Good degassing and filtration are probably the most important processes in pelletizing machines when it comes to post-consumer recycling. In many occasions, a Washed Plastic Waste Pelletizer is preferred by professional recyclers who focus on post-consumer recycling.

The washed material is fed into the compactor for a quick densifying process (which at the same time further dries the material by natural heat and friction); this helps to stabilize the material feeding into the extruder. The material then goes into the first (main) extruder for the filtration process and a two-vented degassing (installed with high efficiency vacuum system). The material then passes through an open area for the third and final degassing, and enters the second stage (short) extruder where the second filtering process is done. 

The Washed Plastic Waste Pelletizer significantly improves the quality of the recycled pellets as the washed material goes through two filtration and three degassing steps in both extruders combined. As a result, the final pelletizing process becomes more stable and easier to operate because the material is already well prepared and pre-conditioned.

A post-consumer recycler located in Belgorod, Russia who is dedicated in the recycling of municipal waste has a complete set up: The automatic sorting lines initially separate paper, glass, metal and plastic. The plastics are then separated by groups: 1) PET bottles, 2) films of HDPE and LDPE and 3) rigid plastic and followed by two washing lines - One for PET bottle and another for plastic films. After washing and drying the process is completed in the POLYSTAR pelletizing recycling machine. The recycled pellets are mainly used for producing plastic boxes for vegetables.

Updates of POLYSTAR in the Russian recycling market:

In Russia, 68 sets of POLYSTAR plastic pelletizing machine have been installed since 2012.
Amongst them, 45 lines are dedicated specially for post-consumer recycling. 

With strong know-how and service team from our local agent in Russia - Evropolimer, we can provide customers with the most suitable and simplest recycling solutions, followed by installation, training, spare parts and maintenance services.

Managing director of the Tennessee-based recycler, Mr. Irvin Payne, shares his own experience with Polystar recycling extruder :

Can you give me your opinion of your POLYSTAR?

My experience includes installing and operating American extruders and German extruders for over 30 years. My opinion of Polystar is they do a very good job of designing and building extruders and for the price, cannot be matched. I looked at buying a German machine at three times the cost before I decided on the Polystar.

Which Model is it?

I have the two stage extrusion pelletizing system with a cutter compactor. I have added a separate shredder as the PP material we now process is much more difficult to shred and slowed the rate down. When we were processing LDPE, LLDPE, and HDPE film (post-industrial, post-commercial, and post-consumer) we did not have any problem with the compactor maintaining rate.

We have ran BOPP film with just the shred drum at over 1500 lbs/hr. We also have a melt filter on the line to remove labels, etc. and it works well with the Polystar. You will likely be processing your own film so you would not need the melt filter unless you were to use recycled content from post-consumer or post commercial film back into your film.