Plastic bottle processing plant is a stable income and investment in the environment. Plastic processing equipment: List with price Line for plastic waste recycling

Would you like to feel like a creator and produce at home (or in the garage) different useful things for life, like those presented in the picture below:

And, to make them almost what is lying under the legs - plastic bottles? Almost nothing (because they are not worth anything). Rather, from free garbage, which rolls everywhere:

One Clevero - Dave Hakkens decided to help you and developed a special mini-plastic processing plant for you and making different useful things from it.

Look at the video of his mini-plant in action:

Such a bank can be collected from affordable materials in almost any terrain, in just 15 days. And it will cost at a cost of approximately 622 euros (and in our conditions can and cheaper).

It consists of: shredder, extruder, injector and press compressor.

The most interesting thing - Dave Hackens tells (though, in English) and shows how to collect these parts of the future mini-plant.

Assembling mini-plant in parts

This is how Schröder can be made, for the materials for which approximately 180 euros will need and which you can do in 4 days:

Creating an extruder (you will need 192 euros and 5 days):

How to make an injector (prepare 130 euros and free 3 days of work):

And finally, how to make a press compressor (you will need 120 euros and 3 days to work):

The creator of the plastic processing mini-plant is ready to share with you not only by video instructions, but it gives full documentation for its creation. You can download at this address: preciouusplastic.com/en/videos/download/

What will your business come to?

With this plant you can:

1. To engage in creativity (creativity is not a business, but the opportunity to declare themselves and prepare future customers to buy your products).

2. Sell the products received in your city and via the Internet.

3. You can organize school excursions so that the children see how others can be created from some things. Firstly, you will clearly demonstrate to them the law of preserving things in nature (that things thrown by them themselves do not disappear and do not dissolve anything). This will call them to a good case - not to scatter around yourself and your home garbage. Secondly, we will show them that and how to create from plastic (let them even bring with them a few plastic bottles and will be brought back home useful for life of things).

4. It is possible to carry out fashionable in the West and gradually implemented in our life master classes like "DIY with your own hands the original gift". People will come to you with their plastic (or buy it with you, if you do not find the right color and textures) and, using your molds or extruders, will be able to make an original gift with their own hands for a loved one.

5. The plastic thread obtained with the extruder can be used in other industries - that is, you can find their industrial consumers and sell the resulting color threads from plastic on an industrial scale.

If you have something else left for the technology of creating a mini-plant and produced from recycled plastic, detailed information you can find on its website preciouusplastic.com

Business promotion

The promotion of your business can help you designated the conservation mission. ambient. As:

1. Products to help save ecology, buying pleasant.

2. Local media will definitely tell your business to the local population. Perhaps you will even take part in some local or regional business competition and will take an honorable place in it.

3. You can declare the population about buying plastic bottles (Dave Hackens, as indicated in his video, takes 1 kg of washed plastic at a price of 10 eurocents). Thus, the whole city can learn about your business for a very short time. Let you receive plastic for a penny - the people and for a penny will cover the entire city and its surroundings, will clean it from plastic garbage, it will happen to you, will bring you, and even tell you all my friends and neighbors. You also help the city to become clean (as can once again remind yourself of local media and local administration, which in turn can use this positive fact in their favor when writing another report).

Plastic Mass Processing Enterprises belong to the category of high-tech industries. The classification of enterprises does not have clearly defined boundaries, because The variety of types of materials (plastics), methods of their processing and volumes impose certain requirements and create special conditions for each enterprise. A variant of a set of elements of basic parameters can serve as a qualifying feature.

Material type

Enterprises, as a rule, use limited nomenclature of materials. This is due to the features of processing different species Plastics, which, in turn, require equipment specialization. For example, the technology of pressing reactoplasts and thermoplastics differ dramatically, and in the class of thermoplastics there are technologies and modes that apply only to a specific type of plastic.

Basic type of products

On this basis, the plants can be divided into enterprises for the manufacture:

• sheet and film materials;
• profiled products;
• bulk products.

The first two production is used extruders that form a product of a certain shape and length. Linear dimensions are determined by the configuration of the forming part of the extruder and the container of the bunker (material preparation technology). Auxiliary mechanisms form bays or cut on dimensional parts and packaged. For these industries, a high degree of automation of work is characterized, large processed volumes and a developed transport structure. The territorial enterprises are close to the place of production of the material used or are the division of the manufacturer of plastics.

