Welcome to the trial run of our 500kg/hr plastic film washing and pelletizing line.
The process begins with shredding, where a single-shaft shredder is used to handle whole bales of PE plastic film with ease. Equipped with a powerful rotor and durable blades, the shredder breaks down bulky materials into uniform strips. A hydraulic feeding system ensures consistent operation without jams, delivering high efficiency and reliable output.
After shredding, the material is transported via a belt conveyor to the trommel, which removes impurities such as dirt, sand, and other debris. This screening step is vital for improving the cleanliness of the material. The cleaned film pieces are then conveyed to the crusher, where they are further reduced into smaller, uniform pieces, preparing them for the next stages of processing.
Next is the washing and densifying stage, a critical phase to ensure the material is thoroughly cleaned and ready for pelletizing.
The shredded film first enters the friction screw, where high-speed rotation scrubs away contaminants like grease, oils, and adhesives. This intensive cleaning step is essential for removing any residues left on the material.
The washed material is then transferred to the sink-float separation tank, where water is used to separate materials by buoyancy. Lightweight plastic films float to the surface, while heavier contaminants, such as dirt, glass, and metal, sink to the bottom for easy removal. This ensures the film is free of impurities before moving forward.
Once cleaned, the material proceeds to the squeezer, a specialized machine designed to remove excess water while compacting the film into a dense form. This step significantly reduces moisture content and prepares the material for efficient drying and pelletizing.
The final stage is pelletizing, where the cleaned and dried material is transformed into high-quality pellets.
In the water-ring pelletizing system, the plastic is melted and extruded through a die, forming continuous strands. These strands are then cut into uniform pellets by a high-speed rotating cutter. Immediately cooled in water, the pellets solidify to ensure consistent size and shape.
After cooling, the pellets are dewatered and pass through a screening system to remove any irregular pieces, ensuring the final product is uniform and durable. These pellets are now ready for reuse in manufacturing, contributing to a sustainable and circular economy.
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Frequently Asked Questions
What are the processing stages of this 500 kg/h line?
The line runs: (1) single-shaft shredding of whole film bales into uniform strips, (2) trommel screening to remove dirt, sand, and debris, (3) crushing into smaller uniform pieces, (4) friction-screw washing that scrubs away grease, oils, and adhesives, (5) sink-float separation by buoyancy, (6) squeezer densifying that removes water and compacts the film, and (7) water-ring pelletizing with dewatering and screening of the finished pellets.
What feedstock can this line process?
It is designed for whole bales of PE plastic film — bulky, baled post-consumer or post-industrial film. The single-shaft shredder with its powerful rotor, durable blades, and hydraulic feeding system breaks down whole bales with ease and delivers consistent, jam-free operation, so heavily compacted bales are not a problem.
How are contaminants removed from the film?
Cleaning happens in three layers: the trommel screens out dirt, sand, and loose debris; the friction screw uses high-speed rotation to scrub grease, oils, and adhesives off the film surface; and the sink-float tank separates by buoyancy — lightweight films float while heavier contaminants such as dirt, glass, and metal sink for easy removal.
Why is the squeezer stage important before pelletizing?
Film holds a lot of surface water after washing, and feeding wet, fluffy film into a pelletizer wastes energy and destabilizes extrusion. The squeezer mechanically removes excess water while compacting the film into a dense form, significantly reducing moisture content so the downstream drying and pelletizing stages run efficiently.
What does the water-ring pelletizing system produce?
The cleaned, dried film is melted and extruded through a die into continuous strands, which a high-speed rotating cutter chops into uniform pellets. The pellets are immediately water-cooled to solidify their size and shape, then dewatered and screened to remove irregular pieces — yielding uniform, durable pellets ready for reuse in manufacturing.
What utilities and space does the line require?
Plan for three-phase industrial power for the shredder, crusher, squeezer, and pelletizer drives, a reliable water supply and drainage for the washing stages, and floor space for the full multi-stage layout from bale infeed to pellet collection. Because this is a 500 kg/h configuration, the engineering team will confirm utilities and footprint for your site during quotation.