What is made from recycled PET bottles. How are plastic bottles recycled?

Plastic bottles have become convenient for transporting and storing liquids. Glass containers are now rarely used. After use, plastic products are usually thrown away. A lot of this garbage accumulates every day. Because of this, the question arises whether equipment designed for such work can be used to establish a profitable business.

Advantages

Nowadays, many business ideas that improve the lives of the population are popular. If bottle recycling becomes popular among people, it will create a permanent source of income. In our country, few people are engaged in such activities, so there is a possibility of profitability of the business.

The benefits include:

The ratio of profit to revenue will be approximately 25%, which is higher compared to other areas.
The businessman who recycles bottles is respected by the residents. This will guarantee some support from them.
Now environmental projects supported by government and local authorities.
There are companies that want to be responsible for protecting the environment. But since this is not their main focus, they choose to invest in such projects.

Flaws

But such a business also has disadvantages that novice entrepreneurs may encounter:

Difficulty opening. Since this area is regulated by law, paperwork can be complicated. It is necessary to obtain many permissions from various organizations. As a result, everything takes about 8 months, which is a lot compared to other types of business.

There is no constant supply of raw materials. But it is necessary for the continuous operation of production. Also, not everyone understands where to sell products.
Requires manual labor. Availability required large quantity employees, each of whom will do their job. Only then will the activity become effective.

Business demand

There are several reasons to understand that such a business is very promising. These include:

Low competition.
Availability of raw materials.
Uncomplicated workflow.
Environmental factors.

Since such factories improve environmental situation, they are supported by the government as well as conservation communities. No matter how profitable it is, the business must be organized competently. Renting or purchasing premises will be required. You also need to formally register your business.

Technology

It is necessary to purchase professional equipment for bottles. The technology consists of the following work:

Products are being collected.
Whatever the equipment for recycling plastic bottles, sorting is mandatory stage. It is carried out by class. Typically, products are divided into unpainted and painted. They are processed separately. A special group are bottles based on polyvinyl chloride, which require a special procedure.

Then manual removal of rubber, paper, and metal is performed.
Then the bottles are squeezed. Once they are compressed, they are loaded onto a packaging recycling line.
The result is considered to be flake-shaped flakes. Flex is the raw material for the production of such bottles or chemical fiber. Many products are made from it - packaging tapes, paving slabs, films.

During recycling, labels and caps are automatically removed and bottles are crushed. The fragments are added to a special cauldron, where they are washed off with water. various elements. Then the plastic is cleaned and dried. It is stored in a special bunker. All this is done by bottle equipment.

Each stage of production is considered important. They are performed by different employees. Responsibilities are distributed among employees based on their qualifications. Only then will the whole process be carried out efficiently.

Equipment

You can use 2 options for organizing a business:

The mobile processing plant is located in a truck. This idea is more suitable in cases where you plan to serve several cities.
Renting a building for a workshop. Equipment for processing plastic bottles (complete line) costs about 3-4 million rubles.

Both options for organizing a business are in demand. You will need the following equipment to recycle plastic bottles:

Belt conveyors.
Rotary machine.
"Crusher" - equipment for processing plastic bottles into granules.
Screw conveyor.
Steam boiler.
Polishing machine.
Dryer-water separator.
Air dryer.
Storage bins.

Each device is important to the production process. It can be purchased either separately or complete. If you purchase equipment for processing plastic bottles in the form of a mobile plant, its price is approximately 5-6 million rubles. For a stationary view it is necessary large area- over 2,000 sq. m. It is better to establish a business in abandoned factories and warehouses on the edge of the city. Then the cost of the premises will not be high.

If you purchase a plot of land and build a hangar, you will profitable processing plastic bottles as a business. The equipment will produce not only flex, but also fiber, which increases profits and profitability. This requires larger investments, so a new entrepreneur should do this after the initial investment in his business has been repaid.

Is a home business possible?

It is unlikely that plastic bottle recycling can be done at home. This equipment takes up a lot of space. But a separate room is perfect for this. Best choice There will be a mobile installation. Although it is more expensive, it can be easily installed indoors.

It is enough to install the equipment, connect the sewer system to eliminate waste, and connect the power supply. The size of the lines is usually 6-10 meters. With such indicators, it will be possible to place equipment for processing plastic bottles at home, if the space of the room allows. This technique does not take up much space and also consumes minimum quantity electricity.

Receiving raw materials

For a business to be successful, it is better to open a plant in big city so that transport costs are low. Although bottles are a lightweight product, they take up a lot of space. Because of this, long-distance transport reduces profitability. The location may be equidistant from several cities.

The assembly of raw materials is carried out manually at landfills, which are available throughout the country. The bottles are placed in bags and then pressed, after which they are delivered to the factory. You can also search for raw materials using the Internet. Now there are many platforms where there are advertisements for the sale and purchase of bottles. The main task will be to offer favorable conditions compared to competitors. Services function like auctions.