The category of plants for the production of bulk products is extremely extensive. The complexity of these industries is the variety of products. The specialization of the plant is largely determined by the industry on which production is focused.

IN general They can be divided into enterprises servicing:

• electrical industry;
• industry associated with the production of vehicles;
• construction industry;
• food industry;
• production of consumer goods.

Plants focused on the production of TNP are in the most difficult position, because Forced to respond flexibly to changes in the situation, which is associated with the manufacture of new molds, technological equipment and the development of new materials.

Basic technology

Plastics processing technologies depend on the basic type of product and to a lesser extent from the industry in which they are applied.

Types of technology:

• extrusion or rolling;
• pressing;
• pneumatic or vacuum molding.

The main problem of processing plastics is the lag in technological equipment manufacturing technologies, which requires the use of flexible, high-tech industries for metal processing.

The Moscow region leads in the ranking of the Ministry of Environment in the number of enterprises involved in plastics processing. According to the ranking, there are 13 existing processing enterprises. Recycle asked some of them how many plastics are recycled here in a month where the company take plastic and what will change after the introduction of a separate garbage collection in the area.

"The capital of polymers"

The "capital of polymers" from Dzerzhinsky works in the processing market of polymers since 2002. Basically, polyethylene and polypropylene are taken on processing. For a month, I process 1100 - 1200 tons of plastic, which comes to the enterprise from large companies. As they assure in the company using a high-quality secondary polymer in production, companies can save up to 50% of the value of the primary polymer.

"Personally, for our company, in connection with the widespread introduction of a separate fee in the Moscow region, everything will remain in the old age. This will not affect this, "said Andrei Mikhailov, head of Recycle.

"Flus"

- The first Russian plant, which works on the Bottle-to-Bottle technology. Recycled plastic is no different in quality from what enters the enterprise. Ready raw materials are used to produce new plastic bottles.

The factory processes 30 thousand tons of plastic annually. Here only PET is recycling.

"The Flus" works with all possible recyclable operators (private, state, physical and legal entities, private entrepreneurs, manufacturers, factories, shops, etc.). More 150 containers are installed in Solnechnogorsk.

Feature of the plant - there are no requirements for receiving minimum plastic volumes.

"If the raw materials are prepared for processing, according to the requirements of the" plain ", we accept any volumes. Even a private person can come to us and put plastic in a collection container, "the department of the procurement department of raw materials" Flus ".

"Ecopolymer"

"Ecopolymer" from Novomoskovsk for more than 15 years is engaged in the processing of secondary polymers: Take PND, PVD, Stretch, polypropylene. A month in the company processes about 600 tons of granules.

Mainly plastic bring firms, companies, various production, agroholdings, warehouse complexes, that is, large private companies.

According to the company, it chose the optimal direction carrying the minimum environmental burden - polypropylene and polyethylene processing.

The company uses for this purpose a whole rank of aggregates, which are pressed, washed, crushed. With the help of extruders, one of the most problematic waste is processed - polyethylene. The resulting secondary granule is in high demand due to low prices and high quality.

"Specifically, the introduction of a separate collection in the Moscow region from 2019 is unlikely to somehow affect, because we still collect no household plastic, and production waste from warehouse complexes and production mainly. We do not take the organic and do not process, so I doubt that this innovation will benefit us. Ecology will benefit this, and specifically recyclars - hardly, "said Anton Mokhov, head of the company" Ecopolymer ".

"Unmaster"

A month in the company "Intermaster" processes about 100 tons of plastic, mainly polyethylene. It is brought by private companies, and sometimes individuals.

"The company is connected with urban waste, because the warehouse film, which is recycled here, is mainly coming from warehouses, logistics complexes, shops. These are not the waste that goes to sorting complexes, "said Recycle George Cherkasov, general director of the company" Intermaster ".

« Those companies that are engaged in sorting on landfills are directly related to urban waste. Machines come to them, relieve garbage, people in masks disassemble it to pieces (banks to cans, films to films, etc.). These companies are tied to urban waste, they depend directly from them, and our company is not. "Unmaster"associated with organizations, warehouse complexes », - adds Cherkasov.

From the recycled plastic in the company produce new products, including the stretch film.

