High-Purity PP/HDPE Rigid Flake Pelletizing System

Convert post-industrial and post-consumer rigid plastic waste into premium, uniform pellets. Our two-stage granulation system is engineered for maximum efficiency, superior purity, and a rapid return on your investment, powering the circular economy.

Request a Quote

From Flake to High-Value Pellet: A 6-Step Process

Automated Feeding

Washed and dried PP/HDPE flakes are automatically fed into the first-stage extruder via a screw conveyor with a VFD-managed motor for stable, energy-efficient operation.

First Stage Extrusion

A specialized single-screw extruder gently melts and plasticizes the flakes. This stage includes coarse pre-filtration to remove larger contaminants.

Vacuum Degassing

The molten plastic moves to a “dual-zone” vacuum degassing system, which effectively removes volatiles, moisture, and low molecular weight substances for a purer output.

Second Stage Extrusion & Filtration

The plastic is further homogenized in the second-stage extruder, where a high-mesh filter removes fine particle impurities, ensuring a high-quality final melt.

Water Ring Pelletizing

A die-face water ring pelletizing system cuts the molten polymer into uniform, spherical pellets, which are immediately cooled by a stream of water.

Dewatering & Drying

The newly formed pellets are transported to an advanced dewatering vibration sieve and a centrifugal dewatering machine to ensure they are perfectly dry for storage and reuse.

Visual Showcase: Equipment & Materials

Complete PP/HDPE Flake Pelletizing Line

Raw Material: Crushed PP/HDPE Flakes

Final Product: High-Quality PP/HDPE Pellets

Unlock Unmatched Purity and Profitability

Two-Stage Design

Our mother-baby extruder configuration ensures optimal melting, degassing, and filtration, producing exceptionally pure pellets that command a higher market price compared to single-stage systems.

Superior Pellet Quality

Advanced dual-zone vacuum and two-step filtration eliminate contaminants and volatiles, resulting in dense, consistent granules perfect for high-end applications like injection and blow molding.

High Throughput

Engineered for industrial-scale recycling, our systems deliver reliable throughput from 160 to over 1200 kg/h, maximizing your operational output and revenue stream.

Automated & Stable

Intelligent VFD-controlled feeding adjusts to the extruder’s load, ensuring smooth, uninterrupted operation while preventing overloads and minimizing energy consumption.

Efficient Filtration

Our smart segmented filtration removes coarse particles first, extending the life of the fine filter screen. This reduces downtime, lowers maintenance costs, and boosts productivity.

Durable Construction

Built with robust, wear-resistant alloys, the screw and barrel are designed for a long service life, ensuring a reliable and profitable long-term investment in your recycling infrastructure.

Turn Recycling Headaches into Profitable Results

Common Rigid Flake Recycling Issues

Inconsistent pellet quality due to variations in flake size and type.
Poor degassing leads to porous, weak, and low-value pellets.
Frequent machine downtime from clogged filters and screen changers.
High energy consumption from inefficient melting and extrusion processes.
Final pellets are unsuitable for high-specification manufacturing applications.

The Two-Stage System Advantage

Two-stage extrusion provides superior homogenization for uniform, consistent pellets.
High-performance dual-zone vacuum system removes all volatiles, ensuring dense, high-purity output.
Segmented pre-filtration protects the fine filter, drastically reducing maintenance and downtime.
Optimized screw design and stable feeding reduce overall energy usage per kilogram of output.
Produces premium-grade pellets ready for use in injection molding, extrusion, and compounding.

Watch It in Action: Precision Engineering at Work

Watch our Two-Stage PP/HDPE Pelletizing System efficiently convert rigid flakes into high-value pellets.

Technical Specifications

Machine Size	Motor Power (Compactor)	Diameter of Screw (mm)	L/D	Motor Power (Extruder)	Throughput Rate (kg/h)
SJ80	37 kW	80	36	45/55 kW	160-220
SJ100	55 kW	100	36	90/110 kW	300-380
SJ120	90 kW	120	36	132 kW	450-480
SJ140	110 kW	140	36	160/185 kW	500-650
SJ160	132 kW	160	34	220/250 kW	800-1000
SJ180	315 kW	180	34	315 kW	1000-1200

*Custom configurations are available to meet specific customer requirements. Contact us for a personalized consultation.

Powering a Wide Range of Industries

Injection & Blow Molding

Create new high-quality products like containers, automotive parts, pipes, and household goods.

Compounding & Masterbatch

Use the pellets as a reliable base for creating specialized polymer compounds and color masterbatches.

Construction Materials

Manufacture durable goods such as plastic lumber, pallets, and other construction components.

Your Questions, Answered

Why use a two-stage (mother-baby) extruder system?

A two-stage system provides better plasticization and degassing. The first (mother) extruder melts the material, while the second (baby) extruder builds pressure for pelletizing. This separation allows for a large, screened degassing zone between them, resulting in much higher quality, bubble-free pellets, especially with printed or slightly moist materials.

What kind of rigid plastics can this machine process?

This system is ideal for recycling washed, rigid PP (polypropylene) and HDPE (high-density polyethylene) flakes. This includes material from crushed bottles, containers, pipes, drums, and other rigid plastic items.

What is the benefit of the segmented filtration system?

By using a coarse filter in the first extruder and a fine filter in the second, the system operates more efficiently. The first filter removes larger contaminants, preventing the fine filter from clogging quickly. This reduces machine downtime and lowers the cost associated with frequent filter screen changes.

How does the automatic feeding system work?

The screw conveyor that feeds the flakes into the extruder is controlled by a Variable Frequency Drive (VFD). It monitors the electrical current of the main extruder motor. If the current gets too high (indicating the extruder is full), the feeder automatically stops. It resumes once the current returns to normal, ensuring a smooth, continuous, and safe operation.

Do you offer different pelletizing heads?

Yes. While the die-face water ring pelletizer is standard and highly recommended for PP/HDPE for its efficiency and pellet uniformity, we can also configure the system with a strand-die pelletizing line upon request, depending on your specific material and application needs.

What Our Customers Say

“The two-stage system is a revelation. Our pellet quality has improved dramatically, and we can now sell to high-end manufacturers. The machine paid for itself in less than a year.”

Alexey V.

Operations Director, EuroPlast Recycling

“We were struggling with downtime from filter changes on our old line. The segmented filtration on this machine is brilliant. We run continuously for much longer, and our output has increased by over 40%.”

Ben Carter

Owner, C&S Polymers

“Reliability was key for us. This pelletizer is built like a tank. The stability of the automated feeding system and the overall robustness have significantly cut down our maintenance headaches.”

Javier M.

Production Manager, EcoResin SA

Ready to Revolutionize Your Plastic Recycling?

Contact us today to receive a personalized quote. Discover how our Two-Stage Pelletizing System can elevate your recycling operations, enhance pellet quality, and drive your profitability.