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 plastic film types including agricultural mulch film, greenhouse covers, LDPE packaging film, HDPE bags, and stretch wrap — 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 2–5 mm recycled PP/PE pellets in a single continuous process. 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 at capacities from 200 to 2,000 kg/h.

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%.
• Twin-Screw Pelletizing Extruder: Dried film flakes are directly fed into a twin-screw extruder that melts, filters, and pelletizes the material into uniform 2–5 mm recycled PP/PE pellets.
• Melt Filtration System: Screen changer filters fine contaminants from the melt stream, ensuring pellet purity for demanding film and injection molding applications.
• PP & PE Material Flexibility: Processes both PP and PE films including LDPE, LLDPE, and HDPE grades with quick parameter adjustments between material types.
• Dust Control System: Integrated filters and directed airflow systems maintain clean, dust-free operating conditions throughout the crushing and drying stages.
• Energy Recovery: Heat exchangers capture and reuse thermal energy from drying stages to reduce overall power consumption of the line.

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. Pelletizing Extrusion: Dried film flakes are fed into the twin-screw extruder where they are melted, filtered through a screen changer, and extruded through a die head for pelletizing.
9. Cooling & Screening: Pellets are water-cooled or air-cooled to solidify, then passed through a vibratory sieve to separate on-spec 2–5 mm 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 PP and PE film waste, including agricultural mulch film, greenhouse covers, LDPE packaging film, HDPE bags, stretch wrap, and industrial plastic scraps. Incoming material is sorted to remove non-plastic debris including metals, paper, and heavily contaminated pieces 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 a twin-screw pelletizing extruder after the drying stage, converting dry flakes directly into uniform 2–5 mm recycled PP/PE pellets in a single continuous process. This eliminates the need for a separate pelletizing step and produces a higher-value output ready for direct use in blown film, bag manufacturing, injection molding, and compounding applications.

What output capacity options are available?

The SUHUI PP PE film crushing pelletizing line is available in configurations supporting capacities from 200 to 2,000 kg/h. SUHUI engineers recommend the appropriate model based on feedstock volume, film type, contamination level, and facility layout. Custom-engineered solutions are available for higher throughput requirements beyond the standard range.

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 to remove residual detergent 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, sized and shaped for direct use in downstream manufacturing processes. Output pellets are suitable for 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.

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. Combined with heat recovery exchangers that capture and reuse thermal energy from the drying stages, the system significantly lowers both water and energy costs per kilogram of output pellets, supporting sustainable and cost-efficient recycling operations.