Processing PET bottles and other plastic products has gained relevance immediately after the start of their mass production for economic needs. In natural conditions, plastic decomposes very long, so the question is sooner or later: what to do with waste from this material - to dispose of or processing in raw materials, in demand for various production purposes. As statistics, the profitability of enterprises engaged in plastic processing is quite high. This is explained by minor costs to create enterprises, ease of processing technology and practically inexhaustible sources of raw materials.

IN Russian Federation This business is much more promoted than in European states. The figures are eloquently talking about it: in Russia, only about 6% of plastic bottles and other types of packaging are processed annually, while in Europe this figure is 80%. The recommended business plan for plastic processing with calculations is a draft organization of a small plant, which will be in demand in almost any region of the country, especially in small towns and near mass recreation.

Market Review

Worldwide every year more than 3 billion tons of waste from different materials. Among this amount, at least 11-12% falls on the proportion of plastics. Most of all waste from the plastic "supply" the United States is about 77 kg per person. In our country, this indicator is 25 kg. Recycling is mainly polyethylene and polypropylene. Waste combined type Practically not processed. Remisry, which is obtained from plastic waste, is sent to enterprises engaged in the production of various constructs, composite building materials, packaging products, etc. An important dignity modern technologies Recycling is that in the process of recycling, many initial properties of plastic materials are lost and the sphere of their secondary use is narrowed, thereby reducing the re-formation of waste.

In Russia, the annual volume of waste generation of plastics is estimated at about 40 million tons, of which only 35% are suitable for processing. As noted above, only 6% of this quantity is sent for processing. The rest is transported to numerous landfills whose sizes grow from year to year.

The main obstacle to the organization in our country of the civilized approach to plastic processing is the absence of a separate collection system. Only such activities can be the primary processing, because the sorting of mixed waste makes it possible to extract only 10-15% suitable for the secondary use of raw materials.

Despite all the difficulties, in Russia, the industry of recycling of plastic waste develops. The country gradually increases the number of plants for the production of flex from the former in the use of plastics, their profitability is growing, the cost of primary raw materials increases, which, in turn, leads to an increase in the use of recycling.

It is gratifying that new laws are accepted at the state level and attractive economic conditions are being developed for market participants. At this time, the main players are:

• 11 thousand polygons and landfills.
• 4 incinerating plants (all are located in the metropolitan region).
• 5 garbage processing plants.
• 39 sorting bases.
• Over 1 thousand transport organizations engaged in waste disposal.

A peculiarity of the domestic processing of plastics is predominantly local in nature, which leads to a constant increase in landfills occupied. According to the FAS of Russia, the market is characterized by extremely low level of competition, especially in the regional cut. An example of this is statistics on cities that depends on the population. In particular, 45% of cities where over 100 thousand inhabitants live are serviced by one enterprise for waste disposal. Recycling is engaged in significantly more organizations,

In general, according to Research.techart, the domestic processing market is estimated at 1.5-2 billion dollars. "Pure" processors on it is quite small, most enterprises prefers to produce products from Flex.

In addition, the Russian plastic processing market is undeveloped technologically, as evidenced by such statistics:

• In the landfills of the country there are 36-38 million tons of waste (i.e. 90-92% of their total number).
• In the country, only 1.8% of MSW is burned.
• Industrial recycling per year is subject to 1.2-1.6 million tons (3-4%).

Thus, the discovery of a small plastics processing plant is a socially significant and economically attractive direction of business.

Organizational and legal form

Plastic Processing Enterprise is created within the Organizational and Legal Formation Limited Liability Company (LLC). This choice is due to the advantages that the plant will have in production and commercial activities. Primarily:

• The possibility of concluding contracts for the supply of products abroad.
• By providing the right to conduct cooperation in legal entities.
• Wider prospects for the development of the enterprise.

In accordance with the chosen form of business organization, taxation is carried out according to the general system.

The main paid taxes and their value are listed in the following table:

Description of the object

The created plastic waste recycling plant will produce flex. This material is granules, which can later be used for the manufacture of disposable plastic dishes, packaging containers, films and tapes from plastic and other products.

Implement the main stages of this project are planned during the following time:

Selection of industrial premises

For the normal functioning of the plastic processing enterprise, an unused plant room is selected or large warehouse A total area of \u200b\u200bat least 120 square meters. m. The object must have a connection to the networks of electrical supply, water supply and sewage. The most preferred is the location of the plant near the polygons for collecting and storing waste. This will reduce the cost of project transport.

