Innovation-Driven, Value-Upgraded: Boretech's ES Process Usher in a New Era of High-Value Recycled Plastics

As the global concept of circular economy is put into practice in greater depth, the recycled plastics industry is undergoing a strategic transformation from "quantity" to "quality". Boretech's new-generation ES process provides a practical and feasible solution for the high-value application of recycled PET (rPET), emerging as a crucial model for driving quality and efficiency improvement in the industry. This process not only enables the high-quality recycling of waste plastics but also significantly enhances production efficiency and product applicability through process integration and intelligent management, helping enterprises strike an optimal balance between environmental and economic benefits.

Boretech serves a Vietnamese customer, a leading local plastic brand dedicated to becoming a major supplier of rigid plastic packaging and household products in the ASEAN region. Adhering to the concept of sustainable development, this enterprise aims to reduce reliance on virgin polyester, alleviate environmental burden, and contribute to the long-term sustainable social and economic development by converting waste plastic bottles into high-quality rPET. To achieve this goal, Boretech has provided it with a complete set of PET recycling solutions, adopting the latest ES process with an annual processing capacity of 20,000 tons. This production line is equipped with enhanced washing efficiency and a fine circulating water filtration system, ensuring the produced rPET has excellent quality and stable performance. The subsequent food-grade pelletizing can be used in its own beverage packaging factory.

Boretech also has a South Korean customer that is already engaged in the recycling and washing of PET bottles and owns downstream pelletizing and viscosity-increasing equipment. However, after gaining an in-depth understanding of the technical scheme and innovative details of the ES process, the customer showed strong interest in its outstanding performance and finally decided to introduce this advanced process to further improve production efficiency and product quality.

Centered on high modularization and process integration, and enhanced by intelligence, Boretech's ES process achieves an efficiency of "1+1>2". In terms of floor space, compared with traditional process schemes, the ES process reduces nearly 1/4, greatly helping customers cut down investment in land and plant construction. Meanwhile, the pulse washing technology in the ES process boasts excellent cleaning ability, which can effectively remove impurities from bottle flakes, with almost zero chemical residue. The bottle flakes after hot washing can increase the filtration performance of subsequent pelletizing by 25%, ensuring the output of high-quality recycled PET bottle flakes. These bottle flakes are not only suitable for bottle-to-bottle production but also can meet the strict production requirements of superfine denier fibers. Benefiting from the highly automated design, while improving efficiency, the ES process reduces the on-site labor demand by 1/3 compared with traditional processes, optimizes the energy consumption per unit production, and significantly lowers production costs. In addition, guided by environmental protection and sustainability, the equipment reduces the energy consumption per ton of finished products by 13.3% through the on-line fine filtration of chemical water, setting a new benchmark for green production while realizing efficient cleaning.

In general, Boretech's ES process features "four highs and two lows": high cleaning quality grade, high level of automation and informatization, high finished product yield, high investment cost-effectiveness; low operational labor demand, low unit output cost.

Beyond the successful practice of the ES process, Boretech has also extended its exploration of high-value to the more challenging pre-washing links of PET trays and flakes. Aiming at the long-standing bottlenecks in the tray recycling industry, such as "highly compacted, complex material composition, excessive adhesive labels and glues, and greater brittleness", Boretech has developed a targeted PET tray washing system. Through four core technologies—de-baling&loosening,intensive hot washing, label removal, and improve recycling yields—the system meets the requirements of high quality and low loss. The final rPET quality meets the FDA and EFSA food-grade standards, opening up a new channel for the high-value utilization of tray recycling. At the same time, Boretech's Compact Prewasher integrates de-labling, separation, washing, and de-watering into one, greatly reducing energy consumption and floor space. With a label removal rate of over 99%, a label scrapping rate of over 95%, and a material loss rate of less than 1%, it significantly improves the purity of flakes and production efficiency. Boretech's PET tray washing line and Compact Prewasher will also be exhibited at the upcoming K Show(H9D56,October 8–15, 2025), demonstrating its latest achievements in the field of high-value recycled plastics to the world.

Boretech's innovative process not only reflects the value-added of technology integration but also provides key technical support for promoting the high-value application of recycled plastics by comprehensively improving production efficiency and product quality, helping customers achieve a win-win situation between sustainable development and economic benefits.