4 Types

One-step, Integrated Systems
For Different Recycling Needs
Repro-FLEX
One-step process for PE, PP film
Repro-ONE
One-step process for
PP raffia and hard-to-grind material
Repro-AIR
Air-cooled. Super compact.
HDPE and LDPE post-industrial film
Repro-DIRECT
Directly processes rigid regrind
(hard plastic)
Repro-FLEX
Repro-ONE
Repro-AIR
Repro-DIRECT
Overview

One-step process for PE, PP film. A cutter-compactor integration

Single shaft shredder integration for one-step process of PP raffia and hard-to-grind material

Air-cooled. Super compact. HDPE and LDPE post-industrial film

Designed specially to process rigid regrind (hard plastic) directly

Suitable Material

Printed and non-printed PE, PP film BOPP, CPP, multi-layered film, shrink film, stretch film, PE and EPE foam. Washed and dried film flakes from washing line. Thermoformed PS, PP. Soft irrigation pipe.

PP raffia, woven, non woven, FIBC/jumbo bags, blown film star-up lumps Film scraps. PP fiber, yarn, tapes. Injection moulding parts, solid lumps. Thermoformed PP products.

HDPE and LDPE film on roll, bag cut-off and punches non-printed or very lightly printed (under 10%) film

Rigid Regrind from injection moulding PE and PP pipes (pre-shredded)

Suitable Industry/ Application

Film, flexible packaging, raffia, woven, recyclers Food packaging, agricultural film production industrial packaging, waste packaging

Raffia, film, flexible packaging, food packaging Agricultural film production, industrial packaging, waste packaging

Film, shrink film packaging, flexible packaging

Injection molded, pipe manufacturer, recyclers

Cutting integration
Repro-FLEX Cutting integration

Cutter-compactor

Repro-ONE Cutting integration

Single shaft shredder

Repro-AIR Cutting integration

Direct Feeding (Nip roller)

Repro-DIRECT Cutting integration

Direct Feeding (Hopper)

Feeding mechanism

Belt conveyor, nip roller feeder

Belt conveyor

Nip roller feeder

Screw conveyor or belt conveyor

Extruder size available

65mm, 85mm, 100mm, 120mm, 150mm, 165mm

85mm, 100mm

120mm (short screw L/D ratio)

65mm, 85mm, 100mm, 120mm, 150mm

Output Range

100~ 1,000kg

150 ~ 300 kg/hr

40 ~ 50 kg/hr

80 ~ 800 kg/hr

Models Available


















Main advantage

Direct, one-step process of light-weighted film scraps without the need for pre-cutting or agglomerating Very stable and consistent output

Integration of the powerful shredder directly processes PP raffia without the need for pre-crushing Discontinuous feeding

Super compact, easy to install. Fits right next to blown film or bag making machines. Waterless. 100% dry pellets Lower machine cost and fast return on investment 100% automatic feeding for film-on-roll.

Rigid regrind (hard plastic) is transported directly into the extruder by feeding hopper. Simple and direct without extra power consumption from unnecessary pre- conditioning unit

Process steps

Cutter compactor (cuts and compacts) --> Directly feeds to extruder after preconditions —> Degassing —> Filtration -> Water ring pelletizing -> Storage silo
For heavily printed material (more than 60% printed area) The filtration and degassing position can be reversed to process the heavily printed material more effectively - Cutter compactor -> Directly feeds to extruder after preconditions —> Filtration —> degassing -> water ring pelletizing -> Storage silo

Single shaft shredder -> directly feeds to extruder after shredding -> Degassing —> Filtration -> water ring pelletizing -> Storage silo

Nip roller feeder —> directly feeds film on roll into extruder (small scraps can be fed manually) —> filtration —> air pelletizing —> storage tank

Belt conveyor —> directly goes into extruder —> degassing —> filtration > water ring pelletizing -> storage tank

Cooling (pelletizing) type

Water ring (hot die face cutting)