The facility is equipped with rooms for:

• Office enterprise.
• Raw warehouses and finished products.
• Workers factory.
• Workshops with installed plastic processing line.
• Sanitary and hygienic needs of personnel.
• Storage of spare parts of equipment and tools.

The plant is equipped with a platform for parking cars delivering raw materials for processing and exporting products.

The best solution for choosing the premises is its provision of city administration within the regional environmental program.

Production and Technological Equipment

The preparatory stage for plastic processing is the following operations:

• Collection of PET bottles and other types of plastic packaging.
• Sort of raw materials in classes (colors).
• Rejection of polyvinyl chloride products (PVC).

After their execution, the raw material is sent to the process processing line consisting of the following units:

• Band conveyer.
• Rotary machine.
• A screw conveyor with an archimedean screw.
• Machine to remove with bottles of covers and labels.
• Crusher.
• Boiler.
• Screw.
• Washing machine.
• Rinse machine.
• Dryer-water separator (centrifuge).
• Air drying equipment (pneumatic car).
• Flotation baths.
• Bunker drive.

The capacity of the acquired equipment is 700 kg of flex per hour. Line service is carried out by two workers.

Personnel search

To work at a plastic waste recycling factory initial stage The project implementation is attracted by 18 employees. The staff schedule and costs of labor are listed in the following table:

Accounting services at the initial stage of the enterprise are transferred to outsourcing.

Financial plan

General investments in the project are distributed as follows:

It is planned that plastic bottles will be purchased mainly by the local population at a price of 15-18 rubles per 1 kg (the calculations use the price of 18 rubles per 1 kg). Given that from 1 kg of plastic waste, approximately 800 grams of flex is obtained, the technological losses of the line will be 20% of the total mass of waste. average cost Flex-granules is 35 rubles / kg. Transport costs are accepted in the amount of 20% of the value of raw materials.

Under these conditions, the revenue of the plant from sales of products for the first year of its work will be 17,248,000 rubles.

General expenses for the project for 1 year functioning of the enterprise are given in this table:

The predictable volume of the factory revenue for 1 year of work will be 17,248,000 rubles with a value of the production cost of 18,651,000 rubles. Taking into account the payment of taxes in the amount of 172,480 rubles, the net profit of the enterprise will be 1,575,480 rubles. Thus, with the horizon of planning the activities of the enterprise 1 year, predicted costs and income, investments in the creation of a plastic processing plant will pay off no later than 8 months from the date of its opening. The profitability of the enterprise during this period will be 27%.

SWOT business analysis

A visual idea of \u200b\u200bthe potential risks and the benefits of this business gives a SWOT analysis.

Strengths:

• The presence of a versatile international experience of enterprises in this industry.
• The presence of typical design and estimate documentation for the creation of plastics processing facilities.
• High social significance of the type of activity.
• Availability of public environmental organizationssupporting the creation of processing enterprises.
• Availability environmental programsimplemented by local government bodies.
• Simplicity of raw material processing technologies.
• Permanent availability of raw materials for processing.

Weak sides:

• Insufficient development of a regional regulatory framework for the activities of plastic waste recycling factories.
• Possible limitation of raw material sources in some regions of the country.
• Insufficient level of organization of separate waste collection.
• Weak development of the industry in the country.
• Low social prestige activities.

As a result, business may face the following risks:

• Market fluctuations in the cost of final products.
• Reduced investment attractiveness.
• Changes in the field of state regulation of waste management rules.

Eventually

The creation of a plastic waste recycling enterprise is a cost-effective and profitable business. The profitability of the production process is ensured by minor costs for the acquisition of raw materials, small current production costs and high levels Profit after entering the enterprise to break-even work.

"Made from recycled plastic." Such inscriptions are found on a wide variety of products - canisters, comb, even children's toys. The civilized world of plastic processing technology has already stepped far away, they allow processing plastic PET bottles ... in exactly the same plastic bottles.

To date, there is only one factory working on Bottle-to-Bottle technology. Let's see how this production is arranged.

Photos and text of Artem Achkasova

1. The plant "The Flus" was opened in 2007 on the outskirts of Solnechnogorsk near Moscow.

2. Today, 1800-2500 tons of plastic bottles per month are processed here. At the entrance - dirty used bottles, at the exit - pure raw materials for the production of new ones.

