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Amandina Bumi Nusantara stands on the land of 20,000 square meters area. The building consists of 3 floors:
Annual capacity of the manufacturing facility is 30,000 MT of rPET flakes and 25,000 MT of rPET pellets.
Raw Material Warehouse covers the area of around 3200 square meters with the capacity of 1000 MT of bales, for 10 days production cover. There are 2 types of bales that we collect, clear bales and light blue bales.
Compressed bales of bottles are pushed into the pit by forklift, transferred with the conveyor into the Bale Breaker.
The bales will be separated into loose bottles for sorting process.
The first step of bottle sorting, ferrous metal will be separated by the Magnetic Belt, then the bottles are transferred to the Drum Screen. The Drum Screen will separate the materials with size below 20 mm and above 200 mm. The accepted bottles will then proceed to the Heavy Trap where heavy materials and light materials will be separated by blow and vacuum process.
The bottles will be transferred into Delabeler machine, in which the shrink labels on the bottles are removed. Then, the Ballistic Sorter will separate the rigid and flexible materials. In this process, the ropes, sack, and any other flexible materials will be removed while the bottles will proceed to next process of color and material sorting.
The bottles will be sorted by Near Infra Red (NIR) and colour sorters followed by manual sorting process. The bottles will be sorted based on the colour, plastic type, and any other contaminants like metals. Only PET bottles will proceed to the next process. The capacity of all the bottle sorting processes is up to 6 MT per hour.
The Wet Grinders cut the bottles into flakes up to the size of 12 mm. Afterwards, the flakes will be cleaned in the Friction Washer and dried in the Mechanical Dryer.
At this stage, the flakes still contain other contaminants which will be removed by the next process.
Elutriator separates labels and lightweight materials which are transferred to Waste Cyclone. Flakes that no longer contain loose labels are transferred and stored in the Flakes Buffer Silo. which can contain up to 15 MT.
Before going to the washing line, the flakes will pass through Metal Detector to remove any ferrous material, and then rinsed in the Prewasher.
Afterward, the flakes will go into the Floatsink Tank to separate PET and polyolefins materials based on density. PET has a higher density than any other plastic materials like polyolefins, HDPE, and LDPE.
Only the PET flakes will sink and be transferred via auger to the next process. Other floating materials will be separated,to be further recycled by other recyclers.
21 | IntensiveWasher A
22 | IntensiveWasher B
PET Flakes will be washed using hot water with a temperature of 85 degrees Celsius and caustic soda to remove any contamination such as dirt, glue, and labels. This process will be carried out 2 times in Intensive Washer A and Intensive Washer B.
The PET Flakes will go into the Floatsink Tank to remove any polyolefins labels once
again and then proceed to the Post Washer. The post-washing process, at temperatures
of
70 to 75 degrees Celsius, will rinse the remaining residue of chemicals from the
Intensive Washer.
The whole washing line process washes up to 4.5 MT of flakes per
hour.
After the washing and rinsing process, the flakes will be dried using Mechanical Dryer and Thermal Dryer. The Mechanical Dryer will dry the flakes with high-speed spin, while the Thermal Dryer uses a hot airstream at the temperature of 120 degrees Celsius. Then, the Elutriator will remove any dust or label from the process with high-speed air.
To achieve high-quality flakes, the flakes need to go through further sorting processes.
First, Fines Screen will sieve and separate
the flakes with sizes above 2 mm. Then, flakes above 2 mm will be transferred into the
Flakes Sorters to classify by Colour and Plastic Type.
Only clean and clear PET Flakes will be temporarily stored in the QC Silo for QC
approval. There are 4 QC Silos, with the capacity of 40 MT of flakes.
After QC Release, the flakes will be dried with Hot Air Dryer and Pre-Dryer to dry the surface of the flakes and remove humidity. The temperature used in Hot Air Dryer is 55 degrees Celsius and Pre-Dryer is 160 degrees Celsius.
PET flakes are fed into the extrusion process at a temperature of around 275 degrees Celsius. To further remove any contaminants, solids greater than 50 microns will be removed by the Filter Screen.
35 | Pelletizer
The pellet cutting process will be carried out underwater and turns the melted PET into
spherical-shaped pellets.
Then the pellets will be transferred to the Classifier to remove undersize and oversize
pellets.
36 | Crystalliser
To enhance the mechanical properties, the pellets need to go through the crystallization
process. This process will take 20 minutes, turning the pellets into white opaque color.
This is the final stage of rPET production. The crystalized pellet will continue to
Solid State Poly-condensation (SSP) Reactor to increase the intrinsic viscosity and
sterilize the pellets. Once the process parameters are all met, the resin will be
discharged and packed into the jumbo bag.
This whole journey to process bottle to food grade rPET pellets takes about
12 hours.
