The Jwell rPET sheet extrusion line is purpose-built to convert washed post-consumer PET bottle flakes directly into food-grade thermoforming sheet without intermediate pelletizing, closing the loop on plastic packaging waste. Processing 500 to 1,200 kilograms per hour of 100% recycled input material, this line represents a strategic investment for sheet producers responding to brand-owner commitments to minimum recycled content — such as the EU Single-Use Plastics Directive and the UK Plastic Packaging Tax — and for recyclers seeking vertical integration from flake production into finished sheet. Unlike standard PET extrusion lines that blend recycled content with virgin resin, the Jwell rPET line is engineered specifically for the challenges of 100% recycled feedstock: variable flake quality, elevated moisture content, residual adhesive and label contamination, and the inherent tendency of post-consumer PET to generate acetaldehyde during remelting. The line incorporates a cascade of dedicated subsystems — a co-rotating twin screw extruder with dual-stage vacuum degassing, a crystallization and drying system, a melt pump, a continuous backflush screen changer, a T-die, and a 3-roller calendar — that together address each challenge systematically rather than relying on a single catch-all solution.
The rPET Sheet Extrusion Line is part of JWELL’s complete extrusion portfolio. Customers evaluating this rPET Sheet Extrusion Line also frequently request our %title% %sep% Jwell Machinery and PET Strapping Extrusion Line | Jwell Machinery, which share the same proven screw, die and control platforms. For layout drawings, pricing and lead times, contact JWELL Machinery directly.
| # | Item | Key Point |
| 1 | 🌀 Processes 100% PCR bottle flake | no virgin blend required |
| 2 | ⚡ Meets EFSA & FDA food-contact compliance for recycled PET | |
| 3 | 🎯 Dual-stage vacuum venting achieves <1 ppm acetaldehyde | |
| 4 | 🔄 40 | 60% energy savings vs virgin PET sheet production |
| 5 | 🔧 From-flake-to-sheet direct processing eliminates pelletizing step |
Processes 100% post-consumer recycled bottle flake directly, or any blend ratio with virgin resin. No minimum virgin content requirement — the line is designed for pure recycled feedstock.
Engineering target of <1 ppm acetaldehyde meets EFSA Regulation (EC) No 282/2008 and FDA 21 CFR 177.1630. PLC-logged process parameters provide full traceability for food-contact certification submissions.
Two sequential vacuum vent zones on the 40:1 L/D twin screw extruder, each maintaining ≤3 mbar. First vent removes moisture and low-boiling volatiles; second vent strips acetaldehyde generated during melting. Some configurations can process flake without full pre-drying.
500–1,200 kg/h output with 38CrMoAlA nitrided screws (0.5–0.7mm nitriding depth). Self-wiping geometry provides low-shear melting to minimize additional AA generation and homogenize IV variations between flake batches.
| Extruder Type | Co-rotating twin screw, 40:1 L/D (extended for degassing) |
| Screw Diameter | 75 mm (also available: 65mm, 92mm) |
| Screw Material | 38CrMoAlA, nitrided 0.5–0.7mm depth |
| Output Capacity | 500 – 1,200 kg/h |
| Barrel Lining | Bimetallic CPM-10V alloy (optional) |
| Crystallizer Type | IR preheating + fluidized bed, 2-stage |
| Dryer Type | Honeycomb-rotor desiccant with molecular sieve wheels |
| Dryer Dew Point | -60°C |
| Moisture Target | <50 ppm at extruder inlet (NIR monitored) |
| Vacuum Vents | Dual-stage, ≤3 mbar each |
| Vacuum Pumps | Water-ring + rotary vane in series |
| Acetaldehyde Target | <1 ppm in finished sheet |
| Screen Changer | Hydraulic continuous backflush, 2.5 m² filtration area |
| Die Type | T-die (adjustable lip) |
| Calendar Rollers | 3-roller calendar, 42CrMo forged steel |
| Roller Coaxiality | ≤0.005mm |
| Roller Surface Finish | Ra ≤0.016μm, HRC 58–62 |
| Sheet Thickness | 0.2 – 1.2 mm |
| Sheet Width | 600 – 1,200 mm |
| IV Retention | ≥95% vs input flake IV |
| Control System | Siemens S7-1200 PLC + 15\” HMI |
| Thickness Gauge | In-line beta-ray or laser thickness measurement |
| Total Installed Power | 350 – 580 kW |
| Certifications | CE, ISO 9001 |
Fruit clamshells, salad bowls, deli containers, bakery trays, and drinking cups made entirely from recycled beverage bottles. Sub-1 ppm AA level meets EU and North American food-contact regulations. High IV retention preserves impact strength for distribution survival. Brands can display ‘Made from 100% recycled bottles’ on-pack.