It is possible to find a direct supplier of waste in the form of PET bottles. This is usually the most profitable option. We need to find companies that produce a lot of this waste. These are offices where employees are provided with various drinks free of charge. The level of consumption there is quite high.

Cost

To organize such a business, many employees are needed, since many activities are performed by manual labor. The minimum number of employees is 10 people. Their average salary is 20 thousand rubles. The costs of the motivation system should be taken into account, since it increases labor productivity.

During calculations, it must be taken into account that the schedule should be in shifts. It will take about 15 thousand rubles to purchase a ton of bottles with transport costs. The purchase price is determined not only by the manufacturer, but also by the type of raw material. For example, brown plastic is considered the most affordable, but it is used only in some areas.

Transparent plastic is considered more expensive. Costs should include the cost of electricity and water consumption. The price of 1 ton of products can be in the range of 40-90 thousand rubles. The cost is calculated based on the size of the granules, characteristics, and color.

Staff

To organize a mini-factory, you need at least 8-10 workers. They will work in shifts. We also need an accountant, a manager and 2 loaders. This composition of workers will allow bottle recycling to be carried out efficiently.

Over time, it becomes possible to expand production. Then you will need to hire more workers to increase the number of products sold.

Sales

For such a business to be profitable, you need to establish the right sales system. A company that does not produce fiber can organize sales to other similar companies where the entire technological cycle operates. Then the cost per ton will be less than the market price, but there will be constant demand.

There are organizations that create fibers from flex. There are few such companies in Russia, but their volumes are large, so this guarantees high profits. You can use the platform to find clients, for example, create an ad and wait for responses.

Profit and payback

The payback period is approximately 1.5-2 years, since it is necessary to make investments, especially at the beginning. The advantage is that the costs of organizing processing are low. Therefore, with revenue of 800 thousand rubles per month, the profit will be equal to 200-300 thousand rubles. Income is determined by the type of raw materials and other factors.

Before deciding on this type of activity, you need to weigh all the positive and negative aspects such a business. Carefully calculate the amount that will be needed to open production, study the package of documents that permit this type of activity. It would also be a good idea to look at a place to rent in advance, compare the cost of equipment and choose the most suitable option.

It’s no longer news to anyone that a plastic bottle takes several decades to decompose. And it is no longer possible to remember how we lived without them before. Meanwhile, they lived wonderfully. Drinks were sold in glass containers and often, in order to buy milk, kefir or lemonade, you had to return the same number of bottles that you would like to buy.

Young people think this is some kind of medieval savagery. But only some 25 years have passed since the day when plastic poured into our market. Therefore, the question is how to recycle plastic bottles, is quite important.

Global environmental problem

And before, the approach was much more civilized than what is happening now. It’s enough just to take a look at the landscape on any city beach, park or even in the forest many kilometers from the city.

In the Moscow region, only unauthorized landfills occupy 1.5 thousand hectares.

About 10 million tons of PET are produced annually in the world. In Russia, tons of PET bottles are taken to landfills, where they are burned and buried.

This waste accumulates, poisoning the air, soil and water. This is global environmental problem. Europe has already begun to more or less cope with this problem. By the way, PET containers are not that good. It allows ultraviolet light and oxygen to pass through, and also does not retain carbon dioxide inside, and this greatly reduces the shelf life of the product.

Such a market has not yet been fully developed

But there is also a plus: PET containers are recyclable. Recycled materials are used to produce insulation for jackets, stuffing for soft toys, so-called artificial wool, which is used for the production of knitwear, etc. So in the UK, about 70% of bottles are recycled, in Germany - 85%, and in Sweden - 95%. And in Russia it is only 6%. This suggests that this market is still very far from saturation. Thus, this is a tasty morsel for investors. Therefore, it is worth considering a business plan.

Recycling of plastic bottles, namely the organization of this business, should begin with the following: you need to find out whether there are any grandees in the region of interest or any government support for this type of business. Then you need to register legal entity and you can start looking for production space and an office.

Searching for premises and obtaining documents

For a production plant for processing PET containers, it is necessary to find a premises with an area of at least 3 thousand square meters. m. It is best to look for it in the suburbs. Abandoned factory, warehouse, hangar. If only it would fit the area, and communications would be provided. The premises will have to be divided into three parts: production workshop, raw materials warehouse, warehouse finished products. This must be taken into account when designing a business plan.

Recycling of plastic bottles is possible only with certain licenses and various approvals from services such as the SES and the fire organization. It will take about 200 thousand rubles to obtain all the necessary documentation.

What equipment will be needed?

Equipment for processing plastic bottles will cost approximately 4 million rubles. You need to be prepared to pay another 400 thousand for its installation and commissioning. Add to list necessary equipment includes a granulation line, a rotary grinder and an agglomerator.

