In the production of polyester fibers from recycled polyethylene terephthalate (rPET), the drying and crystallization of plastic bottle flakes are crucial for ensuring the consistency and strength of the finished fibers. Traditionally, rPET production lines still rely on vacuum drum dryers, which have been suffering from issues including agglomeration, uneven heating, and high energy demand. In this work, we developed a novel continuous system that is capable of achieving a total throughput of 1300 kilograms per hour. The design consists of a pulsating fluidized-bed crystallizer and two cylindrical drying towers operating in parallel. Structural performance of the main systems was analyzed using finite element analysis under material load, thermal expansion, and internal air pressure. Airflow behavior and temperature distribution inside the units were studied using Computational Fluid Dynamics (CFD) models, where the flake bed was treated as a porous medium based on experimental bulk density and pressure drop. Results showed that the drying tower maintained a minimum safety factor above 3 under full-load conditions, while the crystallizer also remained well within allowable stress limits. Additionally, flow-field analysis results indicated stable countercurrent airflow, adequate mixing near the inlet region, as well as acceptable axial temperature gradients for moisture removal below 50 ppm. Compared with conventional drum drying, we believe the continuous configuration simplifies operation and reduces heat loss. Our design approach has been combined with analytical calculations on structural and flow simulation, and can be beneficial when applied to similar rPET drying applications.