Challenge:
Processing PP/PE film with heavy oil contamination (up to 60%) is a primary challenge in the recycling industry. This material is often rejected, landfilled, or processed at extremely low efficiency, as standard washing lines fail to properly degrease and prepare the material.
Our Solution:
Energycle provides a turnkey, industrial-grade washing and densification line engineered to convert this low-value, highly contaminated scrap into high-profit, extruder-ready material. Our system is specifically designed to tackle the challenges of heavily contaminated PP/PE film, improving both the quality and profitability of recycled plastics.
Key Process Flow
- Shredding
Raw material is shredded for uniform size and consistent washing. This ensures that the material is appropriately sized for the washing process. - Intensive Degreasing (Hot Wash)
The core of our solution. Material enters a Hot Washing Tank with automated chemical (e.g., caustic soda) dosing. The high temperature and agitation dissolve and strip the 60% oil content. Our Plastic Film Squeezertechnology ensures that the greasy contaminants are effectively removed. - Friction Washing
A high-speed friction washer further scrubs the material to remove any residual oil and dirt. This advanced washing technology ensures thorough contaminant removal. - Rinsing & Separation
Multi-stage rinsing and floating separation tanks remove chemicals and separate any remaining non-PE/PP contaminants, ensuring that the final material is purified for densification. - Dewatering (Squeezer Dryer)
The clean, wet film is fed into a Squeezer Dryer (Screw Press), which mechanically reduces moisture content to < 3-5%. This is a critical step for ensuring high-efficiency densification. - Densification (Agglomeration)
The clean, dry, fluffy film is immediately transferred to the Agglomerator (Densifier). This machine uses friction and heat to transform the light-volume scrap into high-density, semi-plasticized granules, making the material ready for extrusion.
Benefits for Buyers:
- Unlock New Profit Streams: Process the cheapest, most difficult contaminated film on the market. By effectively recycling heavily contaminated PP/PE films, buyers can unlock cost-effective raw material sources that others overlook.
- Maximize Extruder Throughput: Our densified granules provide stable, high-volume feeding, preventing extruder “bridging” or “starving,” ensuring smooth, uninterrupted production.
- Lower Operational Costs: Fully automated systems reduce labor costs, and our high-efficiency washing minimizes water and chemical consumption, offering significant savings over traditional methods.
- Superior Pellet Quality: Clean, degreased, and densified material results in higher-quality final pellets. The use of Agglomerators ensures that the densified material meets the necessary specifications for high-quality production.
Energycle’s Plastic Film Squeezer and densification solutions are designed to tackle the toughest plastic recycling challenges, offering a high-efficiency system that transforms contaminated films into valuable raw materials. This advanced line maximizes profitability, enhances pellet quality, and ensures that recyclers can tap into new revenue streams.
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