3. The collection of raw materials is made using sorting stations and household waste polygons.

4. In Russia, they are not accustomed to the fact that garbage can cost money, and its separate collection is not developed (the share of "cutting" at the plant is not more than 1%). Part of the plant bottles purchases from fitness clubs and hotels, but this weather does not. The main source of raw materials is ordinary landfills from all over the country (even from the Urals), where the garbage is sorted by hand, the bottles are isolated from it, after which they pack and sell the plant. 300-kilogram piles of dirty pressed bottles are brought to the factor where they are waiting for their own hours.

The first workshop is engaged in selection and sorting bottles. All Equipment Equipment European, from the leaders of the TBC processing industry - BRT Recycling Technologie GmbH (Germany), Tomra Systems ASA (Germany), RTT Steineert GmbH (Germany), BOA (Holland), Sorema (Italy), Buhler AG (Switzerland).

5. Piles are loaded into sorting lines bunkers, after which they are unpacking and sorting.

6. By and large, the plant could work automatically, but in Russian realities it is impossible. Automatic lines are able to distinguish and laying bottles of colors, but both in Europe, where plastic goes into recycling in its pure form, it does not work with us - due to the very strong pollution of the initial raw materials, human assistance is needed, and not one.

8. Several brigades manually sort the bottles, cut the labels, throw out the crushed garbage and container, which cannot be recycled, for example, entirely tightened into heat shrink plastic, with outsidated objects inside or non-standard color. For processing, only blue, brown, colorless and green bottles are suitable for processing. The latter, by the way, enjoy the smallest popularity of customers.

9. Silent bottles sorted by colors are pressed into the pins and are transported to the street - to the warehouse where they expect to get into the second workshop.

10. In the next workshop, everything starts with unpacking "sorted" kip ...

11. ... after which the bottles are sent to the sink.

12. Here the packaging "erases" first in cold water, then in hot, then in an alkaline solution and a special detergent.

14. The bottle is washed out from the outside, the glue dissolves that the label was glued. After a series of washes - the next post of manual sorting and magnetic metal floor.

16. The next stage - crushing. Bottles are grinding together with traffic jams, after which the resulting flakes again pass the procedure for thorough cleaning. In a special drum filled with liquid, a bottle of bottle plastic is separated from the cork. They have different density, and cereal flakes float to the surface.

17. Bottled flakes pass the procedure for the final inductive metal removal, after which a special computer machine is selecting defective phones of another color.

18. Then part of the products are packaged in 2-meter soft containers, the so-called Big-Bag. Flex is a great raw material for the manufacture of various household goods, building materials and even ... Fleece fabric!

19. Before launching further production, the trial of the resulting flakes is taken, which is sent to the chemical laboratory for various tests.

21. After that, the flakes of pneumotransport are fed into the third workshop - on the line of extrusion and granulation. The process is fully automated.

22. The process in the third workshop consists of several stages. First, repeated metal consumption, then pre-warming, removal of acetaldehyde and other harmful impurities, filtering. First, the flakes are cut in the shredder, after which the fox melts at 280 degrees Celsius.

26. Special machine through a fiber squeezes thin threads (strands) from molten and purified plastic, which dried and cut into granules.

28. Amorphous granulate is transported to crystallization and further enters the reactor.

29. After a 16-hour polycondensation in the reactor, under the influence of nitrogen and high temperature, amorphous granulate turns into the final raw materials - highly viscous PET granulate for the production of PET bottles.

30. Each batch of products is re-monitored - the obtained granules are closely studied by experts.

31. The finished product is packaged in large bags, after which they are sent to customers.

34. Granulates approved for use in packing for food products According to the Expert Conclusion of the FBUZ "Center for Hygiene and Epidemiology of the Moscow Region". The bottles of it are exactly the same transparent and pure, as from the usual granulate obtained by chemical path.

35. In a year, a plant on which 150 people work can produce up to 10 thousand tons of finished products, but the current volume is less. The reason is the lack of source raw materials ... That is why one of the organizers of the tours to the Plant "Flus" is the organization ... Greenpeace. Ecologists welcome the separate collection of garbage and plastic processing - this process is three times less harming the planet than the usual production of plastic. A serious reason to think!