You can get by with domestically produced equipment. Such a line for processing PET bottles will cost approximately up to 1 million rubles. But then you need to be prepared for low production capacity and frequent line breakdowns.

However, it should be borne in mind that bottles can be used not only for the production of any other goods. Raw materials can be used to produce energy. This is the so-called pyrolysis recycling of plastic bottles. But this process requires the purchase of additional equipment.

What nuances need to be taken into account when drawing up a business plan?

Recycling plastic bottles without raw materials is impossible. Therefore, it is necessary to purchase it. And this is a difficult question. Raw materials can be purchased from landfills. You will have to travel around a certain number of similar places, agree on a price, discuss the presence or absence of caps on the bottles. Reception points can be organized plastic containers. It would be good if one of these points was right next to the workshop. This will save transportation costs.

Why should you discuss the issue of traffic jams in advance? The whole point is that the complexity of the pressing process will be increased due to the presence of air in the bottle. Taking into account the fact that many begin their activities on weak lines, their breakdown is possible.

Accordingly, it will be necessary to hire employees who will manually check bottles for corks. And this entails additional costs. Based on the foregoing, it can be noted that such an important aspect must be discussed in advance with the supplier. Otherwise, recycling plastic bottles will be difficult.

Waste sorting technology

The habit of sorting garbage in Russia has not yet formed. But, for example, in England it is as natural as breathing. How could it be otherwise if the fine for improperly sorting waste is £1,000? Each type of waste (there are three) is collected only on a certain day of the week. And if the owner of the house confuses the days and places the bin with the wrong type of garbage, he will be fined again. The Germans also sort garbage.

The first type of waste is food waste. This waste is used to feed livestock and is also used as fuel in some energy industry enterprises. Paper is thrown away separately from cardboard, as the recycling methods for these wastes are different. Glass bottles different colors- in different tanks.

Old clothes and shoes are placed in special containers near stores, churches and parking lots. The batteries will have to be taken to the nearest supermarket and thrown into a special bin for batteries. Another tank for plastic and metal. And one more for the "rest".

Everything is not as absurd as it might seem at first glance

At first, it may seem to our person that he has found himself in a “world of the absurd.” It's no joke, about 10 different garbage cans. And in Germany, stores take a deposit (about 25 cents) for each bottle. If you return the bottles, you get your money back. And so it is in almost all European countries. There is hope that the rest will “wake up” soon. In the meantime, residents of high-rise buildings do not really understand why instead of one tank in the yard there are now two.

Capacity planning

You can plan labor costs based on production capacity. That is, a number of questions need to be answered. How many workers are needed at full load and shift work? How many drivers are there to deliver raw materials and ship finished products? Do you need an electrician, plumber, or janitor on staff? And also plan the salaries of the storekeeper, receptionist, loaders, accountant, and sales manager.

Sales of received products

All that remains is to organize sales of the products. From 50 tons of PET waste, about 40 tons of recyclable materials will be obtained. Recipients of commercial proposals can be manufacturers of disposable tableware, packaging film, fiber manufacturers for weaving factories, soft toy factories and many others. A list of potential clients with contact information can be found on the Internet. And then create a price offer, a system of discounts, a payment method - and the commercial offer is ready.

It is necessary to assess the competitiveness of this area

In order not to sit and think later why sales are not happening, you first need to familiarize yourself with the offers of your competitors. The best way to do this is to design a business plan. Recycling plastic bottles requires clear answers to the following questions: what do we sell, to whom, at what price?

The amount of initial capital

To summarize all of the above, we can note the factor that organizing your own business recycling bottles will require about 5 million rubles. This amount will include equipment for processing plastic bottles, the rental of the necessary premises, and the search for personnel. However, you should understand that your own enterprise must be constantly improved. Otherwise, it will not bring the expected income.

Conclusion

If plastic recycling, the business plan for which was described above, is organized correctly, then such an entrepreneurial idea will pay off within two years. Plus the satisfaction that this is an extremely important matter for environmental health. We cannot yet change the planet like an apartment. Therefore, it would be good to learn to live on this.

Recycling plastic bottles is a fairly pressing task today, and business in this area can be called very promising. This is due to the distribution and widespread use of such packaging in all industries national economy. That's why it's worth appreciating process processing, the cost of equipment used for this, as well as markets for the resulting raw materials.

Relevance of the problem

Statistics show that every year a person throws away about 300 kilograms various garbage, a third of which are plastic bottles. Already used containers are no less valuable than glass bottles or waste paper. In the process of processing such waste, a material is obtained from which flex is made in the form of plastic flakes. And it, in turn, is suitable for the subsequent manufacture of containers.

It turns out that recycling a plastic bottle is waste-free production, because plastic makes flex, and vice versa. In addition, such an idea is fully justified in environmentally, since complete decomposition of the polymer requires 300 years, no less.