Water ring (hot die face)

Air cooled (die face)

Water ring (hot die face)

Filter

Two channel (non-stop dual cylinder type) Non-stop operation during screen changing

Two channel (non-stop dual cylinder type) Non-stop operation during screen changing

Manual (lever) type Non-stop operation during screen changing

Two channel (non-stop dual piston type) Non-stop operation during screen changing

Degassing

Double, single vented, or without degassing

Double or single degassing

Without degassing (unvented extruder)

Double, single, or without degassing

Can directly process (Without pre-cutting)

film scraps, film rolls, bag cut-offs, pre-shredded rigid regrind (1cm x 1cm), pre-shredded raffia

Raffia, jumbo bags, PE/PP blown or cast film start-up lumps

_ _ _ _ _

_ _ _ _ _

Can also process

PS, PC, PU, BOPP+PET, OPP

PS, PC, PU, BOPP+PET, OPP

_ _ _ _ _

_ _ _ _ _

Still cannot find the machines that you are looking for?
Successful Cases
Cutting integration
Colombian recycler adds capacities with 2 more POLYSTAR

2 years after the first installation in 2015, the Colombian recycler has decided to increase capacity by adding two more POLYSTAR recycling machines in 2017 in the cities of Barranquilla and Bogota. 

Cutting integration
Japanese LDPE film recycler goes for POLYSTAR

Located in Tokyo, the professional PE film recycler has installed one more POLYSTAR HNT-120V recycling machine to process 400~500kg/hr LDPE and HDPE post-industrial film waste. The industrial waste is collected from local plastic factories that produce various types of bags, both printed and non-printed.

Cutting integration
Leading PE stretch film producer in Taiwan invests in POLYSTAR

As the largest LLDPE stretch and PE cling film producer in Taiwan with monthly production of 3,000 tons (achieved with several 5-layer cast film machines from Germany), in-house recycling is valued highly by the 30-year-old film producer as part of the production process to ensure quality and consistency in the end product remain high.

Cutting integration
Thailand - 100% in-house, minimal property change in pellets

With more than 1,200 professional staffs and over 60,000 square meter factory space, the export-oriented PE bag producer located in Thailand has decided to go for POLYSTAR’s recycling machine to upgrade it’s current in-house recycling process.

FAQS

Plastic film recycling machine

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.

FAQS
What are POLYSTAR’s recycling machines mainly used for ?

POLYSTAR recycling machines have helped thousands of worldwide plastic producers to reprocess their post-industrial (in-house) waste back into high quality pellets in a simple and easy way. Clean, defected factory waste generated from production of film, raffia and injection regrind can be recycled efficiently and put right back into your production lines. This means less amount of new (raw) material needs to be used in your production and thus reduces production cost significantly.

Whether you are a producer of packaging film (blown and cast), raffia, injection molded, woven/non-woven, pipe extrusion or thermoforming, we have just the right recycling solution for you:

Film - PE, PP packaging film. Shrink film, stretch film, BOPP, CPP, OPP. Laminated film and many others
Raffia, woven bags, non-woven, tape and yarn
Rigid regrind of PE, PP and PS
Pipe - rigid regrind. Soft irrigation pipe
Thermoforming - PS cups, PP sheet
Foam - PE foam, EPE foam, PS foam and EPS foam
Washed Material - Wahed LDPE/HDPE film, washed PP jumbo bags, AG (agricultural) film washed/crushed rigid reg rind
*PET bottles are not applicable on POLYSTAR machines. Our machines can only process HDPE milk bottles.

Which recycling machine is best and most suitable for my business?

