Film Densifying Machine for PP/PE: Shred, Wash, Squeeze — US-Ready
Loose film is mostly air — you pay freight on volume, not weight. This line shreds, washes, and squeezes PP/PE film into dense, low-moisture output (~350–410 kg/m³, ~3% moisture) that ships economically and feeds extruders or chemical recycling units steadily. Built for film recyclers, MRFs monetizing film bales, and pyrolysis feedstock preparers. Configured for North American plants: 480V 3-phase power, UL 508A panel option, US spare-parts support, and on-site commissioning.
A Densifying Line Configured for US Operating Reality
Buying recycling equipment from overseas raises the same five questions on every US project. We answer them in the proposal — not after the deposit.
480V 3-Phase Power
Motors, heaters, and controls specified for 480V/60Hz 3-phase — the US industrial standard — instead of a generic "customer voltage" footnote.
UL 508A Panel Option
Control panels available built to UL 508A industrial control panel standards for straightforward inspection and insurance sign-off.
US Spare-Parts Support
Wear-part kits (shredder blades, granulator knives, squeezer screw segments, screens) defined per line, with stateside stocking so a worn screw doesn't idle your plant for six weeks.
On-Site Commissioning
English-speaking engineers for installation supervision, commissioning, and operator training — plus remote diagnostics after handover.
Import & Duty Guidance
We walk through landed-cost planning with you — freight, Section 301 duty considerations, and documentation — before you commit.
Dual-Unit Documentation
Layouts, manuals, and spec sheets in kg/h and lbs/hr, metric and imperial dimensions — written for the crew that will actually run the line.
The Film Logistics Problem, in Numbers
Film recycling economics are decided before the extruder — in the trailer. Here's why densifying pays.
Loose Film Economics
- Bulk density ~30–60 kg/m³ — a 53-ft trailer cubes out long before it weighs out. You ship air.
- Freight per ton is brutal — on long US hauls, transport can exceed the material's value.
- Feeding is unstable — loose film bridges in hoppers and surges in extruders; throughput swings with it.
- Moisture rides along — washed film at ~30% moisture means you're drying (or discounting) water weight.
What Densifying Changes
- ~350–410 kg/m³ bulk density — roughly 8–10× denser; trailers weigh out instead of cubing out.
- Freight cost per ton drops — the single biggest margin lever for regional film collectors.
- Steady feeding — dense, uniform output meters consistently into extruders and pyrolysis reactors.
- ~3% moisture (washed film) — the squeezer mechanically presses water out; less thermal drying, lower energy.
Working Principle & Process Flow
Film bales are opened, shredded and granulated, then washed and separated. The squeezer/densifier compacts the cleaned material — squeezing out water and air — into dense output for transport and stable feeding.
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Bale Opening & Shredding
Breaks film bales into manageable pieces; first size reduction for stable downstream handling.
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Wet Granulation
Cuts shreds into uniform flakes while water reduces friction and starts the washing process.
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Sink-Float Separation
Removes heavy contamination — mud, sand, stones — while PP/PE film flakes float on for continued processing.
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Friction Washing (Optional)
For dirty post-consumer streams: high-speed scrubbing strips surface contamination before densifying.
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Squeezer / Densifier
The core stage: a screw press compacts flakes, squeezing out water (~30% → ~3% on washed film) and air — producing dense, flowable output.
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Final Sizing (Optional)
An additional granulator reduces any oversized lumps to match your extruder or reactor feed spec.
Where Densified Film Makes Sense
Three buyer profiles where densifying is the right answer — and one where it isn't.
Chemical Recycling Feedstock
Pyrolysis and dissolution operators need dense, consistent, low-moisture feed. Densified film meters into reactors steadily — loose film doesn't.
Regional Film Collectors
Collecting film across a multi-state footprint? Densifying at the collection point is what makes long-haul freight pencil out.
Pre-Step to Pelletizing
Dense, low-moisture feed stabilizes extruder throughput and cuts the drying energy before pelletizing.
When to Skip It
Pelletizing clean film on-site with no transport leg? Go straight from washing to extrusion — densifying adds a step you don't need.
Densified Output vs. Conventional Film Handling
What changes when film goes through the squeezer — and what doesn't.
| Item | Conventional Handling | Densified Output |
|---|---|---|
| Bulk density | ~30–60 kg/m³ loose; trailers cube out | ~350–410 kg/m³; trailers weigh out |
| Freight economics | Paying to ship air on long hauls | 8–10× denser; freight cost per ton drops sharply |
| Feeding stability | Bridging and surging in hoppers and extruders | Uniform, flowable output meters consistently |
| Moisture (washed film) | ~30% after dewatering; thermal drying needed | ~3% after the squeezer; less drying energy |
| What it doesn't do | Densifying is not pelletizing — output is a dense intermediate, not finished pellets. And it doesn't clean: dirty film still needs the wash train first. | |
Models, Capacity & Investment Guide
Three standard models cover most US film projects. Final pricing depends on wash intensity, contamination level, and automation — send your bale spec and we’ll price your exact configuration.
| Model | RTM-200 | RTM-500 | RTM-1000 |
|---|---|---|---|
| Capacity | 200 kg/h (440 lbs/hr) | 500 kg/h (1,100 lbs/hr) | 1,000 kg/h (2,200 lbs/hr) |
| Installation power | 160–200 kW | 200–240 kW | 400–450 kW |
| Knife material | SKD11 | SKD11 | SKD11 |
| Operators | 2–3 | 2–3 | 2–3 |
What moves the price: wash train intensity (sink-float only vs. added friction washing), squeezer size, granulator configuration, and automation. Every proposal itemizes these so you can see exactly what you’re paying for — and what you can defer.
What It Costs to Run
The line items to budget before you sign.
Power
160–450 kW installed depending on model; the squeezer screw and granulators are the big loads. We provide a connected-load schedule per model in the proposal.
Wear Parts
Shredder blades, granulator knives (SKD11), and squeezer screw segments. Sand-heavy streams accelerate wear — the wash train upstream is what protects them. Kits stocked in the US.
Water
Wet granulation and washing use recirculated water with filtration; makeup volume depends on contamination level and local discharge rules.
Labor
2–3 operators per shift at any model size. Bale intake and quality checks are the main manual tasks.
What We Need From You for a Real Number
A "price for the line" without your feedstock is a guess. Send these five things and the proposal comes back itemized.
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Bale photos or video
Film type, bale density, visible contamination — a 30-second phone video tells us more than a spec sheet.
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End use
Chemical recycling feedstock, pre-step to your pelletizer, or densified product for sale? Each has a different spec.
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Target capacity
kg/h or lbs/hr of densified output — not bale input. We size the squeezer to output.
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Contamination level
Sand, soil, labels, multi-layer film — decides whether you need the friction-washing stage.
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Site utilities
Available power (amps at 480V), water supply, and floor space with ceiling height.
Frequently Asked Questions
Straight answers to the questions US buyers ask before requesting a proposal.
Is densified film suitable for chemical recycling?
Does densifying replace pelletizing?
Do I need washing before densifying?
What bulk density and moisture can I expect?
Can it run woven bags or raffia too?
Can the line run on US 480V 3-phase power?
Are the control panels UL-listed?
Do you stock spare parts in the US?
What does installation and commissioning look like in the US?
What do you need from me for an accurate proposal?
Send Your Bale Spec — Get an Itemized Line Proposal
Photos or video of your typical film bales plus target capacity. We respond with a configuration and machine-by-machine pricing — not a lump sum.