PP PE Film Crushing Pelletizing Line

The SUHUI PP PE film crushing pelletizing line transforms post-industrial and post-consumer polypropylene (PP) and polyethylene (PE) film waste into high-quality recycled pellets. It processes a wide range of materials including agricultural mulch film, greenhouse covers, LDPE packaging film, HDPE bags, stretch wrap, raffia, filament, woven bags, and non-woven fabric — removing contaminants such as dirt, sand, inks, and adhesives to produce clean, uniform output.

Unlike a standard washing line that produces flakes, this line goes one step further by integrating a direct pelletizing extruder after drying, converting clean film flakes into uniform recycled PP/PE pellets in a single continuous process. The pelletizing section uses the SHP series compactor-type granulating system with electromagnetic heating, vacuum degassing, and selectable filtration and pelletizing configurations. Output pellets are suitable for manufacturing new blown film, bags, containers, and injection-molded products.

With closed-loop water recycling reducing water consumption by 60–80% and integrated heat recovery systems, the SUHUI PP PE film crushing pelletizing line is designed for efficient, low-cost operation across the full SHP capacity range.

Key Features of SUHUI PP PE Film Crushing Pelletizing Line

• Anti-Tangle Film Crusher: High-speed crusher with specialized blade geometry shreds lightweight PP/PE films into 8–12 mm flakes without tangling or wrapping around the rotor.
• Multi-Stage Washing System: Sequential pre-wash, friction wash, and hot wash stages progressively remove loose dirt, embedded sand, inks, adhesives, and oil contamination from film flakes.
• Closed-Loop Water Recycling: Integrated water filtration and recirculation system reduces fresh water consumption by 60–80%, significantly lowering operating costs and wastewater output.
• Centrifugal Dewatering & Thermal Drying: High-speed centrifugal dryers remove bulk surface water, followed by hot air thermal drying that reduces final moisture content to below 1%.
• SHP Compactor Granulating Unit: Dried film flakes are fed into the SHP series compactor — a high-speed rotating compactor thermally densifies the film through friction heat, continuously feeding the single-screw extruder for stable, high-output pelletizing.
• Electromagnetic Heater: Energy-efficient electromagnetic induction heating on the extruder barrel reduces power consumption versus conventional resistance heaters while providing faster, more precise temperature response.
• Vacuum Degassing System: 1–2 zone vacuum exhaust removes moisture, gases, and volatiles from the melt before pelletizing — producing denser, more uniform pellets with improved mechanical properties.
• Multiple Pelletizing Options: Three pelletizing configurations available: Strand Pelletizer (standard, versatile), Water Ring Pelletizer (ideal for soft or sticky materials), and Underwater Pelletizer (highest pellet uniformity and surface finish).
• Four Filter Options: Two-Position Plate Type, Two-Position Piston Type, Back Flush Piston Type, or Automatic Self-Cleaning Type — matched to your material contamination level and required production continuity.
• Optional Second Extruder: A secondary extruder can be added for two-stage filtration and additional degassing, improving output pellet quality for demanding applications.
• Wide Material Compatibility: Processes PE, PP, CPP, BOPP, PS, EPS, ABS, PA, PLA, and PET films, as well as raffia, filament, woven bags, and non-woven fabric.
• CE & ISO9001:2008 Certified: Meets international environmental and safety standards. Energy consumption: 0.2–0.33 kWh/kg.

PP PE Film Crushing Pelletizing Line — Technical Data (Pelletizing Section)

The complete crushing pelletizing line integrates upstream washing and drying with the pelletizing unit above. Total line capacity and configuration depend on feedstock type, contamination level, and facility layout. Contact SUHUI for a complete line proposal.