Current trends

Recycling plastic bottles as a business is great idea, since thanks to this you can get quite a good profit, but only if you draw up a business plan correctly, as well as if you have the required amount of money for this. Organizing such an enterprise is quite expensive. The main points here concern the search for suitable premises, arranging the supply of raw materials, as well as the search for sales markets. This business is not just profitable, but also quite useful. In addition, recycling of plastic bottles is not yet very developed in the CIS countries, so you will not have much competition.

Main technological stages

You can consider the recycling process that occurs at such an enterprise.

At the first stage, bottles are collected and sorted. There are no difficulties here, and this process will be discussed in more detail later. Only one thing is worth noting: at this stage, an uninterrupted supply of raw materials with its further sorting should be established.

Grinding

The second stage is crushing. Here you will already need certain equipment for processing plastic bottles, namely a special crushing installation. Sorted raw materials are placed in it, which is crushed to produce flakes of 0.8-1.2 cm in size, it all depends on which grid is used in the installation. This is the same flex. Next, this crushed mass is thoroughly washed using caustic soda. The line for recycling plastic bottles sends all this to a centrifuge, where pieces of paper labels are separated from the bulk. The flotation process allows you to remove rings and caps, as well as labels made of polypropylene. The flexible is washed again, this time using clean water, and then placed in a tube dryer, where a stream of hot air ensures drying. At the end, the plastic bottle recycling machine unloads and packages the flex. In this form, the material is already suitable for sale. But you can use a slightly different technology.

Agglomeration and granulation

The third stage is agglomeration. Sometimes this technology for recycling plastic bottles is used. This is a simple procedure. The crushed mass is exposed to high temperatures, as a result of which it sinteres and turns into small lumps. These lumps can be sold as ready-made raw materials, or they can be granulated, due to which they are “improved.”

The fourth stage is granulation. You can already see how versatile plastic bottle recycling can be. The technology in this case involves subsequent processing of raw materials. This significantly increases its quality and purity, which makes it possible to increase the cost of the product. Granulation is often called briquetting; the essence of this process is to turn the crushed mass into pieces of the correct shape, that is, peculiar granules of the same size and weight. This is done this way: the particles are compacted under slight pressure, since there may be voids between them. After this, the particles themselves are deformed, due to which they adhere at the molecular level. The final stage involves increasing pressure to transform the elastic modification into a plastic one. The result of this is the production of durable granules of the same shape.

Even taking into account the fact that equipment for these purposes is quite expensive, it is quite possible to open such a business. The processing line alone costs around 130 thousand dollars. But this is the price to pay for how beneficial recycling plastic bottles is. A business plan for such a plant should be based on specific project to demonstrate it to potential investors.

First of all, you need to register a company. It is worth noting that this type of activity will be recognized as trade in small products, so it can be started even before the opening of an individual entrepreneur. Next, you need to take care of a suitable premises, purchase or rent equipment for processing plastic bottles. But it’s worth considering everything in order. First, you will need to obtain a license for this type of activity, and also coordinate everything with the SES and the fire organization. Obtaining all the documents required for this costs about 200 rubles.

Business premises

When the “paperwork” issues have been resolved, you can begin to search for premises where the line for the production of plastic bottles will be located. This requires an area of at least 3000 square meters, it is best if it is located outside the city. An abandoned factory or warehouse is suitable for these purposes; it is important that all communications necessary for work are connected to it. The premises will need to be divided into three parts (this must be taken into account when drawing up a business plan): for raw materials, for finished products, for production.

Business staffing

So, have you decided to open a plastic bottle recycling plant? In this case, you need to have a rough idea of the prices and equipment that will be required for these purposes. The minimum amount you should expect is 4 million rubles plus another 400 thousand for installation. For a production shop there are several elements that are mandatory. Equipment for recycling plastic bottles must include:

Agglomerator (≈ 222 thousand);

Granulation line (≈ 1-2 million);

Rotary chopper (≈1.5 million).

It is important to understand that the specified set is the minimum required to set up a line that will process plastic bottles. The following is a list of components for the finished line:

Bath in which the flex will be soaked;

A dynamic centrifuge designed for harsh cleaning of plastic from residual dirt, labels, and other debris;

A hot bath of water heated to 60 degrees, with the addition of sodium phosphate, is used for maximum effective cleaning of the flex;

A dispenser that supplies flakes in equal portions into pipes with heated air;

A friction auger, which is designed to accumulate flex and transport it to the soaking bath. It includes an inclined auger, a flushing system and a storage hopper;

Rinse bath, which is designed to wash away any remaining detergent from the flakes.

Purchasing options

Of course, it is quite possible to acquire domestic technology, which will be much cheaper, but in this case there is a high probability frequent breakdowns or that the equipment capacity will not be enough. Although the cost of this equipment will be approximately 1 million rubles. You can also choose the option of purchasing used machines, then you can save about half the amount.