PET bottle recyclers selling washed flake as commodity ($700–1,000/ton) can capture the sheet value-add ($1,600–2,000/ton) by installing an rPET sheet line. Sized to match a typical 3–5 ton/hour washing plant output, creating a seamless bale-to-roll vertical operation. Several Jwell customers in Latin America and Southeast Asia operate this model.
Jwell recommends installing an in-line melt viscometer between extruder and die that continuously measures melt flow index. Data feeds back to the PLC, which auto-adjusts barrel temperature profile and screw RPM within preset limits to compensate for viscosity variations. The twin screw’s self-wiping geometry and extended L/D ratio provide sufficient residence time distribution to homogenize moderate IV variations. For operations receiving flake from multiple washing plants with significantly different intrinsic viscosity, Jwell offers an optional IV booster dosing system that meters solid-state-polymerized (SSP) resin pellets at 2–5% into the flake stream.
The line is designed to support compliance with FDA 21 CFR 177.1630 and EU Regulation (EC) No 282/2008 on recycled plastic materials intended for food contact. Critical process parameters — vacuum level, melt temperature profile, residence time distribution, and output rate — are continuously logged by the Siemens PLC with time-stamped records stored for a configurable period (typically 2 years). Jwell’s engineering team provides a process validation protocol document and on-site support during challenge test campaigns conducted by your chosen EFSA or FDA-recognized laboratory.
Yes. The Jwell rPET line is engineered for 100% post-consumer recycled bottle flake as the primary design case. The dual-stage vacuum venting, extended L/D screw geometry, and integrated crystallizer-dryer system are sized and configured to handle the full range of challenges that pure recycled feedstock presents — elevated moisture, residual contamination, and IV variability. No minimum virgin content is required.
Processing 100% recycled flake consumes 40–60% less energy than virgin PET sheet from petrochemical-derived resin, because the polymerization step is eliminated — the PET molecule already exists in the flake. The IR crystallizer further reduces drying energy by 35% versus hot-air-only systems. Combined savings translate to approximately 2.5–3.5 tons of CO₂ avoided per ton of rPET sheet produced.
Standard nitrided screws processing washed bottle flakes typically last 2–3 years due to silica, aluminum, and label-adhesive abrasion. Jwell’s bimetallic alloy screws with 64–66 HRC surface hardness (roughly double that of nitrided steel) and CPM-10V barrel lining extend service life to 5–7 years in 24/7 operations. This represents $40,000–60,000 in avoided replacement costs over the machine’s first 5 years.
Extruder Type: Conical twin-screw, vented; Screw Material: 38CrMoAlA, nitrided, bimetallic optional; Screw Structure: Conical twin, designed for PVC + wood flour + CaCO₃ + foaming agent; L/D Ratio: Optimized for controlled foaming zone
Screw Diameter: Φ 80 mm / Φ 92 mm / Φ 110 mm / Φ 180 mm; Output (24h, SPC): 6-8 T / 12-18 T / 25-32 T / 70-100 T; Line Speed at 4 mm: 0.4-0.6 m/min / 0.8-1.3 m/min / 1.8-2.4 m/min / 5-9 m/min; Screw Material: 38CrMoAlA, nitrided, bimetallic optional / ← Same / ← Same / ← Same
Applicable Material: EVA copolymer (VA content 14-28%), EVA + LDPE blends, EVA + carbon black; Sheet Width: 2,000 – 4,000 mm; Sheet Thickness: 1.0 – 3.0 mm; Production Capacity: 300 – 600 kg/h
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Jwell has manufactured PET sheet extrusion equipment since 2005, accumulating field data from over 400 installed PET lines worldwide. Each new machine generation incorporates refinements validated across hundreds of real production environments — not just lab prototypes.
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Our Changzhou facility operates a full production-scale PET line for customer trials. Bring your raw materials and target specifications — we run your recipe before you commit. The line delivered to your factory is a proven configuration, eliminating startup risk.
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Factory-trained Jwell engineers based in Brazil, Spain, Mexico, and Shanghai travel to customer sites for installation and operator training. Remote diagnostic support via WeChat/WhatsApp responds within 2 hours. Critical spares ship from Shanghai within 48 hours.
Jwell Machinery Co., Ltd sets up in 1997 , we are large manufacturer of plastic extrusion machinery in China, our headoffice was located in Shanghai.
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