1 Bale Breaking

The process starts with the arrival of incoming bales of PET bottles. The
bales of PET (polyethylene terephthalate) are clamped by a forklift
operator onto an incline conveyor to singulate the bottles. The conveyor
can hold up to ten bales at a time.

2 Green Bottles Are Detected and Removed

Early in the process, green bottles are detected and kicked out. They
are accumulated for sale.

3 Pre-Wash Process Prepares Bottles for Scanners

During prewash, the outsides of bottles are cleaned of dirt so that the
near infrared (NIR) scanners can accurately detect the type of plastic.

4 Label Separation
The material is then run through a label separator. Steam and chemicals
aid in the removal of labels and loose caps, which are then separated.

5 Near Infrared Sorting

Empty bottles then go through two infrad sorting processes. The first
removes ferrous and non-ferrous metals, as well as any residual green
bottles that might still be in the material. A second step scans for mixed
plastics, which are also ejected.

6 Manual Sorting
The following step is the manual sortation of any greens, labels, or
contaminants that have made it through to this stage of the recycling
process.
7 Metal Detector Pass
After manual sorting and before going into the grinder, material must
again go through metal detection. If any metal is identified, it is sent down
the shoot to be sure it is removed.

8 Grinding
Remaining bottles then proceed through a wet grinder where they are
reduced to the desired PET flake size.
9 Washing
After grinding, the flakes are then washed with hot water and chemicals
to remove dirt and glue.

10 Sink/Float Separation
After washing, the flakes then travel to a float/sink tank where caps and
rings are separated from PET flakes. PET sinks while polypropylene
(PP) floats to the surface where it is skimmed off for separate resale.

11 Final Rinse and Metal Detection

After the final rinse, the PET and water are separated. The product is
spun dry and put on a conveyor to go through yet another metal detector.

12 Blending/Mixing Silo
PET is then directed into a blending/mixing silo where any residual PVC
is detected. PET is fed out the bottom. An elutriator removes the tiny
particles.

13 Storage Silo
The storage silo can hold up to 12 hours production of utility grade PET
material until it sent to be "super cleaned" in the LNO converter for use
in food packaging.

14 Finished Product Ready for Shipping

Super sacks are then filled with finished material, ready for shipping.