Are you looking for a highly automated PET bottle washing line that can reliably process various types of PET bottle bales and deliver high-quality PET flakes?
Whether you're based in Asia, Europe, Africa, or South America, Boxin’s PET Bottle Washing Line is designed to help you efficiently convert PET waste into food-grade, filament-grade, or fiber-grade high-value PET flakes.
This system is specifically engineered to process post-consumer PET bottles—whether in compressed bales or loose form. It covers a complete processing line that includes debaling, label removal, intelligent optical sorting, wet granulation, hot washing, dewatering and drying, and final flake color/material sorting.
The entire line is flexibly configurable based on raw material conditions and desired output specifications. It is widely used in PET recycling plants, fiber production facilities, sheet extrusion manufacturers, and bottle-to-bottle recycling projects.
Boxin’s fully automated PET bottle washing line has been trusted by customers in over 50 countries and regions worldwide. Thanks to its modular, highly adaptable design, it has earned a strong reputation for delivering stable and efficient solutions, regardless of the complexity of the bottle source, production capacity, or target flake grade.
The Advantages of PET Bottle Washing Line
▶ Watch video: High-Efficiency PET Washing Process
01. Modular and Flexible Configuration ▼
The system can be tailored to handle various contamination levels of PET bottles—including clean, mixed, or oil-stained bottles—by adjusting the washing intensity and automated sorting stages accordingly.
02. Three-Stage Deep Cleaning System ▼
Combines cold washing, hot washing, and friction washing to effectively remove grease, glue, and PVC contaminants, ensuring thorough purification throughout the entire process.
03. Water- and Energy-Efficient Design ▼
Features a closed-loop water filtration system and high-efficiency dewatering units, significantly reducing water and energy consumption per kilogram of PET flakes.
04. High-Purity Final Flakes ▼
Achieves an exceptionally high cleaning rate with residual impurities controlled to ≤ 100ppm, meeting food-grade and filament-grade recycling standards.
Standard Process of PET Bottle Washing Line
From Baled Bottles to Clean PET Flakes
The entire process consists of a series of mechanical, thermal, and chemical steps, each designed to progressively remove specific types of contaminants. Below is a detailed process flow of Boxin Machinery’s modern washing line.
1. Debaling Unit
The debaling system serves as the starting module of the PET bottle washing line. It is responsible for automatically breaking down compressed PET bottle bales and ensuring consistent feeding into downstream equipment.
Key Features:
• Dual-axis tilt design combined with twin powerful shredding shafts.
• Works in tandem with a chain plate conveyor for stable feeding.
• Energy-efficient operation, adaptable to varying bale densities.
2. Screening Unit
The trommel screening system acts as the first barrier against contaminants. It removes large foreign particles such as sand, stones, glass, and metals.
Key Features:
• Rotating drum design enables continuous tumbling and screening.
• Equipped with a dual collection system for separate recovery.
• Significantly reduces impact from hard contaminants.
3. Label Separation Unit
Boxin’s label removal system features a large-diameter cutting rotor with low-speed rotation, enabling high-efficiency label stripping without damaging the bottle body.
Key Features:
• Patented Rotor Design: Precisely cuts and separates shrink labels.
• Integrated Collection: Air-blown conveyor system collects stripped labels.
4. Manual Sorting Unit
This module serves as a final quality control checkpoint before the crushing process to remove any remaining off-color bottles or metal contaminants.
Key Features:
• Fills Blind Spots: Manual inspection for subtle variations.
• Metal Detection: Fully automated flip-gate metal separator.
• Ergonomic Design: Built for worker safety and comfort.
5. Crushing Unit
Boxin adopts a wet crushing method, where cleaning water is injected during the granulation process to remove surface contaminants and control temperature.
Key Features:
• Wet Crushing: Enables pre-cleaning and dust suppression.
• High Shear Efficiency: Optimized blade combination.
• Ton-Bag Packing: Suitable for high-throughput lines.
13. Finished Product Display
The final output of the entire washing line: High-purity, clean PET flakes ready for reprocessing into polyester fiber, strapping, or new bottles.
Quality Indicators:
• Purity: > 99.9%
• Moisture: < 1%
• PVC Content: < 100 ppm
Types & Applications of PET Bottle Washing Lines
PET washing lines are not one-size-fits-all—they are engineered in modular or integrated designs based on raw material conditions, capacity goals, and final product applications. Understanding these differences is critical for global buyers to select systems tailored to their needs.
Cold Wash vs. Hot Wash Lines
Cold Wash Lines
Mainly used to produce lower-end downstream products such as PET strapping. The system primarily relies on friction and float-sink separation to remove contaminants. While cost-effective, the resulting rPET typically has lower market competitiveness.
Hot Wash Lines
Designed for post-consumer PET bottles contaminated with grease, organic residues, or adhesives. The process includes a hot caustic wash (NaOH). Hot wash units are recommended for all applications beyond basic strapping production.