Among the manufacturers of equipment for recycling plastics, the leading positions belong to Herbold, Shredder, Sorema, RIKO RT, Redoma and others. Most of the equipment used today is manufactured in China. If we talk about domestic manufacturers, the quality of their products is much inferior even to Chinese ones. One exception is the Machinery and Technologies company.

Raw materials

The easiest production stage in this case is organizing the supply of raw materials. We are talking about plastic bottles, of which you can find a lot in every city. Extraction of raw materials can be done in one of several ways:

You can install special ones around the city garbage containers, intended for sorting. Instead of one old one, you can install several new ones. They need to be labeled accordingly so that people who dispose of waste sort it immediately. At the same time, you can count on the support of the city authorities, as they are always happy to have new garbage cans.

You can send people directly to the solid waste landfill, where they will sort the waste right on the spot. This method is not so expensive, since you do not need to spend money on purchasing additional containers.

Organize collection points for plastic bottles throughout the city. Now the cost of one kilogram is about 20-30 cents. In this case, the costs are not as high as if it were necessary to purchase trash cans or send people to the city landfill. Since your goal is precisely the recycling of plastic bottles, and not collection, you don’t have to organize your own collection points, but use the services of existing ones. You can also negotiate with city waste collection services on regular supplies of raw materials. The cost of one ton is about $100.

A deposit scheme is another option. Its essence is to arrange the return of used packaging back to points of sale of products for a certain fee.

Profitability and payback of business

So, if you are interested in recycling plastic bottles as a business, then when drawing up a plan, you need to determine the profitability of the future enterprise. First you need to decide on personnel: you need 4-5 workers, an accountant, several people for control production process, manager.

It turns out that when organizing such a business, you may encounter the following average statistical expenses:

4 million rubles - purchase of equipment and its installation;

400 thousand rubles - rent of premises and payment of utilities;

200 thousand rubles - other expenses.

In total we're talking about about the amount of 4.6 million rubles, to which it is worth adding the salaries of employees - 270 thousand rubles.

The processing results in a product that would sell for 2.9 million per tonne, depending on the type of plastic. When the enterprise operates 23 days a month for 8 hours and produces 1 ton of products per day, you can count on a net monthly benefit of 300-350 thousand rubles.

Conclusions

If you strictly follow the business plan, you can say that the opening costs will pay off in about a year and a half, but this is subject to proper organization of the entire production. In addition to the fact that recycling a plastic bottle is a profitable activity, it should also bring moral satisfaction from the fact that a person is making a contribution to improving the environmental situation.

“Made from recycled plastic.” Such inscriptions are found on a wide variety of products - canisters, combs, even children's toys. In the civilized world, plastic recycling technologies have already come a long way; they make it possible to recycle PET plastic bottles... into exactly the same plastic bottles.

Today in Russia there is only one plant operating using bottle-to-bottle technology. Let's see how this production works.

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

2. Today, 1800-2500 tons of plastic bottles are processed here per month. The input is dirty used bottles, the output is clean raw materials for the production of new ones.

3. Raw materials are collected at sorting stations and household waste sites.

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 “separation” at the plant is no more than 1%). The plant buys some of the bottles from fitness clubs and hotels, but this doesn’t make any difference. Main source raw materials - ordinary landfills from all over the country (they are even brought from the Urals), where garbage is sorted by hand, bottles are separated from it, after which it is packaged and sold to the factory. 300-kilogram piles of dirty pressed bottles are brought to the factory site, where they wait in the wings.

The first workshop is busy with the selection and sorting of bottles. All equipment of the enterprise is European, from the leaders in the solid waste processing industry - BRT Recycling Technologie GmbH (Germany), TOMRA Systems ASA (Germany), RTT Steinert GmbH (Germany), BOA (Holland), SOREMA (Italy), BUHLER AG (Switzerland).

5. Bales are loaded into the bunkers of sorting lines, after which they are unpacked and sorted.

6. By and large, the plant could operate automatically, but in Russian realities this is impossible. Automatic lines are able to distinguish and arrange bottles by color, but as in Europe, where plastic is recycled in pure form, this does not work for us - due to the very high contamination of the raw materials, the help of a person is needed, and not just one.

8. Several teams of workers manually sort the bottles, cut off the labels, throw out any loose debris and containers that cannot be recycled, for example, those entirely wrapped in shrink plastic, with foreign objects inside, or of a non-standard color. Only blue, brown, clear and green bottles are suitable for recycling. The latter, by the way, are the least popular among customers.

9. The bottles, sorted by color, are again pressed into bales and transported outside to a warehouse, where they await delivery to the second workshop.

10. In the next workshop everything begins with the unpacking of the “sorted” bales...

11. ...after which the bottles are sent for washing.

12. Here the container is “washed” first in cold water, then in hot water, then in an alkaline solution and a special detergent.

14. The outside of the bottle is washed, the glue that was used to attach the label is dissolved. After a series of washes, there is another manual sorting station and magnetic metal separation.