- POLYSTAR provides different recycling technology with various shredding/cutting systems based on material type and industry (film, raffia, injection, post-consumer).
- Small to big production output range (from 50kg per hour all the way up to 1,000 kg per hour) are available depending on the production capacity you require.
- More information can be found on our official website: http://www.polystarco.com/en/products_sub_F01.html
- Or consult a POLYSTAR sales person by sending us an em-mail at sales@polystarco.com

How do I receive a quotation from you ?

please send us an email to sales@polystarco.com and indicate the following:

  1. Processing material: HDPE, LDPE, PP, BOPP, PS or others
  2. Material type (form): film, raffia, rigid regrind, foam, washed material (flak
  3. Film - if it is un-printed, lightly printed (under 30% printed area) or heavily printed (over 60% printed area)
  4. Production output required (ex: 100kg/hr, 200kg/hr, 300kg/hr, 400kg/hr, 500kg/hr, and up to 1,000kg/hr etc)

How easy is it to operate a POLYSTAR recycling machine?

For 30 years we have designed our machines to be simple and focus on what’s most important for plastic producers who are looking for an easy and stable operation.
We focus on user-friendliness of the machines through continuous re-engineering and making recycling extremely simple for the users - Easy operation and maintenance is the key value and core competence of POLYSTAR recycling machines.
Even if this is your first recycling machine for your factory, your operators can manage to learn how to use it within a very short period of time. This have been proven in thousands of users in 103 countries.

Spare parts - how are consumable spare parts managed ?

Upon machine delivery, a detailed user manual is provided including a list of all the mechanical spare parts with clear and organized labels that can be easily identified, ordered and replaced later on. In addition, the Online Spare Parts system allows customers to place spare parts quickly and easily.
Simply place your spare parts order online: http://www.polystarco.com/en/spare_part.html
There is also a list of free, commonly-used standard spare parts that POLYSTAR supplies to all of its customers along with the machine purchase.

Warranty - what is the warranty offered on the POLYSTAR machines ?

POLYSTAR provides 1 year warranty on the machine mechanically and six months on all electrical components. All POLYSTAR machines are powered by the best available electrical components from world-class companies.

How does POLYSTAR’s in-house (post-industrial) recycling help my plastic business ?

There are many advantages of in-house recycling, especially with the POLYSTAR machines.

  1. High Quality recycled pellets - Up to 100% reusability back into your production line. Post-industrial waste generated from production of film, raffia and injection regrind can be recycled efficiently and put right back into your production lines. Meaning less amount of new (raw) material needs to be used in your production and thus reduces production cost significantly.
  2. Lower power consumption - thanks to excellent screw design and energy saving motors, you can produce more kg/hr using less energy.
  3. Lower production and logistics cost - POLYSTAR machines are both labor and space saving.
  4. Engineered for easy operation - POLYSTAR’s recycling machines are extremely simple to operate and can be easily integrated into your production line.
See how in-house recycling have helped plastic producers worldwide to become more competitive in their businesses: http://www.polystarco.com/en/news_sub_NS010.html

Where can I see a POLYSTAR machine ?

  1. There are hundreds of videos on our official Youtube channel where you can see all POLYSTAR machines in detail: https://www.youtube.com/user/polystarco
  2. Attend a plastic exhibition near you - POLYSTAR participates in all major exhibitions worldwide: http://www.polystarco.com/en/news_sub_N01.html
  3. International visitors are also welcomed to visit POLYSTAR’s manufacturing facility in Tainan, Taiwan where hundred of recycling machines are produced every year.

Why POLYSTAR ?

  1. Proven success - POLYSTAR has installed 3,500 machines in 103 countries worldwide in last 30 years. See our hundred: http://www.polystarco.com/en/news_sub_N01.html
  2. Our experience, your advantage - 30 years of manufacturing experience focusing on user interface and customer feedback. We continue to develop simple solution and technology to avoid the unnecessary complexity in operation.
  3. Simple machine operation and maintenance, easy spare parts replacement

Is overseas machine installation and training available ?

Yes, POLYSTAR can send an experienced technician to assist with the assembly and start-up of the machine and provide basic training and maintenance guidance to your operators. Under normal circumstances the installation and training can be completed within 6 working days.