Johor, Malaysia – LDPE Agricultural Film Anti-Jam Plastic Granulator Success Case

Background

Mr. Mohd, a 38-year-old male with a junior high school education and 6 years of experience in agricultural waste recycling, owns a 450㎡ family-run workshop in Johor Bahru, Johor. As Malaysia’s top agricultural state, Johor produces massive volumes of LDPE agricultural film waste (mulch films, silo films) from its palm oil and vegetable farms. Mr. Mohd started his business in 2020 with the support of Johor’s Agricultural Green Incentive Scheme, collecting waste films from local farms. However, his old Plastic Granulator struggled to handle the light, wet, soil-contaminated LDPE films, limiting his ability to serve Johor’s agricultural sector and grow his business. A specialized agricultural Plastic Granulator was critical to overcoming these challenges.

Plastic Granulator

The Challenge

1. The LDPE agricultural films had a low density (0.92g/cm³), causing frequent feeding bridging and jammingin the old Plastic Granulator—requiring manual intervention 5+ times per hour and halting production, a major flaw of his outdated Plastic Granulator.
2. Moisture content in the films reached 16%due to contact with farm soil and rain, leading to foaming and porosity in the granulator output—making the granules unsuitable for reuse in agricultural films.
3. The old Plastic Granulatorhad an output of only 230kg/h, unable to keep up with Johor’s 6-ton daily agricultural film waste, leaving Mr. Mohd unable to expand his client base.
4. Frequent screw clogging required 2.5 hours of daily cleaning, reducing operational efficiency and increasing labor costs—competing machines failed to address this, as they lacked self-cleaning features.

The Solution

We customized the TL-G110 Agricultural Plastic Granulator—Johor’s top-selling model for agricultural film recycling, tailored to handle farm-based LDPE waste:

• A forced feeding screw with an anti-bridging hopper, designed to handle low-density LDPE films and prevent feeding jams, eliminating manual intervention.
• A large-volume dual vacuum exhaust system that removes 99.7% of moisture (up to 16%) and soil-related volatile gases, solving foaming and porosity issues.
• A special LDPE screw design with a 34:1 L/D ratio, optimized for plasticizing soft, flexible agricultural films.
• A self-cleaning screen changer that reduces downtime by 85%, cutting daily cleaning time from 2.5 hours to 15 minutes.
• An energy-efficient 40kW motor, tailored for processing wet agricultural films while reducing power consumption.
• Johor-based service team, offering same-day maintenance and support during peak agricultural waste collection seasons (harvest periods).
  

  Plastic Granulator

The Results

Since installing the TL-G110 Plastic Granulator, Mr. Mohd’s workshop has experienced dramatic growth, with the agricultural-specific Plastic Granulator solving all his operational pain points:

• Production output reached 550kg/h—a 139% boost, allowing him to process all 6 tons of daily agricultural film waste and expand his client base to 15 local farms and 3 agricultural cooperatives.
• Foaming and porosity issues were completely eliminated; recycled LDPE granules are uniform, free of black spots, and suitable for reuse in agricultural mulch films.
• Daily cleaning time reduced to 15 minutes, increasing machine uptime to >98%.
• Energy consumption dropped by 19%, translating to annual savings of 82,000 Malaysian Ringgitin electricity costs.
• The equipment supports Johor’s Agricultural Green Incentive Scheme, earning Mr. Mohd a reputation as a reliable, sustainable recycling partner for local farmers.

Mr. Mohd’s Quote: “This Plastic Granulator is made for Johor’s farms—no jams, handles wet films, and easy to maintain! It’s the best investment I’ve made, and it’s helping me grow my business while supporting Johor’s agricultural sustainability.”

FAQ

1. Q: How does this Plastic Granulator handle low-density LDPE agricultural films without jamming?
   A: The forced feeding screw and anti-bridging hopper ensure smooth, consistent feeding, even for light, flexible LDPE films that jam standard granulators.
2. Q: Can the machine process LDPE films with 16% moisture content?
   A: Yes, the large-volume dual vacuum exhaust system removes excess moisture, producing dense, pore-free granules even with 16% moisture.
3. Q: What support is available for Johor’s agricultural recycling workshops using this Plastic Granulator?
   A: We offer same-day local maintenance and support, critical during peak harvest seasons when waste collection is highest.