring pure color;

a pump for dosing the blended flakes with pure color;

a pelletizer for pelletizing the blended flakes;

a second extruder for combining the pelletized blended flakes with V-PET to form the perform, the preform being at least about ten percent (10%) by weight pelletized flakes; and

a blower for shaping the preform into the beverage bottle.

65. The system of claim 64, wherein the second extruder forms the preform, the preform being about twenty percent (20%) by weight palletized flakes.

66. The system of claim 65, the first extruder being adapted to blend the colored R-PET flakes with the substantially clear PET flakes to form the blended flakes, the blended flakes being about seventy-percent (70%) by weight the colored R-PET flakes.

67. The system of claim 64, comprising a shredder for forming colored R-PET flakes from colored beverage bottles and for forming substantially clear R-PET flakes from substantially clear beverage bottles.

68. The system of claim 64, comprising a dryer for drying at least one of the blended flakes and the pelletized flakes.

69. The system of claim 68, wherein the dryer comprises:

a first chamber for drying the pelletized flakes, thereby transferring pellet moisture to the chamber air;

a second chamber for vacuum evacuation of the moist chamber air; and

a third chamber for storing the pelletized flakes in a vacuum condition.

70. The system of claim 64, wherein the first extruder comprises a twin screw extruder having co- and contra-rotation, ring extruders

71. The system of claim 64, wherein the pelletizer comprises a strand-cut pelletizer.

72. The system of claim 64, wherein the first extruder and the pelletizer form an integrated machine.

73. The system of claim 72, wherein the first extruder comprises a twin screw extruder having co- and contra-rotation, ring extruders

74. The system of claim 72, wherein the pelletizer comprises a strand-cut pelletizer

75. The system of claim 64, wherein the pump comprises a peristaltic pump.

76. The system of claim 64, wherein the pump doses the blended flakes with pure color to implement a color depth correction.

77. A system for manufacturing a beverage bottle utilizing significant amounts of R-PET, comprising:

a shredder for forming colored R-PET flakes from colored beverage bottles and for forming substantially clear R-PET flakes from substantially clear beverage bottles;

a first extruder for blending colored R-PET flakes with substantially clear PET flakes to form blended flakes having substantially homogenous color and being about seventy-percent (70%) by weight the colored R-PET flakes.;

a weigh scale blender for measuring pure color;

a peristaltic pump for dosing the blended flakes with pure color;

a pelletizer for pelletizing the blended flakes;

a dryer for drying at least one of the pelletized flakes comprising;

a first chamber for drying the pelletized flakes, thereby transferring pellet moisture to the chamber air;

a second chamber for vacuum evacuation of the moist chamber air; and

a third chamber for storing the pelletized flakes in a vacuum condition;

a second extruder for combining the pelletized blended flakes with V-PET to form the perform, the preform being about twenty percent (20%) by weight pelletized flakes; and

a blower for shaping the preform into the beverage bottle.

78. The system of claim 77, wherein the first extruder comprises a twin screw extruder having co- and contra-rotation, ring extruders

79. The system of claim 77, wherein the pelletizer comprises a strand-cut pelletizer.

80. The system of claim 77, wherein the pump doses the blended flakes with pure color to implement a color depth correction.