The Ultimate Guide to Recycling Soft Plastics: How to Profitably Process PP/PE Film

Introduction: The Challenge and Opportunity of Soft Plastics

Polypropylene (PP) and Polyethylene (PE) films are ubiquitous in our modern world, from packaging and agricultural films to industrial liners. Yet, these soft plastics are notoriously difficult to recycle through conventional municipal systems. Their lightweight, flimsy nature causes them to jam machinery, leading them to be predominantly landfilled—a significant loss of resources and a persistent environmental issue.

However, what many see as waste, we see as opportunity. When handled correctly, these soft plastics represent a valuable, untapped resource. The key lies in utilizing a robust industrial process to transform this challenging waste stream into a high-quality, reusable raw material.

As specialists in plastic recycling solutions, Rumtoo is here to provide a definitive guide on the best way to recycle PP/PE film, empowering businesses to turn a disposal problem into a profitable enterprise.

The Optimal Pathway for Soft Plastic Recycling: The Industrial Pelletizing Line

For efficient, large-scale recycling of soft plastics, the washing and pelletizing line is the industry-standard solution. This process converts low-density, bulky film waste into high-density, uniform pellets that are easy to transport, store, and re-introduce into manufacturing.

A complete industrial recycling workflow consists of these critical stages:

Step 1: Collection and Sorting

This is the foundational step that dictates the quality of the final product. Waste film must be collected and sorted by material type (e.g., PP, LDPE, HDPE) and level of contamination. Post-industrial scrap is often cleaner, while post-consumer or agricultural films require more rigorous sorting to remove foreign materials like paper labels, dirt, and other debris.

Step 2: Crushing, Washing, and Drying

Once sorted, the film is processed through a washing line.

• Crushing/Shredding: The material is shredded into smaller flakes to allow for effective cleaning.
• Washing: A series of friction washers and floating tanks are used to scrub the flakes, removing dirt, grime, and other contaminants.
• Drying: The clean flakes are dewatered in a centrifugal dryer and then passed through a thermal drying system to reduce the moisture content to an absolute minimum, which is critical for the next stage.

Step 3: Melting, Extrusion, and Pelletizing

This is the heart of the recycling process and where Rumtoo’s technology excels. The clean, dry flakes are fed into a plastic pelletizing machine.

1. Feeding and Compacting: Due to the light, fluffy nature of plastic film flakes, consistent feeding into the extruder can be a challenge. The Rumtoo ML Series Single-Screw Pelletizer features an integrated cutter-compactor. This unit aggressively shreds, heats, and compacts the material, forcing it consistently into the extruder screw and dramatically increasing throughput.
2. Melting and Extrusion: Inside the heated barrel of the extruder, a specially designed screw melts, mixes, and homogenizes the plastic into a consistent molten polymer.
3. Filtration and Degassing: The molten plastic is passed through an advanced filtration system to remove any final impurities. A vacuum degassing zone on the barrel removes trapped volatiles and moisture, ensuring the final pellets are dense and free of air bubbles.
4. Cutting: The purified polymer is extruded through a die head into strands, which are instantly cut into uniform pellets by a high-speed cutting system. A water-ring pelletizer is typically used for this application, as it provides rapid cooling and produces perfectly spherical pellets.

Step 4: Cooling and Packaging

The newly formed pellets are immediately cooled by water and air, screened for consistency, and then conveyed to a storage silo for bagging. They are now a finished, marketable commodity.

Why Pelletizing is the Superior Recycling Method

• Value Addition: It transforms low-value (or even negative-value) waste into a high-demand industrial feedstock, creating a significant revenue stream.
• Logistical Efficiency: The high bulk density of pellets dramatically reduces storage space requirements and transportation costs compared to raw film waste.
• Broad Market Application: Recycled PP/PE pellets are used to manufacture a vast array of new products, including pipes, pallets, containers, and new film products, effectively closing the loop in the circular economy.

Rumtoo: Your Partner in Plastic Valorization

Understanding the process is one thing; implementing it requires robust, reliable, and efficient equipment.

At Rumtoo, we are more than just a machine manufacturer; we are your strategic partner in plastic recycling. Our ML Series Single-Screw Pelletizing Line is engineered specifically for the challenges of soft plastics. By integrating the compactor directly with the extruder, we offer a compact, energy-efficient, and highly automated system that delivers maximum performance and reliability.

Whether you are an established recycler looking to upgrade your capabilities or an entrepreneur entering the green economy, the Rumtoo team can provide comprehensive support, from plant layout and machine selection to process optimization.

Ready to transform your plastic waste stream into a value stream?

Click here to explore the technical specifications of the Rumtoo ML Series Pelletizer and contact our experts for a customized quote today.