PP PE Film Crushing and Pelletizing Process Workflow

1. Sorting & Inspection: Incoming film waste is inspected and sorted to remove non-plastic debris including metals (via magnetic separator), paper, and heavily contaminated pieces.
2. Crushing: Film waste is fed into an anti-tangle high-speed crusher that shreds it into uniform 8–12 mm flakes for consistent downstream washing and feeding.
3. Pre-Washing: Film flakes enter a pre-wash tank where ambient water agitation removes loose dirt, sand, and surface debris in the initial cleaning stage.
4. Friction Washing: High-speed friction scrubbers mechanically clean flake surfaces, stripping embedded contaminants, ink residues, and label adhesives.
5. Hot Washing: Flakes pass through a heated detergent wash tank (60–80°C) that dissolves oils, agricultural chemical residues, and stubborn adhesive contamination.
6. Rinsing & Centrifugal Dewatering: Clean flakes are thoroughly rinsed with fresh water to remove residual detergent, then centrifugally dewatered to reduce surface moisture before drying.
7. Thermal Drying: A hot air drying system reduces final flake moisture content to below 1%, producing dry film flakes ready for direct extrusion.
8. Compacting & Pelletizing Extrusion: Dry flakes are fed into the SHP compactor where friction heat densifies the material into a semi-molten state for continuous, stable feeding into the single-screw extruder. The melt is then vacuum-degassed, filtered, and extruded through the selected die for pelletizing.
9. Cooling & Screening: Pellets are water-cooled or air-cooled to solidify, then passed through a vibratory sieve to separate on-spec pellets from fines and oversized pieces.
10. Packaging: Finished recycled PP/PE pellets are conveyed to bulk storage silos or automatically weighed and bagged for sale or use in film blowing, injection molding, or compounding lines.

Frequently Asked Questions

What types of plastic film can the SUHUI PP PE film crushing pelletizing line process?

The line processes a wide range of post-industrial and post-consumer film waste, including PE, PP, CPP, BOPP, PS, EPS, ABS, PA, PLA, and PET films, as well as raffia, filament, woven bags, and non-woven fabric — sourced from production factory trim or post-washing recycling operations. Incoming material is sorted to remove non-plastic debris before entering the crushing and washing stages.

What is the difference between this line and a standard film washing line?

A standard washing line produces clean film flakes as its final output. The SUHUI PP PE film crushing pelletizing line goes one step further by integrating an SHP compactor granulating unit after the drying stage, converting dry flakes directly into uniform recycled PP/PE pellets in a single continuous process. The compactor uses friction heat to densify film for continuous extrusion, with vacuum degassing and selectable filtration producing higher-purity pellets than a direct extruder alone.

What output capacity options are available?

The pelletizing section (SHP series) covers SHP80 (150–250 kg/h) through SHP180 (1,000–1,200 kg/h). The upstream washing line capacity is matched to the pelletizing unit. Contact SUHUI for model selection based on your feedstock volume, film type, contamination level, and facility layout.

How does the multi-stage washing system remove agricultural chemical residues and oil contamination?

The line uses a three-stage washing sequence: pre-washing with ambient water agitation removes loose dirt and surface debris; high-speed friction scrubbers mechanically strip embedded ink residues and label adhesives; and a heated detergent wash tank (60–80°C) dissolves oils, agricultural chemical residues, and stubborn adhesive contamination that mechanical washing alone cannot remove. Clean flakes are then rinsed with fresh water before centrifugal dewatering and thermal drying.

What pellet size does the line produce, and what applications are the pellets suitable for?

The line produces uniform 2–5 mm recycled PP/PE pellets suitable for direct use in blown film production, bag manufacturing, injection-molded containers, and plastic compounding applications. A vibratory screening stage removes fines and oversized pieces to ensure consistent pellet quality. Pellet size and shape can be adjusted by selecting the appropriate pelletizing configuration (strand, water ring, or underwater).

How does the closed-loop water recycling system reduce operating costs?

The integrated water filtration and recirculation system continuously treats and reuses process water throughout all washing and rinsing stages, reducing fresh water consumption by 60–80% compared to open-loop systems. The SHP compactor granulating unit adds further efficiency with an energy consumption of only 0.2–0.33 kWh/kg of output, compared to conventional single-stage dryer-extruder systems. Certification: CE, ISO9001:2008.