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

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 plastic recycling machine to upgrade it's current in-house recycling process.

Established in 1980, the ISO 9001 certified HDPE and LDPE bag producer has earned multiple prestigious awards including Exporter Award and Thai Quality Product.

The Bangkok-based PE film manufacturer is one of the market leaders for frozen food bags, sandwich bags, hanging bags, hole punching bags, garbage bags, disposable and zip bags.

Despite its previous successes, the Thai PE bag producer is determined to continuously develop and improve its production to maintain its leader status in product quality.

The investment of adding a POLYSTAR plastic recycling machine fits perfectly in the quality improvement plan, as production waste is now being processed 100% in-house efficiently with the best possible quality. The return on investment is particularly short because much lesser raw materials are needed for high end quality film products.

Amongst many economic and technical benefits of using a POLYSTAR recycling line for post-industrial, in-house reprocessing, these are the ones that have the most immediate, strongest impacts on the Thai PE film producer at the moment:

Uniform sized plastic pellets - POLYSTAR's high-tech pelletizing system ensures that the recycled pellets size are as uniform (same size) as possible. The round shaped, virgin-like recycled pellets are optimal for reprocessing in extrusion as the shape, size, property and color are very close to virgin material.

Minimal material degradation - a higher percentage of recycled pellets can be re-used in the production process compared to the recycling machines that the company previously owned. The special screw design, advanced filtration and degassing system ensures that the material is processed at an optimal temperature

Extremely simple operation, one-step recycling technology
The one-step plastic recycling technology (combining cutting/compacting + extrusion + pelletizing) requires little space requirement and labor intervention.

The production waste enters the plastic waste recycling machine from the conveyor belt (for film scraps and rigid plastic regrind) and also through nip roll feeder (for film-on-rolls) at the same time. The input is controlled automatically based on the load of the cutter compactor. Through natural heat and friction, the cutter compactor then cuts and densifies the material into a semi-molten condition (a brief gentle heating just below the agglomeration point), which is ideal for the extrusion process then follows. The cutter compactor subsequently feeds the compacted material directly and consistently into the extruder then into the degassing, filtering and pelletizing processes.

feeding unit of a plastic recycling machine

Minimal Property Change: Recycling without quality loss - recycled pellets used immediately in blown film lines

With Polystar's plastic recycling technology, the recycled HDPE and LDPE pellets are put directly back into the blown film extrusion process. The gentle recycling process results in minimal material degradation without significant property change. The virgin-like recycled pellets have an reusability of 95% upto 100%.

Part of the film products such as HDPE and LDPE T-shirt and garbage bags are made of high percentage recycled material and the quality of the end product remains high.

This new installation was the fifth HNT-V plastic recycling model that POLYSTAR has commissioned in Thailand in the previous 5 months.