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Plastic film recycling machine
Direct, one-step process of light-weighted PE/PP film scraps
Plastic film recycling machine
Cutting
Extruding
Pelletizing
Flexible
Packaging
Material
Output
100-1200
kg/hr
Printed and non-printed PE, PP film, multi-layered film, shrink film, stretch film, PE and EPE foam. Thermoformed PS, PP. Soft irrigation pipe. Pre-shredded regrind. Washed and dried film flakes from washing line. 
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Recycling Materials
  • PE/PP film rollPE/PP film roll
  • BagsBags
  • Film scrapsFilm scraps
  • Bubble FilmBubble Film
  • Film SheetFilm Sheet
  • Shrink FilmShrink Film
  • Waste BagsWaste Bags
  • Stretch FilmStretch Film
  • Garbage BagGarbage Bag
  • Swimming Pool CoversSwimming Pool Covers
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Select Your Model
Output:
80~120 kg/hr
2.8 ton/ day 
84 ton/month
Screw diameter: 65mm

Repro-Flex65

Output:
150~250 kg/hr
6 ton/day
180 ton/month
Screw diameter: 85mm

Repro-Flex85

Output:
250~400 kg/hr
9.6  ton/day
288 ton/month
Screw diameter: 100mm

Repro-Flex100

Output:
400~500 kg/hr
14.4 ton/day
432 ton/month
Screw diameter: 120mm

Repro-Flex120

Output:
700~800 kg/hr
19.2 ton/day
576 ton/month
Screw diameter: 150mm

Repro-Flex150

Output:
850~1000 kg/hr
24 ton/day
720 ton/month
Screw diameter: 165mm

Repro-Flex165

Output:
1000~1200 kg/hr
28.8 ton/ day 
864 ton/month
Screw diameter: 180mm

Repro-Flex180

Installation Photos
Specifications
Model Name Repro-Flex
Final Product Plastic pellets/granule
Machine Components Conveyor belt, cutter compactor shredder, extruder, pelletizing unit, water cooling
unit, drying unit, silo tank
Recycling Material HDPE,LDPE,LLDPE, PP, BOPP, CPP, OPP, PA,PC,PS,PU,EPS
Output range 100kg~ 1200 kg/hr
Feeding Conveyor belt (Standard), Nip roll feeder (Optional)
Screw Diameter 65~180mm (customized)
Screw L/D 30/1,32/1,34/1,36/1 (customized)
Screw Material SACM-645
Degassing Single or double vented degassing, Unvented for non-printed film (customized)
Cutting Type Hot die face pelletizing (Water ring pelletizer)
Cooling Water cooled
Voltage Customized based on request (For example: USA 480V 60Hz, Mexico 440V/220V 60Hz, Saudi Arabia 380V 60Hz, Nigeria 415V 50Hz...)
Optional Devices Metal detector(S+S) , Nip roller for film roll feeding , Additive feeder for masterbatch, Centrifuge dryer for drying
Delivery Time 75~120 days for customized machine. In stock machines available
Warranty 1 year
Technical Assistance Engineers available to service machinery overseas


Simple in Design . Flexible in operation

How Repro-Flex works


Feeding (1)
With belt conveyor: Feeding of scraps is easy and automatically controlled
Feeding (2)
Film-on-rolls can be fed with nip roll feeder at the same time
Cutting and Compacting
Cutter compactor with rotary knives & direct feeding to extruder :
Cuts, dries and compacts the material which enables a fast and stable feeding from the compactor directly into the extruder
Degassing
Two-zone degassing (double-vented degasification) : Able to process films with larger printed area and some water content
Filtration
Screen change with dual channel system :
For non-stop operation and prevents material from leaking
Pelletization
Hot die face pelletizer :
Produces high quality plastic pellets for reprocessing
Product
The plastic pellets can be put directly back into the production line such as blown film extrusion and pipe extrusion
Easy to use, high performance recycling machine
High Performace Recycling Machine

Polystar's high efficiency, one-step plastic recycling machine Repro-Flex is designed for the reprocessing of PE polyethylene (HDPE, LDPE, LLDPE) and PP polypropylene flexible packaging material, printed and non-printed. This cutter integrated pelletizing system eliminates the need of pre-cutting the material, requires less space and energy consumption while producing high quality plastic pellets at a productive rate.


In addition to in-house (post-industrial) film waste, the system is also able to process washed flakes, scraps and regrind (pre-crushed rigid plastic waste from injection and extrusion). This equipment is highly recommended for packaging film producers of commercial bags, garbage bags, agricultural films, food packaging, shrink and stretch films, as well as producers in the woven industry of PP woven bags, jumbo bags, tapes and yarns. Other types of material such as PS sheet, PE and PS foam, PE net, EVA, PP mixed with PU are also applicable on this machine.

Re-usable pellets

The pellets produced by the recycling machine can be put directly back into the production line, in most cases for blown film or pipe extrusion processes.

