5 Tips to Increase Efficiency in Plastic Recycling Process

2022-11-11 | Technical Blog | By Resul Gökpınar |

In parallel with the increase in the consumption of plastics, driven by economic development and population growth, global plastic waste is projected to triple by 2060 based on OECD reports. Increasing plastic recycling efficiency is one of the major keys to returning more plastic waste to production lines as a valuable recycled polymer. Here we have listed 5 tips to increase efficiency in the plastic recycling process.

  1. Sorting recyclables

  2. Sorting plastic recycling materials based on their types and removing non-recyclable things from the material is the first crucial step for efficient recycling. This can help to a continuous plastic recycling process and ease the operation.

    On the other hand, preventing plastic waste from humidity and contamination as much as possible can help prevent material loss and increase the final pellet quality.

    sorting recycling plastic materials

  3. Integrated machine design

  4. In the recycling process, several plastic recycling equipment has important duties. For instance, a cutter compactor or shredder reduces the size of waste plastic, an extruder melts the material to be able to reshape it, then a pelletizer unit cuts the plastic melt into final pellet shapes.

    POLYSTAR’s easy-to-use integrated machine designs allow the combination of these different pieces of equipment into one plastic granulator machine. These integrations provide a continuous operation by decreasing operation steps, minimize labor intervention, and save time and energy.

    • Cutter compactor integration for PE/PP Film

    • Cutter compactor integration of Repro-Flex and Repro-Flex Plus plastic granulator machine models eliminates the need for a separated crusher and improves feeding consistency. Post-industrial plastic film waste and washed/dried post-consumer film waste can be directly fed to the cutter compactor, and cut by rotary and stationary knives. Cutter compactor pre-conditions (cuts, compacts, pre-heats) these lightweight materials and directly feeds to the recycling extruder since it is directly connected to the extruder. After the following extrusion and pelletizing steps in the same machine, the final recycled pellets are ready for reuse. Therefore, this system helps with a smoother and more stable recycling process.

    • Shredder integration for Raffia, Woven, and Hard-to-grind Materials

    • In the conventional method of recycling raffia, woven, and hard-to-grind plastic materials; these materials require pre-crushing before feeding to the recycling extruder because of their rigid structure. This takes time, space, and more labor effort. Repro-One plastic granulator machine solves this problem with its integrated single-shaft shredder. In this system, the material is only required to be fed to the built-in shredder. The built-in shredder processes the plastic waste at a low temperature to prevent degradation, then conveys it to the recycling extruder directly for the following extrusion and pelletizing steps. Therefore, Repro-One provides a one-step recycling process for PP raffia, woven bags, nonwoven, shrink film rolls, start-up lumps, and many other hard plastic materials.

    • Repro-One Shredder Integrated Plastic Pelletizer - Blog

  5. Consistent feeding of the plastic waste

  6. Consistent material feeding in plastic recycling machine

    Consistent material feeding in the plastic recycling process is one of the keys to higher pellet output, hence for the recycling efficiency. It also eliminates the machine downtime caused by over-feeding or insufficient feeding.

    POLYSTAR solves inconsistent feeding problems with feeding optimization. For instance, the auto-controlled belt conveyor’s feeding speed is synchronized with the cutter compactor ( on the Repro-Flex model ) and shredder ( on the Repro-One model ) of the plastic granulator machines, based on their loading.

    Moreover, an integrated plastic granulator machine design with either a built-in cutter compactor or shredder, stabilize the material feeding to the recycling extruder, resulting in a smoother recycling process along with higher and good quality pellet output.

  7. Automated smart recycling systems

  8. Automation in recycling not only reduces labor intervention but also makes a faster and smoother recycling process possible. In addition to the auto feeding control mentioned above, POLYSTAR also provides further automation features such as:

    • Dual channel filter system for screen changing without stopping the machine
    • Back-flush filter system for automatic melt waste discharging
    • Third-party filter systems integration for a more advanced post-consumer recycling
    • Auto-adjustment of pelletizing knife speed and pressure for having uniform size and shape pellets, eliminating material loss
    • PLC control system with HMI upgrade for efficiently performing many different tasks including online troubleshooting, automatic pre-heating, parameter optimization with cloud IP control, etc.

  9. Simple and easy-to-maintain machine design

  10. Simple machine design, easy operation, and maintenance are indeed the factors that help to increase recycling efficiency. Because these aspects allow operators to learn how to run the machines efficiently in a short time and maintain the machine in a good condition. Besides, this results in lower operational costs.

    Therefore, POLYSTAR focuses on manufacturing operator-friendly plastic granulator machines through continuous re-engineering. This is the reason why POLYSTAR is so popular in the market today.

    Easy to maintain machine design


Achieving higher recycling efficiency is one of the crucial keys to returning more waste plastics back to production lines. Because higher efficiency in the recycling process refers to achieving high quality and high reusability recycled pellets with lower cost and minimum material loss.

Once the quality and reusability of the recycled pellets obtained from the plastic waste are high, this allows using less virgin polymer, which is more costly, in plastic production. Thus, economic benefits and environmental benefits can be achievable at the same time.

For long-term plastic recycling efficiency, investing in the right plastic granulator machine for your needs plays a very important role. Whether you are a professional plastic recycler or a producer who wants to recycle your plastic production wastes, POLYSTAR has a ‘Simple’ solution for you.

We’ll help you to find a simple solution for your plastic waste. Contact us.

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About the Author
Resul Gökpınar

POLYSTAR’s International Sales Representative

Resul creates up to date content based on his experience, gained by solving customers problems from Turkey and EMEA market.

Find Resul on LinkedIn.