Customer Overview

KuibyshevAzot is a well-known large-scale chemical manufacturing enterprise in Russia, primarily producing PA6 synthetic fibers and related chemical products. Its production processes continuously generate substantial amounts of fiber waste, spinning trimmings, and non-conforming products. Adhering to the principle of circular production, the company aims to achieve closed-loop internal recycling of production waste, reduce its reliance on purchasing virgin PA6 raw materials, and simultaneously meet green production requirements.

Core Pain Points

1. PA6 fiber waste is fluffy and bulky; conventional feeding methods often lead to bridging and slippage, resulting in unstable material input, significant fluctuations in production capacity, and difficulty in ensuring consistent production efficiency.

2. Conventional pelletizing equipment, operating at high temperatures, can cause thermal degradation of PA6 materials, leading to a sharp decline in intrinsic viscosity. Consequently, the recycled material fails to meet performance standards and can only be sold externally at low prices.

3. The cost of procuring virgin PA6 raw materials remains high, while the external disposal process for industrial waste is cumbersome and expensive—both of which conflict with the company’s goals of cost reduction, efficiency improvement, and green transformation.

Purei’s Customized Solution

Addressing the customer’s specific needs in chemical fiber production, Purei has provided an ML130 plastic pelletizing line, specially tailored to efficiently recycle PA6 fiber waste:

• A dedicated pre-compression feeding system compacts the fluffy fiber waste before smoothly feeding it into the screw, fundamentally resolving issues of bridging and slippage during feeding and significantly improving feed uniformity.

• An extrusion process featuring precise low-temperature control, combined with a vacuum degassing system, ensures thorough melting and plasticization while minimizing thermal degradation, thereby preserving the core properties of the raw material.

• A multi-stage, high-precision filtration system thoroughly removes oils, lubricants, and fine impurities embedded in the waste fibers, guaranteeing the purity and quality of the recycled pellets.

• The entire machine is adapted to Russian local industrial voltage standards and production conditions, supporting continuous, stable operation 24/7.

Quantified Project Outcomes

• The equipment achieves a stable production capacity of 500 kg/hour, yielding 12 tons of recycled PA6 pellets per day under continuous 24-hour operation.

• 100% of the plant’s fiber waste and production trimmings are now recycled internally, reducing annual purchases of virgin PA6 raw materials by over 3,600 tons.

• The recycled pellets maintain an intrinsic viscosity retention rate of ≥90%, fully meeting the key performance criteria required for spinning operations and enabling direct reuse in upstream production stages.

Customer Value

This project has helped the customer establish an internal closed-loop production system encompassing “fiber production – waste recycling – recycled reuse,” effectively lowering the cost of virgin raw material procurement while addressing compliance challenges associated with industrial waste disposal. It supports the company’s transition toward green, low-cost, sustainable production, setting a benchmark for in-plant resource circulation within Russia’s chemical industry.