Standard vs. Food-Grade Lines
Standard PET Washing Lines
Generally include hot washing, multi-stage cleaning, centrifugal drying, and optional advanced sorting modules. These are suited for non-food applications such as fiber, injection-molded parts, or sheet extrusion.
Built to comply with international food-contact safety standards (e.g., FDA CFR 177.1630, EFSA EC/282/2008). Configuration is highly dependent on the input bale’s contamination level.
Modular Washing Lines:Offer layout flexibility and staged expansion, ideal for recyclers in developing regions or those anticipating future growth.
Turnkey Washing Lines:Fully integrated, pre-tested systems designed for rapid setup, guaranteed performance, and reduced engineering complexity.
Capacity Range & Scale
PET washing lines vary from 500 kg/h pilot-scale systems to 6,000 kg/h industrial lines. Capacity selection affects:
01Total system cost and cost per ton
02Utility consumption (kWh/ton, m³/ton)
03Labor per unit of output
04Flake consistency and quality
Note: Boxin Machinery custom-builds lines across all capacity levels and provides pre-sales engineering support to match buyer-specific input material and output requirements.
Pricing and Cost Considerations in PET Recycling Lines
Pricing Factors
Pricing for PET bottle washing lines varies significantly depending on several factors:
Capacity: (e.g., 500 kg/h vs. 5,000 kg/h)
Hot washing inclusion: (standard vs. food-grade output)
Final flake purity targets: (e.g., <300 ppm, <100 ppm)
Additional Cost Considerations:
Freight cost: (FCL shipping)
Installation costs: (typically 1%–3% of total project value)
Utilities: Water and electricity availability costs
Chemical inputs: (e.g., caustic soda, antifoam agents)
Reference FOB Price Range (China)
500 kg/h Cold Wash Line
$60,000 – $80,000
1,000 kg/h Hot Wash Line
$120,000 – $160,000
3,000 kg/h Turnkey System
$300,000 – $450,000
Financial Indicators to Calculate:
ROI period: Based on current rPET market prices.
Indirect benefits: Local environmental tax incentives.
Trade-offs: Labor costs vs. Automation investment.
Careful assessment of both capital expenditure and long-term operating costs is essential for ensuring commercial sustainability.
Project Case Study
Kazakhstan — 15 Years of Operation
One of our earliest clients (since 2009). The line has been operating continuously under high load for over 15 years, proving Boxin's durability.
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Lebanon
Transitioned from trading baled bottles to processing them. Boxin helped them build a complete line to supply local manufacturers.
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Ghana
A complete integrated production line—from PET bottles to recycled pellets—supporting the local government's recycling initiatives.
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Saudi Arabia
Fiber-grade PET flake production line. Processes locally collected waste bottles to supply spinning enterprises.
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Custom OEM Services & Solutions
As a professional PET bottle washing line manufacturer, Boxin stands out with its custom engineering capabilities, adapting systems to local raw materials, regulations, and factory layouts.
Tailored Engineering
Raw material assessment
Custom plant layout (CAD)
Modular equipment selection
Turnkey delivery (platforms, wiring)
Pre-Sales Testing
Clients can send samples to our R&D center. We analyze contamination type (glue/oil) and recommend configurations to meet target IV retention.
Global Installation
On-site commissioning
Operator training
Electrical diagrams
Maintenance schedules
After-Sales Support
1-year full warranty
24/7 technical response
48h spare parts dispatch
Lifetime guidance
Industry Knowledge Extension :::
More information about PET bottle recycling Production Line
1. Global PET Consumption & Waste Challenges
Polyethylene terephthalate (PET) remains the fastest-growing packaging polymer, with global demand exceeding 43 million tonnes in 2024—roughly double the volume from a decade ago.
However, according to the World Bank’s What a Waste 2.0 database, less than one-third of post-consumer PET bottles are collected for recycling on average, and only a small portion reaches food- or fiber-grade quality. This widening gap between consumption and closed-loop recycling capacity is placing mounting pressure on brands, regulators, and recyclers to adopt more efficient and scalable washing technologies.
2. How PET Bottle Washing Lines Drive the Circular Economy
A PET bottle washing line is a fully integrated system that converts baled or loose PET waste into contaminant-free, high-purity flakes while preserving intrinsic viscosity (IV). These flakes are ready for direct extrusion, pelletizing, or bottle-to-bottle solid-state polycondensation (SSP).
Properly configured washing lines can reduce glue, PVC, and aluminum content to below 100 ppm—meeting FDA and EFSA food-contact standards. By producing high-purity flakes locally, converters can reduce reliance on virgin resin, cut greenhouse gas emissions by up to 70%, and comply with increasingly strict recycled-content mandates in the EU, USA, and ASEAN.
3. Key Drivers for Investing in Advanced Washing Systems
Regulatory Pressure: From the EU Single-Use Plastics Directive to California’s SB 1013, legislation is increasingly linking market access for beverage bottles to minimum rPET content (EU target: 25% by 2025). Plants without food-grade washing capabilities risk being phased out.
