PE/PP Plastic Film Recycling Process & Machine Solutions: The Industrial Expert’s Guide

In the rapidly evolving Plastic Recycling Machine industry, processing PE (polyethylene) and PP (polypropylene) film is no longer just an environmental obligation—it is a significant business opportunity. From post-consumer shopping bags to industrial agricultural mulch, these soft plastics are abundant but notoriously difficult to process efficiently.

For recycling plant owners and machinery buyers, the challenge is clear: How do you turn light, fluffy, and contaminated film into high-density, high-value pellets that yield a profitable ROI?

At Rumtoo, we look beyond the basics. We understand that standard recycling lines often fail due to the unique low-density properties of plastic film. This guide dives into the technical best practices for recycling PE/PP films and how to select equipment that minimizes downtime and maximizes output.

Understanding the Material: The Challenge of Soft Plastics

Before optimizing your recycling line, it is crucial to address why PE/PP film behaves differently than rigid plastics (like HDPE bottles). These films present three main processing hurdles:

• Low Bulk Density: Films are voluminous but lightweight. Standard extruders struggle to “grip” and feed the material, leading to unstable output.
• High Moisture Retention: The large surface area traps water, requiring advanced drying technologies to prevent “foamy” pellets.
• Elasticity & Wrapping: Soft films can easily wrap around shredder rotors, causing jams if the blade design is not specific to flexible materials.

The Step-by-Step Professional Recycling Process

To produce premium recycled pellets (repro) that manufacturers actually want to buy, your process must be rigorous. Here is the industry-standard workflow optimized by Rumtoo engineers:

1. Shredding and Size Reduction

The process begins by reducing large bales of film into manageable flakes. For dirty agricultural or post-consumer films, we recommend Wet Crushing using a specialized plastic granulator. By spraying water into the cutting chamber, you pre-wash the material and reduce friction heat, which prevents the plastic from melting onto the blades and extends knife life.

2. Friction Washing and Separation

Once shredded, the film enters the washing phase to remove contaminants that degrade pellet quality:

• Sink-Float Separation: Utilizes water density to separate floating PE/PP from heavy contaminants like metals, rocks, or PVC (which sink).
• High-Speed Friction Washing: A critical step where centrifugal force aggressively scrubs off stubborn dirt, oils, and paper labels.

3. Advanced Drying (Squeezing)

Traditional hot air dryers are energy-inefficient for thin films. The modern standard is the Squeezer Dryer. This machine mechanically presses water out of the flakes—similar to wringing a towel—reducing moisture from roughly 30% to under 3%. This mechanical process saves massive amounts of thermal energy compared to heating alone.

4. Compacting and Pelletizing

This is where the magic happens. Clean, dry film flakes are too light for direct extrusion. Rumtoo’s Cutter Compactor Pelletizing System integrates three steps into one unit:

1. Densification: High-speed rotating blades cut and friction-heat the material, compacting it into a dense, semi-molten state.
2. Stable Feeding: The densified material is force-fed into the extruder screw by centrifugal force, eliminating “bridging” issues.
3. Degassing & Filtration: Vacuum zones remove volatile gases (from inks or moisture), while continuous screen changers filter out remaining impurities.

Comparison: Standard Lines vs. Rumtoo Integrated Solution

Choosing the right machine architecture determines your operational costs. See the difference below:

Feature	Standard Loose Feeding Line	Rumtoo Compact-Pelletizing Line
Feeding Mechanism	Passive Hopper (Prone to clogging)	Active Force Feeding (Cutter Compactor)
Material Density	Requires separate densifier machine	Integrated densification (All-in-one)
Energy Efficiency	Low (Heats cold material)	High (Uses friction heat to pre-warm)
Moisture Tolerance	Strict (< 1%)	Flexible (< 5% is acceptable)

Overcoming Common Recycling Challenges

Even with good machinery, operators face daily challenges. Here is how Rumtoo technology addresses them:

Challenge: Printed Inks and Volatiles

The Problem: Heavily printed films release gases when melted, creating porous, low-quality pellets.
The Solution: Rumtoo utilizes Double-Vacuum Degassing systems. By creating a high-vacuum zone within the extruder barrel, trapped gases and moisture are extracted before the plastic is formed, ensuring solid, glossy pellets.

Challenge: Variable Material Quality

The Problem: Post-consumer waste varies in contamination levels, which can overload motors.
The Solution: Our intelligent PLC Control System monitors the amperage of the compactor motor. If the load gets too high, it automatically adjusts the feeding speed, preventing jams and protecting your investment.

Why Choose Rumtoo for Your Plastic Recycling Business?

Investing in a Rumtoo recycling machine is investing in reliability. We don’t just sell equipment; we provide engineered solutions tailored to your specific material—whether it’s LDPE shrink wrap, PP woven bags, or BOPP films.

• Heavy-Duty Gearboxes: Built to withstand high torque and 24/7 operation.
• Custom Screw Designs: Optimized geometry for PE/PP gentle shear, preventing material degradation.
• Comprehensive Service: From facility layout planning to installation and operator training.

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Frequently Asked Questions

Q: Can Rumtoo machines handle wet agricultural film?
A: Yes. For agricultural film, we design lines with specialized washing trommels and robust squeezer dryers to handle soil, sand, and high moisture levels effectively.

Q: What is the lifespan of the screw and barrel?
A: We use bimetallic screws and barrels with specialized surface treatments. Depending on the abrasiveness of your material, our components typically last significantly longer than standard nitrided steel options.