16. The next stage is crushing. The bottles are crushed together with the corks, after which the resulting flakes again undergo a thorough cleaning procedure. In a special drum filled with liquid, bottle plastic is separated from cork plastic. Their density is different, and flakes from the corks float to the surface.

17. Bottle flakes undergo a final inductive metal separation procedure, after which a special computer machine selects rejected flakes of a different color.

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

19. Before starting further production, a sample of the resulting flakes is taken and sent to a chemical laboratory for various tests.

21. After this, the flakes are transported by pneumatic transport to the third workshop - the extrusion and granulation line. The process is fully automated.

22. The process in the third workshop consists of several stages. Firstly, repeated metal separation, then preheating, removal of acetaldehyde and other harmful impurities, filtration. First, the flakes are cut in a grinder, after which the flex melts at a temperature of 280 degrees Celsius.

26. A special machine, through a die, extrudes thin threads (strands) from melted and cleaned plastic, which are dried and cut into granules.

28. The amorphous granulate is transported for crystallization and then enters the reactor.

29. After 16 hours of polycondensation in a reactor, under the influence of nitrogen and high temperature the amorphous granulate is converted into the final raw material - high-viscosity PET granulate for the production of PET bottles.

30. Each batch of products is re-controlled - the resulting granules are carefully studied by specialists.

31. Finished product Packed in large bags and then sent to customers.

34. The granulate is approved for use in packaging for food products according to the expert opinion of the Federal Budgetary Institution of Health "Center for Hygiene and Epidemiology of the Moscow Region". Bottles from it are exactly the same transparent and clean as those from ordinary granulate obtained chemically.

35. A plant employing 150 people a year can produce up to 10 thousand tons of finished products, but the current volume is less. The reason is the lack of raw materials... That is why one of the organizers of tours to the Plarus plant is the organization... GreenPeace. Environmentalists welcome separate collection garbage and plastic recycling - this process is three times less harmful to the planet than conventional plastic production. A serious reason to think!

Recycling plastic bottles as a home business and do-it-yourself equipment is of interest to many due to the availability of raw materials. You can only use material that has the corresponding symbol. This is an image of a triangle made up of three arrows. Inside the triangle there is a marking of the specific plastic from which the product is made. Only plastics that, when heated, do not emit harmful substances to health, are selected for recycling.

In some cases, when strips are made from plastic bottles for the subsequent production of wicker products, bottles from any type of plastic can be used.

Bottles made of HDPE and high-density polyethylene are an interesting material for reuse. Plastic is made from petroleum products, it chips easily, and is resistant to alkalis and acids. The scope of production from such material is very extensive. It is used to create containers for storing motor oils, water, bearings, and various handles.

You should not use plastics with other markings for recycling at home - when melted, they can release harmful substances or simply spoil the composition.

General principles for recycling plastic containers at home

Plastic becomes plastic at temperatures above 180˚C, so it can be used for recycling at home. The plastic is first crushed and then the resulting mass is heated. It is impossible to heat the plastic at home, as is sometimes recommended - in the oven, to a state similar to liquid, it becomes simply plastic, therefore, from the heated mass of crushed plastic, you can easily form any product in the appropriate shape, but there will be cavities in the craft.

Modern equipment for small businesses

Russian-language websites traditionally describe the processes of processing plastic bottles using domestic equipment, which requires more than two hundred square meters to accommodate and about six hundred thousand rubles to purchase. Along with this, today there is a lot of equipment, small in size and very cheap in production cost, for processing plastic bottles at home.

Such equipment does not require a lot of space to be placed; it is easy to rebuild it to change the products being produced; you can do it yourself. Naturally, it will not provide the opportunity to earn millions every month, but it will make a startup for converting plastic raw materials accessible to almost everyone and will serve as the foundation further development similar business.

Complete plastic bottle recycling line includes:

shredder;
agglomerator;
extruder

This set of units will ensure complete recycling of plastic bottles.

Shredder

This unit is designed for shredding plastic products. The resulting small plates of plastic are called flex. Industrially manufactured devices are quite expensive.

For example, the simplest crusher AMD-200D, which processes about fifty kilograms of feedstock per hour, will cost about one hundred and thirty-five thousand rubles. But making such a unit with your own hands won’t take much work.

Those interested will find the drawings useful:

If conditions permit and it is possible to place baths in the room for washing the resulting flex and a centrifuge for drying, you can limit yourself to its production. Today, according to the Flagma company, such material is sold from thirty-five to forty-nine rubles per kilogram, and bought from twenty to thirty-five rubles per kilogram.

Agglomerator

This unit is intended for sintering flex. The cost of the cheapest industrial designs is about two hundred thousand rubles. Therefore, it is not surprising that craftsmen make such units on their own. Of course, it is impossible to manufacture such a unit from scratch without milling and turning. However, you can use the drawing and ask your friends who work at the factory to make the necessary parts.

