POLYSTAR Plastic Pelletizer + Third-Party Filter – Simple Solution for Post-consumer Recycling

2022-10-13 | Customer Experience | By Jack Lin |

Improve the quality of recycled pellets from post-consumer waste.

The need for a more automatic, self-cleaning filter to reduce labor costs and improve efficiency has been a key factor for professional post-consumer recyclers, for applications such as paper label removal and milk/shampoo bottles. However, most of the solutions available in the market today have a very high initial investment cost and even higher maintenance costs that follow (mainly because of expensive spare parts), which could be challenging as the operation cost remains high and the return on investment is too slow.

World-class plastic recycling machine.

The POLYSTAR extruder pelletizer and FIMIC filtration system combination provide professional recyclers with a simple, cost-effective solution that has a much lower operation and maintenance cost, which results in a higher profit margin. Fast delivery time and fast return on investment, make things even easier for recyclers who need to have a machine up and running within a short time.

Advantages of using third-party filters

Plastic recycling machine integrated third-party filter

  1. Easy to operate

    The FIMIC filter is much simpler because it requires only 30 minutes and one operator to replace a screen, whereas other solutions in the market generally require 1.5 ~ 2 hours.

  2. Less investment and operation/maintenance cost

    The FIMIC system does not need to install an extra pre-filter to protect the screen against possible damage as the “scraper” collects the contamination immediately from the screen.

    The melt losses are also less because the filter discharges only when it is needed ( instead of discharging continuously like in some filter systems).

Advantages of Using POLYSTAR Recycling Machine

The design of the POLYSTAR pelletizing extruder is simple and focused on the most important features for recyclers to have a stable operation in order to reduce downtime and lower production costs.

The emphasis on an easy user interface makes sure that the Initial training time and cost for (new) machine operators can be greatly reduced. The simplicity of the design also makes it easy for the operators to perform maintenance on the machine.

Plastic extruder integrated filter

  1. Lower maintenance cost

    The key advantage of using POLYSTAR plastic recycling machine is that the cost of consumable parts is 2.5~3 times lower compared to European machine suppliers of similar built quality.
    POLYSTAR uses universal electrical components from Siemens and Schneider so that it’s easy for the users to source locally if required.

  2. Less waste generated

    POLYSTAR unique design has much less change over time (up to 30~40%) during the “purging” process and therefore generates less production waste compared to other recycling extruders, which can fit professional recyclers’ needs.

    Both a single-stage extruder and a two-stage (cascade type) plastic extruder from POLYSTAR can adopt a FIMIC filter, with a production output range from 500kg ~ 1,000kg (1,100 ~2,200 pounds) per hour to select from. The FIMIC enhances the filtration performance whereas the POLYSTAR two-stage extruder improves the degassing ability.

Integration is simple and fast - Customer experience

During the project preparation stage, POLYSTAR and FIMIC work very closely together with the customer for the customized build-up, providing each other with all the necessary details to ensure the extruder + filter integration is flawless.

FIMIC filter in the recycling machine.

During the installation and start-up stage, technical engineers from both FIMIC and POLYSTAR will be present at the same time to assist customers and provide necessary training.

“The setup was very easy, their engineers came over for the setup, and in just 4 days we had the machine running already.”

Mr. Irvin said.

This Tennessee-based recycler in the US who installed the system in 2018 has been running the POLYSTAR + FIMIC recycling machine for the past two years, processing mainly coffee bean bags and peanut bags. The recycler already plans to set up another line as the business expands.

Plastic recycling integrated filter in Russia.

Quoting a Rostov, Russia-based recycler Europolimer who recently installed a second 750kg/hr two-stage plastic recycling line,

“Both FIMIC and POLYSTAR focus on simplicity and low maintenance cost, we have been able to control our production cost well and stay competitive in the market.”

Mr. Pavel Said.
The production director of the Russian post-consumer plastic recycler.

In the case of a professional recycler located in Sweden, a FIMIC + POLYSTAR integration was even successfully done “remotely” due to recent travel restrictions and the effect of the COVID-19 coronavirus that prevent technicians from going overseas.

“The installation was successful! Big thanks to their team for the preparation and further action taken during the remote start-up and afterward to make it happen in this new way!”

said Mr. Peter of the Swedish plastic recycler.

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About the Author
Jack Lin

Regional sales manager for Latin America

Jack 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.

You can find Jack on LinkedIn.