Soft Material Recycling Factory Improves Quality and Reduces Cost by Launching 180 Type PE Granulator for Waste PE Film Pelletizing
In the soft PE material recycling industry, most small and medium-sized processing factories initially adopt ordinary single-stage granulating equipment to process greenhouse films, packaging films and waste plastic bags, which can meet basic pelletizing needs in the short term. However, with the continuous improvement of market requirements for recycled pellet quality and intensified industry low-price involution, the defects of ordinary equipment are fully exposed: soft PE materials have loose plasticization and porous pellets, unable to undertake high-end film blowing and wire drawing orders; uncleaned high-moisture materials cause severe pellet adhesion, mildew and high waste rate; frequent shutdown for screen changing and easy screw carbon deposition and wear lead to limited production capacity and high maintenance costs, continuously squeezing factory profits. A medium-sized factory in Hebei specializing in waste agricultural PE film and packaging film recycling and regeneration has completely solved production pain points and achieved three major upgrades in production capacity, quality and profit by launching a new high-grade two-stage production line of the 180 type PE granulator.
The customer mainly engages in the recycling and regeneration of waste PE greenhouse films, industrial packaging films and waste plastic bags with stable long-term order reception. Before renovation, traditional single-stage granulating equipment brought prominent production problems. Firstly, poor finished product quality: single-stage extrusion cannot realize sufficient mixing and plasticization of soft PE materials, resulting in porous, low-transparency recycled PE pellets with fine residual impurities, unrecognized by high-end buyers and only available for low-price bulk sales with meager profits. Secondly, high material loss: PE films have high water content after cleaning, and ordinary equipment without water removal devices causes frequent pellet adhesion, caking and mildew with a persistently high waste rate. Thirdly, poor production continuity: traditional manual screen changing requires equipment shutdown and disassembly for multiple times daily, delaying production. Ordinary screws are prone to carbon deposition and scratches when processing sediment-containing waste agricultural films, requiring frequent monthly shutdown maintenance and parts replacement with rising labor and accessory costs.
To get rid of low-price competition, improve finished product quality, expand stable production capacity and reduce maintenance loss, the customer finally selected our complete high-grade two-stage extrusion production line of the 180 type PE granulator after on-site comparison, production capacity testing and process debugging of multiple models, completely replacing old single-stage equipment. The improvement effect is immediate after commissioning, completely reversing the production dilemma.
In the core production link, the two-stage extrusion process of the180 type PE granulator thoroughly solves the core problems of loose plasticization and insufficient purity of soft PE materials. The 75KW high-power output of the 180-type main machine matched with a 315-type low-noise reducer ensures stable operation. The 180×3000mm high-frequency wear-resistant screw performs preliminary melting and extrusion of soft PE materials, and the 80KW electromagnetic heating + dual heating ring zoned precise temperature control accurately adapts to the low-temperature melting characteristics of PE, avoiding high-temperature carbonization and insufficient low-temperature plasticization of materials. Loose materials preliminarily processed by the main machine are sent to the 165-type auxiliary machine for secondary fine plasticization and mixing. The 30KW auxiliary machine adopts reasonable power matching, and the refined screw realizes more thorough material melting and denser texture, effectively eliminating pellet looseness, bubbles and residual impurities, and greatly improving pellet transparency and compactness.
The hydraulic non-stop screen changing system and professional water removal process greatly reduce production costs and improve product premium for customers. The 350 large-diameter mesh provides sufficient filtration area to efficiently intercept sediment, dust and burnt impurities mixed in agricultural PE films. The 4KW hydraulic pump station provides stable pressure for alternate left-right screen changing without shutdown or strip breaking, increasing the effective machine operation rate from the original 75% to over 95%, significantly boosting daily output and reducing waste generation. Matched with an exclusive water shaking and strip drying integrated machine, it completely removes residual water on strip surfaces through high-frequency vibration and high-pressure air blowing, solving the pain points of PE pellet damp adhesion and mildew deterioration. The finished pellets reach full dryness standard for long-term storage, successfully undertaking multiple high-end film blowing and wire drawing procurement orders.
The full-line automatic supporting system simplifies production and reduces maintenance costs. The 600×600 forced variable-frequency feeder completely solves bridging, blocking and uneven feeding of light soft PE materials, ensuring uniform feeding and stable extrusion pressure. The 4-meter extended stainless steel water tank adapts to the cooling characteristics of soft PE materials for flat and regular strip shaping. The variable-frequency alloy pelletizer produces uniform and regular pellets without crumbs and burrs. The rear stainless steel storage bin fan realizes automatic dust removal and air drying for consistent and clean finished product appearance. The national standard variable-frequency electric control system is simple to operate, requiring only one worker for whole-line monitoring, greatly reducing labor costs.
The customer’s production supervisor feedback: After upgrading to the 180 type PE granulator, the factory completely bid farewell to excessive defective pellets, frequent shutdown maintenance and low-price sales. The currently produced recycled PE pellets are compact, pure, dry and impurity-free with stable quality, fully meeting medium and high-end market standards, with a price increase of 200-400 yuan per ton. The production capacity is stable and sufficient, the equipment failure rate is extremely low, and maintenance is time-saving and labor-saving, enabling quick return on equipment investment. The factory plans to expand the recycling and processing scale of waste PE films and develop more high-end cooperative orders based on this stable production line.
This case fully verifies that for the recycling and production of soft waste PE materials, the core advantages of the 180 type PE granulator including two-stage extrusion, non-stop stable production, thorough water removal and wear resistance & energy saving fully meet the large-scale and refined production needs of medium-sized recycling factories, making it the preferred equipment for the PE plastic recycling industry to improve quality, reduce costs and increase profits.
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