1. Pellets from in-house, post-industrial recycling
On average, post-industrial waste makes up 5% or more of the entire production line, making in-house recycling very important nowadays as it can significantly reduce the cost of raw/virgin material purchasing.
The plastic pellets produced from in-house waste are almost like-new and can be re-used for producing high quality plastic products once again.
2. Pellets from post-consumer recycling
The Repro-Flex is also designed to work with washed, post-consumer and used agricultural film. The cutter compactor, which generates frictional heat during the compacting process, helps to further dry and remove the water moisture from the washed film flakes (processed first by the washing lines). The recycled pellets can be used again in extrusion process, whether 100% (such as garbage bag, LDPE pipe production and etc) or as part of the mixture to reduce raw material cost. The pellets quality can also be improved by direct dosing of masterbatch and additives.


Re-usable pellets
Re-usable pellets
Re-usable pellets
Machine Advantage

One Step, All-in-One direct recycling

The Repro-Flex plastic recycling machine combines cutting, extrusion and pelletizing into one compact and efficient recycling line. The cutter compactor of the recycling machine prepares (pre-conditions) the material into an ideal condition for the extrusion process and feed the material directly into the extruder with a centrifugal force. Comparing to the conventional recycling machines, this integrated system does not require a separate crusher, andtherefore, eliminates the problem of inconsistent feeding (over-feeding or insufficient feeding)


Easy material feeding without the need for pre-cutting

The waste material enters the machine from the belt conveyor (for film scraps and rigid plastic regrind) and the nip roll feeder (for complete film rolls) at the same time. An extra silo tank can also be added to store and feed pre-washed film flakes. The feeding is controlled automatically based on how full the cutter compactor is. The cutter compactor then cuts, dries and compacts the material into a semi-molten condition (just below the agglomeration point), which is optimal for the extrusion process that follows. The cutter compactor then feeds the material directly and consistently into the extruder screw


Higher output capacity

The integration of the cutter compactor and extruder ensures extremely fast and stable feeding, the tangentially connected extruder is continuously filled with pre-compacted material. This results in a much higher production output comparing to other types of recycling systems on the market


Higher pellets quality

The stable material feeding together with the hot die face pelletizer produce round-shaped, uniformed size pellets that are higher in value and optimal for reproduction (extrusion processes).


Other benefits

  • Lower investment cost for a high quality and durable machine
  • Low energy consumption with high production output
  • Fast machine delivery and installation: Polystar produces on an average of 8 sets of Repro-Flex per month and can deliver the machine faster than most manufacturers. The average delivery time of a Polystar recycling machine is 60 days.
Cutter compactor
Cutter compactor shredder Easy material feeding
Easy material feeding by belt conveyor Higher output
30% higher output and higher quality pellets
Suitable industry
Suitable Industry: Blown film producers

Blown film producers
Leftover waste of edge trim from blown film in the format of scraps (T-shirt bags cut-offs from bag making and punching processes), complete film rolls and sheet can be efficiently recycled in a simple process. The high quality, uniformed sized recycled pellets are almost like virgin material which can be put directly back into the film production line.


Suitable Industry: PP woven producers

PP woven producers
In-house waste generated from the production of PP woven bags, non-woven, jumbo bags, PP raffia, PP woven sacks and tapes. The recycled PP pellets can be reused (100%) for production. In most cases in circular weaving looms and tapelines.


Suitable Industry: PP woven producers

Recycling Centers
Professional Recyclers who collect both post-consumer and post-industrial waste.
The pellets quality can be improved by direct dosing of masterbatch and additives.


Work with POLYSTAR

An experienced market leader in the recycling field, especially for the recycling of packaging film

  • More than 1,700 Polystar plastic recycling machines have been installed worldwide since 1988
  • Proven success and positive feedback from satisfied customers in 102 countries
  • Flexible, personalized machine design to meet your specific requirement and factory layout
  • Top quality components used for the machines: Energy saving and high performance motors
  • Cost-effective machine: Lower investment cost for a high quality and durable machine

    Service and Communication
  • Overseas installation service and training are available
  • Machine warranty with in-time spare parts delivery
  • Fast online trouble shooting
Model Comparison

Model Repro-Flex65 Repro-Flex85 Repro-Flex100 Repro-Flex120 Repro-Flex150 Repro-Flex165 Repro-Flex180
Output 80-120 Kg/hr 180-250 kg/hr 300-400 kg/hr 450-600 kg/hr 700-800 kg/hr 850-1000 kg/hr 1000-1200 kg/hr
A
(Standard)
5250 5950 6600 7550 8550 8800 9100
A
(With all option)
6000 7000 8000 9000 10000 11000 12000
B
(Standard)
7300 8200 9400 15000 16000 17500 18000
B
(With all option)
10000 12000 12000 15500 16500 18000 19000
C 2900 3100 3200 3400 3500 3600 3700



The machine layout (picture) is for reference only. The actual layout changes depending on the optional devices (metal detector, centrifugal dryer, nip roll feeder, venting option, filter option and machine cover option) that the customer chooses.
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