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Bulk Bag Recycling - Which recycling machine to buy?
![Bulk Bag Recycling Bulk Bag Recycling](https://www.polystarco.com/upload/catalog_blog_b/Bulk Bag Recycling - Which recycling machine to buy___23L12aNxih.png)
Why the Shredder + Extruder + Pelletizer recycling machine is ideal for all kinds of woven bag and raffia production waste?
Recycling gives advantages and competitiveness to woven bag production companies if a higher re-using rate of recycled pellets can be added back to tape extrusion lines.
In most cases, producers can use up to 100% of recycled pellets from production waste such as pp raffia, pp bag, bulk bag, and endless tape, while still able to maintaining the strength and quality of the end product (woven bags).
![Integrated recycling machine reprocess pp Raffia, FIBC jumbo bag and woven sacks Integrated recycling machine reprocess pp Raffia, FIBC jumbo bag and woven sacks](https://www.polystarco.com/upload/catalog_blog_b/Bulk Bag Recycling - Which recycling machine to buy_ repro-one__23L12Nnzyi.png)
The following factors may make recycling PP bags, bulk bags, woven sacks, non-woven/woven bags, and FIBC bags challenging for post-industrial manufacturers:
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Difficult to process in one single step
When recycling has to be done in several processing steps due to the size and strength of the material (ex. FIBC, jumbo bags, and bulk bags), it is not cost-effective for the producers in terms of labor, electricity, and occupying too much factory space.
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Difficult to retain material property (strength and elasticity)
After recycling the material degrades excessively and therefore, the reusability of the recycled pellets back into the production lines is relatively low.
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Difficult to process heavily printed woven bags
The degassing and screw design of the recycling machine is not ideal for this type of material with an extra amount of ink. (For example, printed PP bags and cement bags.)
(Compared to film waste, it is more difficult to cut and feed raffia waste consistently into the recycling machine for its strength and size. Usually, it has to be done in separate steps.)
One-step, Simply recycle bulk bags and PP raffia
1. One-step process with shredder + extruder + pelletizer all integrated into one simple, easy-to-operate recycling machine.
![POLYSTAR one step plastic recycling machine process with shredder, extruder, pelletizer POLYSTAR one step plastic recycling machine process with shredder, extruder, pelletizer](https://www.polystarco.com/upload/catalog_blog_b/Bulk Bag Recycling - Which recycling machine to buy_ one step__23L12ZSoyw.png)
2. Low processing temperature in the single shaft shredder – higher quality recycled pellets
3. Specialized degassing and screw design for processing heavily printed bags
![Special screw design and double degassing system for processing heavily printed materials Special screw design and double degassing system for processing heavily printed materials](https://www.polystarco.com/upload/catalog_blog_b/Bulk Bag Recycling - Which recycling machine to buy_ 3D__23L12JtW64.png)
Efficient degassing is another key factor to ensure the pellets are solid (instead of fluffy and hollow in the middle), especially when recycling cement bags or AD*STAR bags that are heavily printed. Recycled pellets from laminated fabric can be used back again in tape line production running at lower line speed.
The optimal screw design can eliminate the problem of material coming out from the degassing (venting) area almost completely, so the machine can operate at full speed with stable production.
![high printed woven bag high printed woven bag](https://www.polystarco.com/upload/catalog_blog_b/high printed woven bag__23L12bOaVN.png)
Raffia producers who recycle in-house have many advantages
![In-house plastic recycling solution, recycling process, woven bag recycling In-house plastic recycling solution, recycling process, woven bag recycling](https://www.polystarco.com/upload/catalog_blog_b/Bulk Bag Recycling - Which recycling machine to buy_ woven recycling__23L12ky52x.png)
In general, 8% of production waste is generated during the process (from extruder start-up, winding, weaving, bag conversion, and printing). The price of raw material is almost doubled compared to the cost of having it recycled in-house.
![shredder plastic pelletizer for bulk bags PP raffia shredder plastic pelletizer for bulk bags PP raffia](https://www.polystarco.com/upload/catalog_blog_b/Bulk Bag Recycling - Which recycling machine to buy_ raffia recycling__23L12jWbWu.png)
It would make sense for medium and large-sized raffia/woven producers (who generate more than 30~40 tones of scraps per month or more) to recycle the production waste internally to reduce production costs.
The PP production waste is too valuable to be wasted regardless of what the market price is at the moment.
Filler masterbatches, additives, and modifiers can also be added during the recycling process to improve the properties even more.
Simple-to-use, plastic recycling pelletizing machine for PP
![Water ring pelletizer cut the material into uniform-size Water ring pelletizer cut the material into uniform-size](https://www.polystarco.com/upload/catalog_blog_b/Bulk Bag Recycling - Which recycling machine to buy_ pelletizing__23L127JPcW.png)
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Automatic pelletizing speed adjustment
Prevents pellets from sticking due to the higher melting index of PP material. Produces more uniform-sized pellets without labor intervention.
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Automatic blade pressure adjustment
Allows the pressure between the pelletizing blades and the die head to remain constant. As a result, there is less machine downtime, easier and faster to change blades.
About the Author
Jack Lin
Sales ManagerJack has visited and spoken to hundreds of POLYSTAR machine users around the world over the last 10 years. Having collected practical information on customer feedback and user experiences, he enjoys sharing the advantages and disadvantages of using different types of machines with others, especially coming from the customers' perspectives.