Market Incentives: Over the past 18 months, rPET pellet prices have averaged 14–22% higher than virgin PET, rewarding recyclers who can deliver consistent quality and IV retention.
Operational Efficiency: Next-generation friction washers and closed-loop filtration systems reduce water usage to under 2 L/kg. Energy-efficient high-speed dryers cut power consumption to as low as 0.28 kWh/kg.
4. Why Choose Boxin Machinery as Your China-Based Custom Supplier
Founded in 2005 and headquartered in Zhangjiagang, Boxin Machinery operates a 12,000 m² advanced factory and has delivered over 80 turnkey PET bottle washing lines worldwide, including FDA-compliant rPET projects in the USA, Chile, Saudi Arabia, and Vietnam.
Its modular design philosophy allows buyers to customize debaling, hot wash, and optical sorting stages based on input bottle characteristics and product targets—ensuring optimal price-performance ratio and long-term cost control (with equipment lifespans of up to 15 years).
FAQ & Expert Tips: Most Common Buyer Questions
Straight Answers to the Questions You Might Be Hesitant to Ask
What is the minimum order quantity (MOQ)?
A complete system starting from 500 kg/h. However, if the budget allows, a 2,000–3,000 kg/h system is recommended for better ROI.
What is the standard lead time?
40–60 days depending on customization level.
Can clear and colored bottles be processed together?
Yes, but since downstream uses differ, an optical sorter is recommended for color separation.
Is hot washing necessary?
It is strongly recommended for all applications except PET strapping production.
How much water is consumed?
With a closed-loop water recycling system, consumption is 1.5–2.5 m³ per ton of PET.
What chemicals are used?
Mainly caustic soda and antifoaming agents; surfactants are used in some cases.
Does Boxin provide training?
Yes, both on-site and remote training are included in the turnkey service.
Can the system handle oily/contaminated bottles?
Yes, as long as it includes hot washing and high-speed friction modules.
What is the power consumption?
Depending on the setup, energy use ranges from 0.28 to 0.45 kWh per kg of PET.
What after-sales support is offered?
One-year full machine warranty, 24/7 technical response, 48-hour dispatch of critical parts (excluding custom items), and lifetime maintenance guidance.
★★★★★ Rated 4.9/5 based on 138 client reviews for Boxin Machinery solutions.
Application Areas & End Products
Textile & Fiber Industry
rPET flakes are the primary raw material for polyester staple fiber, filament yarns, and nonwovens. They are widely used in apparel, bedding, automotive textiles, and carpets, accounting for nearly 70% of the market share.
Requirement: Fiber-grade flakes must have a neutral pH, an IV above 0.72, and extremely low contamination to ensure stable spinning performance.
Strapping & Injection Molding
Lower-grade flakes can be pelletized and used for PET strapping, injection-molded components, or construction profiles.
Requirement: These sectors tolerate higher glue levels but still require consistent flake size and <1% moisture content to maintain processing efficiency.
Packaging & Thermoforming
High-quality PET flakes are processed into sheets for various transparent packaging solutions. These applications demand high optical clarity and zero PVC contamination.
Food trays & containers
Blister packaging
Transparent clamshells
Bottle-to-Bottle Recycling (SSP)
The most demanding use of rPET is in the production of beverage bottles and preforms. Downstream Solid-State Polycondensation (SSP) is used to increase IV to 0.84–0.90.
Over 99.5% PET purity required
Glue residue below 100 ppm
IV retention above 0.80
▶ Watch Video: High-Efficiency PET Bottle Washing Line Process
PET Bottle Washing Line Capacity & Parameters
Model
Capacity (kg/h)
Water (T/h)
Power (KW)
Steam (T/h)
Install Size (m)
BXP-500
500
3 - 4
100 - 130
0.3
35 × 5 × 5
BXP-1000
1000
4 - 5
180 - 220
0.5
45 × 6 × 6
BXP-2000
2000
6 - 8
350 - 400
0.8
60 × 6 × 6
BXP-3000
3000
8 - 10
480 - 550
1.0
75 × 7 × 6
BXP-5000
5000
12 - 15
700 - 800
1.5
90 × 8 × 7
* Note: Data is for reference only. Steam consumption depends on hot washer configuration.
Zhangjiagang Boxin Machinery Co., Ltd is China PET Bottle Washing Line Manufacturers and Custom PET Bottle Washing Line Factory, an innovative company that remains committed to plastic recycling and extrusion technology and specializes in providing plastic recycling washing and granulation equipment.
We are a professional supplier of customized solutions to plastic recycling, on the basis of our development teams and a wealthy content of industrial experience.
Main Products of Boxin: PET bottle recycling washing line, PE film /PP woven bag recycling washing line, HDPE /PP hard plastic recycling washing line, plastic pelletizing line and plastic shredder, plastic crusher machine.
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