DRV Technology for Continuous Vacuum Drying

A recent installation for a leading preform producer in the beverage sector highlights not only engineering excellence but also how technology can actively support the circular economy.

An integrated process vision

At the core of the system is centralized material management, built around six external silos of 250 m3 each. These are connected to a fully automated conveying network, with flow controlled by PLCs. An intuitive interface and advanced monitoring tools ensure complete traceability, order, and operational safety. Material handling takes place on technical mezzanines, optimizing floor space and simplifying maintenance. Every design detail supports maximum hygiene, flexibility, and rapid production changeovers.

DRV Technology: Continuous Vacuum Drying for rPET

The technological centerpiece of the plant is the DRV series - a multi-patented continuous vacuum drying technology developed in-house by PET Solutions.

Specifically engineered for rPET, DRV addresses critical challenges such as residual moisture, contaminants, material thermal history, and sensitivity to high processing temperatures. The vacuum-based system enables deep, uniform drying while drastically reducing residence time at high heat. The result: no degradation, yellowing, or pellet sticking.

The process is carried out through four sequential hoppers, each with a dedicated function:

• Pre-heating - warms the resin and removes surface moisture.
• Thermal activation - brings material to the optimal temperature for vacuum treatment.
• Vacuum drying - applies low pressure to remove residual moisture and contaminants.
• Thermal finishing: - fine-tunes resin temperature before feeding it to injection molding machines

A concentrate of efficiency and simplicity

DRV technology is designed to combine high performance with low resource consumption. Key advantages include:

• Fast material changeover – complete in just 2 hours, 65% faster than conventional systems.
• No molecular sieves - vacuum pumps remove moisture directly, eliminating desiccants.
• No oil condensers - condensable compounds are extracted under vacuum, removing the need for condensers.
• Low maintenance - only one filter, with no heat exchangers or sieves required.
• Advanced controls - proprietary software regulates vacuum and temperature, boosting efficiency and cutting energy use by 24%.
• User-friendly interface - touchscreen interface, self-cleaning system, and easy component access
• Integrated safety - valves, sensors, alarms, and interlocks ensure maximum reliability.

Brick-style modularity: Tailored to every plant

One of the DRV system’s greatest strengths is its modular “brick-style” design. Each hopper can operate independently and be installed vertically or horizontally, even on differant levels. This ensures seamless integration into existing facilities without compromising performance.

The layout is flexible and scalable: production capacity can be increased, or new materials introduced, simply by adding modules—without the need for a complete redesign.

A strategic edge in rPET processing

Processing rPET demands consistent quality despite variable input material. The DRV system guarantees stable, homogeneous drying while preventing polymer degradation, volatile compound formation, and reduced product performance.

The ability to process two materials simultaneously, thanks to independent hopper operation, adds significant productivity benefits.

Ready for the Future

After more than four years of intensive testing, the DRV series is a proven solution now running in multiple beverage sector plants worldwide. Its combination of sustainability, flexibility, and product quality sets a new benchmark for companies aiming to adopt rPET on a systemic, competitive scale.

Concrete innovation for the circular economy

With DRV technology and its modular plant design approach, PET Solutions shows that innovation is not only about performance but also about making conscious choices.

Reducing resource consumption, enhancing efficiency, and simplifying the handling of complex materials: this is how the recycled plastics industry can become more sustainable while meeting both market expectations and environmental challenges. PET Solutions is helping lead the way toward that future.

www.petsolutions.it