The global demand for high-performance bottle-to-bottle recycling solutions is on the rise. In response to this trend, the specifications for PET recycling machines are evolving to handle higher capacities.

As commented by Christoph Wöss, Business Development Manager for the Bottle segment at EREMA, “While the bottle-to-bottle market initially tended towards 3-ton machines, over the past three years we have been seeing increasing demand for PET recycling solutions with throughputs in excess of three tonnes per hour.”

Ultra-high throughput capacities

EREMA’s VACUREMA technology delivers a reliable solution for throughputs ranging from 600 to 6,000 kilograms per hour. Since 2020, a dozen VACUREMA machines with capacities ranging from four to six tonnes have been installed and commissioned worldwide. “Together, these large recycling machines produce almost 350,000 tons of rPET per year, which is a clear sign that this order of magnitude is now commonplace in the industry,” adds Wöss. 

VACUREMA system for bottle-to-bottle recycling.

Versatility and competitiveness

The system excels in efficient decontamination and gentle intrinsic viscosity (IV) treatment, meeting the stringent requirements of European and North American food safety authorities. Even the basic version produces food-grade rPET, enabling a wide range of end applications.

Whether the pellets are used with solid-state polycondensation (SSP) for IV adjustment in bottle-to-bottle or high-IV applications, or undergo additional vacuum treatment for direct integration into preform production, or are processed inline into sheets or fibers, the VACUREMA system is a versatile, food-grade certified solution.

“This versatility allows users to react flexibly to changes in the market and fluctuations in demand, an important advantage in a dynamic market environment,” explains Wöss. 

Superior Quality with VACUNITE Technology 

For applications requiring exceptionally high material quality, EREMA offers advanced VACUNITE technology, which is available for machines with throughputs of up to 2,500 kilograms per hour, featuring low energy consumption and a compact design. 

This system combines the proven VACUREMA technology with integrated vacuum-assisted SSP in a nitrogen atmosphere. The process further enhances material properties, significantly reducing pellet yellowing—a key quality factor in bottle-to-bottle recycling. Additionally, the closed nitrogen cycle and optimized process control minimize nitrogen consumption, resulting in a highly efficient and environmentally friendly operation.

EREMA at CHINAPLAS 

EREMA has already installed over 50 VACUREMA and VACUNITE systems in China, though only a few have throughputs exceeding four tons per hour. Against this backdrop, Wöss sees significant potential and expects to explore these possibilities in detail at CHINAPLAS: “For Chinese recyclers, the bandwidth and flexibility of the VACUREMA and VACUNITE systems offer great potential for a wide variety of applications.”

In several markets, including Latin America, there is a clear trend toward larger PET recycling machines. Wöss expects a similar shift in China to address the growing demand for high-quality rPET, particularly for sensitive applications like food packaging.