Transforms washed PET flakes into food-grade R-PET pellets with controlled viscosity and stable color.
| Process type | Food-grade PET pelletizing (bottle-to-bottle) |
| Feedstock | Washed PET flakes from post-consumer bottles |
| Finished product | Food-grade R-PET pellets |
| Drying system | Pre-crystallization in a vacuum hopper, using friction heat |
| Decoloring | Extrusion system with decoloring function |
| Melt filtration | Automatic back-flushing filters |
| Vacuum system | Three-stage Roots pumps |
| Quality control | Inline viscometer, in real time |
| Pellet cutting | Automatic water-jet strand cutting |
| Food contact | 100%, all types of food |
| Certification | Compliant with food contact requirements (FDA approved) |
| Capacity | Configurable per project |
| Accepted feedstock | Notes |
| Flakes from post-consumer PET bottles | The main source for bottle-to-bottle pellets |
| PET sheet from thermoforming | Accepted after grinding and washing |
| Reject PET preforms | From injection or blow molding |
| PET strapping and fiber | Depending on the degree of contamination |
If you want to turn washed PET flakes into food-grade pellets, instead of selling them cheaply to other recyclers, a food-grade PET pelletizing line closes the bottle-to-bottle loop right in your own facility. The system takes flakes from PET bottles and produces food-grade R-PET pellets with controlled viscosity and stable color, ready for direct contact with food and beverages.
In the recycling flow, this PET pelletizing line sits right after washing and drying, exactly where the material becomes a sellable product. It replaces selling flakes at a low price with the production of high value-added food-grade pellets, integrating naturally into any plant that processes post-consumer PET waste. See the full range of PET recycling equipment and where each piece fits into your flow.
• Food-grade pellets, a well-configured PET pelletizing line produces material compliant with direct food contact, eligible for new bottles and packaging, a far better outlet than low-value fiber.
• Pre-crystallization drying using friction heat, the vacuum hopper thoroughly dries the flakes and prevents yellowing through oxidation, while using noticeably less power than classic electric heating.
• Strong melt decoloring, the optimized extrusion system reduces color deviations, so the R-PET pellets come out clear and uniform, batch after batch.
• Real-time viscosity control, the inline viscometer continuously monitors the melt and protects yield, without lab samples for every batch.
• Filtration with automatic back-flushing, the back-flushing discharge filters maintain filtration accuracy and reduce how often screens need changing, which means fewer stoppages.
• Efficient devolatilization, the three-stage Roots vacuum pump set extracts volatiles and odors, raising the purity of the finished pellet.
• Uniform, automatic cutting, the water-jet strand cutting unit delivers consistently sized pellets and saves labor.
• Maximum waste valorization, food-grade pellets sell at a price well above raw flakes, shortening the payback period of the investment.
• Reduced energy consumption, friction-heat drying and process heat recovery lower the cost per kilogram of pellet compared with purely electric heating solutions.
| Parameter | Value |
|---|---|
| Process type | Food-grade PET pelletizing (bottle-to-bottle) |
| Feedstock | Washed PET flakes from post-consumer bottles |
| Finished product | Food-grade R-PET pellets |
| Drying system | Pre-crystallization in a vacuum hopper, using friction heat |
| Decoloring | Extrusion system with decoloring function |
| Melt filtration | Automatic back-flushing filters |
| Vacuum system | Three-stage Roots pumps |
| Quality control | Inline viscometer, in real time |
| Pellet cutting | Automatic water-jet strand cutting |
| Food contact | 100%, all types of food |
| Certification | Compliant with food contact requirements (FDA approved) |
| Capacity | Configurable per project |
A PET pelletizing line primarily serves recyclers and bottlers who want to produce food-grade resin for new bottles and packaging. The resulting R-PET pellets feed directly into the manufacture of PET preforms, sheet for food thermoforming, and packaging strapping, replacing part of the expensive virgin material with no loss in quality. For a beverage producer, this means in-house recycled content, controlled from flake to pellet.
More and more beverage and packaging producers are required by regulation to include a minimum percentage of recycled material, and a PET pelletizing line internalizes exactly this material, under your own control, instead of buying it at a high price from third parties.
Production of food-grade R-PET pellets is strictly regulated at the European level; material produced by a compliant PET pelletizing line meets the requirements of Regulation (EU) 2022/1616 on recycled plastic materials intended for food contact.
Beyond packaging, food-grade pellets also feed the production of premium polyester fiber, strapping, and technical parts that require a material with high, stable viscosity. For recycling service providers, moving from selling flakes to selling food-grade pellets raises the margin on each processed ton and opens contracts with bottlers who require material traceability. A single investment in a PET pelletizing line can thus serve both the food packaging market and the technical fiber market at the same time, depending on current demand.