Many who organize the conversion of plastic bottles in garages and other utility rooms outside the attention of government agencies monitoring compliance with sanitary and environmental standards use existing electric furnaces as the working chamber of the agglomerator, since the flexible begins to sinter at temperatures starting from 180˚C. The most popular are Dave Hakkens agglomerators.

Extruder

This unit is a device for obtaining finished products or granules used subsequently for processing. Screws feed the flakes into the chamber, where they heat up and become plastic, until they liquefy. Passing through the filter, the plastic is cleaned and, passing through the extruder, takes the form of threads. These threads can be used for various products, or can be cut and sold.

Dave Hakkens offers homemade extruders that are combined with a press and produce any product that fits the mold. In the unit, the flex is heated to an almost liquid state and fed into the mold by screws under pressure.

What can be made from PET bottles

For people with creative imagination, plastic bottles are an inexhaustible source of inspiration.

You can also make strong ropes from plastic bottles. To do this you will need a “bottle cutter”. Craftsmen make this simple device from a blade, several washers, mounted on a wooden base.

When assembled, the bottle cutter looks like this.

Reels on which threads obtained from PET bottles are wound can also be made from bottle necks. First, cut off the necks of two bottles and the tops of two caps. The cut caps are fastened onto the rod, onto which the cut necks are then screwed; holes are made in the necks with a hot nail, through which the beginning of the thread is passed and, after tying a knot, it is fixed.

The resulting tapes can be used not only to make ropes, but also to make tubes from them. To do this, a strip cut from a plastic bottle is passed through a hole of the required diameter for the tube and, when heated, begins to be pulled through it. The principle of operation is clear from the photo.

It is quite possible that such a mini-business would be suitable for someone, the equipment requiring only a bottle cutter with reels and premises, such as the production of brooms and brooms from plastic tapes. How such products are made can be easily understood from the picture.

Perhaps many people will think that the business on bottle tapes is very small, not worth attention. However, in India it is serious business. Several vertically placed bottle cutters are used, the cut strips are wound on reels that rotate from a mechanical drive. One worker installs bottles on bottle cutters and ties the resulting strips, the second worker controls the speed of rotation of the reels on which the strips are wound, from which ropes are subsequently produced.

IN lately V southern countries Roof tiles made from PET bottles are becoming increasingly popular. The molten flex is mixed with a mineral filler (fine sand fractions) and filled into molds through an extruder. In countries former USSR such a business is just beginning, so the field for the activities of craftsmen is quite wide.

Paving slabs, chain-link mesh, greenhouse walls and much, much more are also made from plastic bottles.

But no matter what the entrepreneur decides to manufacture from such recyclable materials, success, as in any business, will depend on the literacy of drawing up a business plan. Such a document will not only allow you to organize knowledge and build a system of actions, but can be useful if you need to attract investment money.

Principles of writing a business plan

Like any other business plan for the organization and operation of an enterprise aimed at processing plastic bottles and other plastic products, it is drawn up in accordance with the requirements for such documents by the reviewing specialists. This must be taken into account, because a business plan is prepared not so much for oneself, but for those who, on its basis, will allocate the money needed to turn the idea into practice. Financial specialists are the most picky. If you yourself don’t know something thoroughly, you will definitely turn to specialists to get an assessment of the proposed document. Therefore, the document being created must comply as much as possible with accepted standards, since, as they say, you meet people by their clothes.

Before writing, you need to clearly understand that a business plan, in essence, is just written explanation the proposed project, the amounts required for its implementation, as well as the optimal time frame for implementation. This approach to the matter will immediately clarify what is main and what is secondary, what needs to be emphasized and what needs to be relegated to the background.

Information about the project of the future enterprise is divided into several sections:

Section I. Front page. Preamble information about the name of the enterprise, its form of ownership and address is posted here, the name of the proposed project is posted, telephone numbers and addresses are posted email. The date of preparation of the document is indicated and information is provided on the need to calculate cash costs and profits, which are included in the document or placed in a separate appendix.
Section II. This section containing copyright information is often referred to as the “Confidentiality Memorandum.” It sets out information about the authors of the business plan materials and their rights, obligations regarding non-disclosure of information received without the author's consent, as well as obligations to return the business plan after reading it if the decision on it is not positive.
Section III. This section is often called the “Summary”. This section briefly outlines the entire business plan and reveals the essence of the project. It is recommended to create this section after writing the entire business plan and arrange the information following the following structure:

project description;
resource provision;
ways and means of implementation;
answer to the question - what is unique about the project;
required investment amount;
projected profit;
ways to return money to investors;
effectiveness of the proposed project.

