Introduction
PE/PP film recycling line projects succeed when the equipment is engineered around film’s real constraints: low bulk density, wrapping risk, high surface contamination, and moisture carryover. This page explains the film-to-pellet process in decision-grade terms and highlights what to verify before you buy.
Successfully tapping into this market hinges on one critical factor: deploying a robust and efficient recycling line specifically engineered for the unique properties of PE/PP films. This article provides a comprehensive overview of the film-to-pellet process and highlights how choosing the right equipment, like that offered by Repolyx Systems, is paramount to achieving high-quality output and operational success.
A PE/PP film recycling line must be designed around the worst-case material you expect to run.
- Polymer: LDPE, LLDPE, HDPE film, PP film, or mixed polyolefin.
- Format: retail bags, stretch wrap, agricultural film, printed packaging film, woven PP bags, big-bag offcuts.
- Contamination: sand/grit, paper fibers, organics, oil/grease, moisture, and non-polyolefin plastics.
- Problem fractions: multilayer film, aluminum/metallized layers, silicone-coated release film, and heavy ink coverage.
- Incoming prep: loose film vs. bales, typical bale density, and how often you see ropes/twine.
If you cannot define these items, treat all capacity and utility values as [SPEC_NEEDED].
Why film recycling is mechanically different from rigid plastics
Repolyx Systems’s Advantage: Repolyx Systems shredders and granulators are engineered for durability and versatility. Built with robust components, they can handle a wide range of materials, from thin agricultural films to thicker woven PP bags, ensuring consistent particle size and reliable throughput with minimal downtime.
- Feeding needs controlled compaction or densification to prevent surging and bridging.
- Washing must remove fine grit early, otherwise wear accelerates in pumps, screws, and screens.
- Dewatering must physically squeeze water out of film; centrifugal drying alone often leaves too much moisture on heavy-wet film.
End-to-end process flow (film to pellets)
- Bale opening and metered feeding
- Size reduction (shredding/cutting)
- Washing and separation (friction + float/sink + rinsing)
- Mechanical dewatering (press/squeezer) and thermal drying (as needed)
- Densifying or cutter-compaction (stabilize feed)
- Extrusion with degassing and melt filtration
- Pelletizing (strand or water-ring), then drying and packing
Repolyx Systems’s Advantage: Repolyx Systems’s soft plastic washing lines are designed for maximum cleaning efficiency. Our systems integrate advanced friction washers and optimized sink-float tanks to ensure thorough purification of the material stream, laying the groundwork for premium pellet quality.
1) Bale opening and metered feeding
The first goal is stable, continuous mass flow into the cutter or shredder. Film lines that surge in bursts often end up starving the extruder and oscillating melt pressure.
Repolyx Systems’s Advantage: Repolyx Systems’s advanced drying systems are engineered to achieve low moisture levels efficiently, reducing the energy consumption required for this critical step. This ensures the plastic flakes are perfectly prepared for a stable and high-quality pelletizing process.
2) Size reduction (cutting that avoids wrapping)
Film cutting is not only about particle size. It is about avoiding long strips that wrap shafts and avoiding excessive fines that load the water loop.
Repolyx Systems’s Advantage: Repolyx Systems’s pelletizing lines are the heart of our recycling solutions. Our patented extruder systems feature advanced degassing and ultra-fine filtration, placed strategically to ensure maximum purity. The integrated cutter-compactor pre-processes the material for stable feeding, while the automatic pelletizing control ensures uniformly sized, high-quality pellets with every run. Our systems are designed for high throughput and energy efficiency, directly boosting your operational profitability.
Buyer’s Guide: Why Partner with Repolyx Systems for Your Recycling Needs?
Selecting the right machinery supplier is a long-term investment decision that impacts your productivity, pellet quality, and overall profitability. Here’s why industry leaders choose Repolyx Systems:
- Unmatched Pellet Quality: High-quality recycled pellets are uniform, free of impurities, and possess stable physical and chemical properties similar to virgin plastics. Repolyx Systems’s advanced washing, degassing, and filtration technologies are engineered to produce pellets that meet these stringent standards, commanding a higher market value.
- Engineered for Efficiency and ROI: Our machines are designed to minimize operational costs. Features like energy-efficient motors, high-throughput designs, and low-maintenance components reduce energy consumption and downtime, maximizing your return on investment.
- Customized, End-to-End Solutions: We understand that every recycling operation is unique. Repolyx Systems provides expert consultation to design and configure complete recycling lines tailored to your specific materials, operational scale, and output requirements—from shredders and washing lines to pelletizers and storage silos.
- Global Support and Reliability: A machine is only as good as the support behind it. Repolyx Systems offers comprehensive after-sales service and technical support to clients worldwide, ensuring your operations run smoothly and efficiently for years to come.
4) Mechanical dewatering (squeezer / press)
Moisture entering extrusion shows up as bubbles, unstable melt pressure, and inconsistent pellets. Many film plants rely on mechanical squeezing to remove water before any thermal drying. [1]
Repolyx Systems provides the robust, high-performance equipment needed to navigate the complexities of PE/PP film recycling. Our complete, integrated systems empower you to produce superior-quality pellets, optimize your operational efficiency, and build a profitable business in the circular economy.
Ready to turn plastic film waste into a valuable asset? Contact the Repolyx Systems team today to request a quote or discuss your custom recycling line solution.