The system is designed for PET flakes from the recycling of post-consumer bottles, but it also accepts other PET sources, as long as the material is properly washed and dried. The quality of the finished pellet depends directly on how clean the incoming flakes are, which is why a PET pelletizing line works best coupled after a high-performance washing line. We recommend the lowest possible moisture content at the inlet, for a consistent final viscosity and a uniform pellet color.
| Accepted feedstock | Notes |
|---|---|
| Flakes from post-consumer PET bottles | The main source for bottle-to-bottle pellets |
| PET sheet from thermoforming | Accepted after grinding and washing |
| Reject PET preforms | From injection or blow molding |
| PET strapping and fiber | Depending on the degree of contamination |
The flow on a PET pelletizing line is continuous and automated, from washed flake to packaged food-grade pellet:
1. The washed PET flakes are loaded into the vacuum hopper, where friction-heat pre-crystallization dries them and prevents yellowing.
2. The dried material passes into the optimized extrusion system, with melt decoloring function.
3. The three-stage Roots pumps extract volatiles and residual moisture under high vacuum.
4. The melt is filtered through the automatic back-flushing filters, which retain impurities without frequent stoppages.
5. The inline viscometer checks viscosity in real time, confirming food-contact quality.
6. The extruded strands are cooled and automatically cut with a water jet into uniform pellets, ready for packaging.
Because the process is continuously monitored, the operator rarely needs to intervene, and resuming a recipe for a given flake type is quick. As a result, a PET pelletizing line quickly brings new staff to consistent results, a real advantage for plants with operator turnover. The automation system keeps parameters per recipe, and switching from one flake type to another does not require laborious recalibration.
Are the pellets produced on a PET pelletizing line truly food-grade?
Yes. The combination of pre-crystallization drying, three-stage vacuum devolatilization, and melt decoloring ensures an R-PET pellet compliant for food contact, eligible for new bottles and packaging. The process meets the European requirements for recycled materials in food contact. In addition, melt decoloring maintains transparency, essential for beverage bottles where the visual appearance of the packaging matters.
What feedstock can I use?
The main source is flakes from post-consumer PET bottles, washed and dried. The system also accepts PET sheet from thermoforming or reject preforms. The cleaner the incoming flakes, the better the food-grade pellet comes out, which is why we recommend coupling it with a high-performance washing line.
Is the delivered equipment new?
Yes. We deliver new, unused equipment, built to order, not refurbished units. The construction uses components from established suppliers, with CE marking where applicable, and every unit undergoes a complete inspection before shipping. You receive the technical documentation and operating manuals in your language, for a commissioning without surprises and predictable long-term operation.
What makes URSTAG a premium brand?
European design, top-tier components and experience. Every machine is designed by our engineering teams in Europe and built from components by industry leaders such as Siemens, Schneider Electric, ABB, WEG, SEW-Eurodrive, NORD Drivesystems and Bonfiglioli. The result is reliable, energy-efficient and durable equipment, backed by over 15 years of experience and by delivery, installation, training and service included.
How long does installation and commissioning take?
Transport, commissioning, and operator training are included and carried out by a local team, in your language. Before shipping, the line undergoes a free inspection, so your unit becomes operational quickly, with no hidden costs.
Can the line be integrated with an existing production line?
Yes. A PET pelletizing line can feed preform injection machines, fiber spinning lines, or packaging strapping lines directly, for recycling and production in a single step. This integration reduces material handling, lowers the energy consumption of the whole flow, and shortens the path from flake to finished product. We configure the coupling according to your equipment and the desired capacity, so the recycling loop stays continuous, without unnecessary intermediate stock.
URSTAG is a premium brand of recycling equipment, with over 15 years of experience. You don't just get a machine, you get a solution engineered by specialists, built from top-tier components and backed by a team that supports you from design through commissioning.
• European engineering, every machine and every complete line is designed by our engineering teams in Europe, with a focus on reliability, safety and energy efficiency.
• Premium components, we build on motors and automation from industry leaders: Siemens, Schneider Electric, ABB, WEG, SEW-Eurodrive, NORD Drivesystems and Bonfiglioli.
• Over 15 years of experience, we know how materials and machines behave in real-world operation, and we configure each solution for your flow and volume.
• New equipment, configured for you, we supply new units, made to order for your application, with complete technical documentation.
• Delivery, installation and training included, we handle transport, commissioning and operator training, with support throughout the equipment's life.
As a premium brand, URSTAG relies on European engineering, top-tier components and experience. You choose a partner that supports your production long term, with equipment built to run reliably in demanding industrial environments.
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