Section IV. Project goal. This section describes the intended purpose of the proposed business, describes the services or goods supplied to the market, indicating the benefits that customers will receive. For this purpose, the advantages of the manufactured products are described in detail. If there is their uniqueness - at the moment should be described as thoroughly and extensively as possible. If used latest technologies- it is necessary to indicate how copyright will be implemented.
Section V Market analysis in the area of the proposed business. Here the results of marketing research regarding the products offered are presented, and the activities of competitors are analyzed. If, when writing a business plan, there is no uniqueness of the proposed business in a given region, the emphasis is on reducing costs through the use of new technologies, reducing energy costs, personnel, and so on. It is imperative to take into account that today there are practically no areas that are no longer covered by business, therefore, having found competitors, you need to justify why the proposed business is more attractive.
Section VI. Position of the enterprise being created in the industry. Here the main characteristics of the enterprise are described and, based on their analysis, the place of the planned production or trade in the existing industry is noted. The preferred form of ownership of the enterprise is indicated and what costs will have to be incurred to create it. The section also contains information about:

company address;
the type of premises required, indicating whether it already exists or needs to be purchased, whether repairs are necessary or not;
economic performance indicators;
temporary characteristics of the specifics of production activities.

If the business is planned to be started from scratch, the presence or absence of experience in this area of the proposed management is indicated. The manager's lack of experience in the proposed field is a very negative characteristic and, as a rule, initiates the refusal of third-party investors.

Section VII. Product Description. The section is created after an analysis of the existing market. Based on the analysis, a conclusion is drawn about the advantages of the proposed product and the competitive ability of the company. Product samples or their photos and a description of technical characteristics must be present in this section or attached to it. If several units of a product are produced, each of them is described in detail. Structurally, the section is divided into several subsections:

the name of the product, as well as its description;
purpose and areas of use;
technical specifications
competitive advantages;
presence or absence of copyrights;
environmental friendliness of the product or lack thereof;
quality certificates;
service and operation.

Section VIII. Sales of products. The section contains a marketing plan for the sale of the manufactured product. Such a plan should include:

market behavior patterns;
reasoned explanation of the quantity of products purchased by customers;
describes the methods used to influence demand;
describes the methodology for calculating prices;
information on methods of sale is provided;
indicated legal status main consumer.

Any material on organizing a business includes governing council- find a consumer. This is what a marketing plan is designed to do. This structural unit is subject to close study, so it is necessary to indicate in detail:

what criteria for evaluating the product from the consumer’s point of view were studied when writing the business plan;
what place in the supply chain occupies the client to whom the goods are supplied.

This section is based on the characteristics with which the product is assessed not by the manufacturer, but by the consumer. It is very desirable to provide an analysis of the evaluation of a similar product by competitors’ consumers and, based on this information, justify the attractiveness of your own product. This section also includes the logistics concept - how and to whom the goods are delivered, who is responsible for sending them. A strategy for conducting advertising campaigns is given. Prices and sales volumes are indicated by time periods. Payback periods and profitability are calculated.

Section IX. Production plan. The material in this section requires close attention and elaboration, especially in cases of planning to open a company from scratch. The section describes and analyzes in detail the chain of production of the product, examines the premises and the equipment located in it, its location, transportation routes for raw materials, parts, finished products, and so on. Not only a comprehensive description of production is provided, but also control over its processes, it is indicated which aspects will be entrusted to subcontractors, and the reasons for their choice are indicated. This section describes all production costs, and also calculates the cost of the product, provides a cost estimate, and indicates variable and fixed costs. The information is arranged following a specific structure:

production structure;
technology used;
what kind of premises are needed;
staffing needs;
raw materials;
equipment characteristics;
production capacity;
cost estimate;
selection of subcontractors;
cost analysis.

Section X Organizational plan. The section describes organizational issues, lays out regulatory documents and describes how they will be implemented.
Section XI. Financial planning. Information about the required financial investments and their expenditure is posted here. The timing of financial movements, the timing of stages, and the finances for working capital are also outlined. It is also indicated if there is a need to attract loans and how they will be repaid. In this section, the conclusion of the above is an analysis of the effectiveness of the company and its work. Structurally it looks like this:

profit received;
tax payment structures;
need for investment;
loan servicing;
description of project effectiveness

Section XII. Risk analysis. The section contains information about difficulties that may hinder the implementation of the project. This includes difficulties caused by legislation, weather, competitors, and so on. The more complete the list indicating ways to solve difficulties, the higher the assessment of the plan as a whole.

The difficulties of doing business include the wrong choice of employees - success depends not on the degree of familiarity, but on professionalism.

To assess the degree of risk, the following analysis methods are used:

statistical method (based on the study of known statistics);
method of analogies - analysis based on studying the development of similar projects;
expert method, the basis of analysis is expert opinion;
modeling - the response to external influence is analyzed.

A description of possible risk countermeasure systems is also provided, and possible guarantees are named - government authorities, product guarantees, bank guarantees, and so on.

Section XIII. Applications. Here we collect documents that are not included in the planning description, but which are important, copies of contracts for similar products, data sources, price lists, etc.