PCR recycling machine

Repro-Flex -- High Efficiency Line for Packaging Film
Plastic film recycling machine
Repro-Flex Plus – Design for PCR recycling, such as plastic packaging, plastic container (pre-crush), etc.

Plastic Recycling Materials

  • Post- consumerPost- consumer
  • Pre-crushed Printed FilmPre-crushed Printed Film
  • Laminated filmLaminated film

Select Your Model (Can select more than one model)

Give us some more information

Q1.Plastic Recycling Materials (Can select more than one model)
Q2.Plastic Material Source (Can select more than one model)
Q3.Plastic Material Type (Can select more than one model)
Q4.Plastic Film/Bag Printing % on surface (Can select more than one model)
Q5.Moisture level after washing (Can select more than one model)


Model Name Repro-Flex Plus
Final Product Plastic pellets/granule
Machine Components Conveyor belt, cutter compactor shredder, extruder, pelletizing unit, water cooling
unit, drying unit, silo tank
Recycling Material HDPE, LDPE, LLDPE, PP, BOPP, CPP, OPP, PA, PC, PS, PU, EPS
Output range 80~1100 kgs/hr
Feeding Conveyor belt (Standard), Nip roll feeder (Optional)
Screw Diameter 65~180mm (customized)
Screw L/D 30/1,32/1,34/1,36/1 (customized)
Screw Material SACM-465
Degassing Double vented or triple degassing (customized)
Cutting Type Hot die face pelletizing
Cooling Water cooled
Voltage Customized based on request (For example: USA 480V 60Hz, Mexico 440V/220V 60Hz, Saudi Arabia 380V 60Hz, Nigeria 415V 50Hz...)
Optional Devices Metal detector(S+S) , Nip roller for film roll feeding , Additive feeder for masterbatch, Centrifuge dryer for drying
Delivery Time 75~120 days
Warranty 1 year
Technical Assistance Engineers available to service machinery overseas

Simple in Design . Flexible in operation

How Repro-Flex works

Belt Conveyor Feeding
With belt conveyor: Feeding of scraps is easy and automatically controlled
Nip Roller Feeding
Film-on-rolls can be fed with nip roll feeder at the same time
Cutting and Compacting
Cutter compactor with rotary knives & direct feeding to extruder :
Cuts, dries and compacts the material which enables a fast and stable feeding from the compactor directly into the extruder
Two-zone degassing (double-vented degasification) : Able to process films with larger printed area and some water content
Screen change with dual channel system :
For non-stop operation and prevents material from leaking
Hot die face pelletizer :
Produces high quality plastic pellets for reprocessing
Second filtration
The extra filtration on the second extruder ensures better pellets quality. Therefore, giving more stable production when re-used again in production lines.
Simple-to-use die face pelletizing
Automatic pelletizing speed adjustment:
Produces more uniform-sized pellets without labor intervention.

Automatic blade pressure adjustment:
Less machine down time, easier to change and adjust knife.
Final Product
The recycled plastic pellets can be put directly back into the production line such as blown film extrusion and pipe extrusion and injection molding.

Re-usable plastic pellets

Re-usable pellets

The plastic pellets produced by the PCR recycling machine can be put directly back into the production line, such as injection molding machines and the blown film extrusion machine (making garbage bag),and LDPE pipe extrusion.

1. Pellets from in-house, post-industrial recycling
On average, post-industrial waste makes up 5% or more of the entire production line, making in-house recycling very important nowadays as it can significantly reduce the cost of raw/virgin material purchasing.
The plastic pellets produced from in-house waste are almost like-new and can be re-used for producing high quality plastic products once again.
2. Pellets from post-consumer recycling
The Repro-Flex Plus is also designed to work with washed, post-consumer and used agricultural film. The cutter compactor, which generates frictional heat during the compacting process, helps to further dry and remove the water moisture from the washed film flakes (processed first by the washing lines). The recycled pellets can be used again in extrusion process, whether 100% (such as garbage bag, LDPE pipe production and, etc.) or as part of the mixture to reduce raw material cost. The pellets quality can also be improved by direct dosing of masterbatch and additives.

PCR Recycling Machine

POLYSTAR’s high efficiency, one-step PCR recycling machine Repro-Flex is designed for the reprocessing of the PCR plastic waste such as: medical plastic packaging, plastic bottle and containers. This cutter integrated pelletizing system eliminates the need of pre-cutting the material, requires less space and energy consumption while producing high quality plastic pellets at a productive rate.

In addition to recycle PCR plastic film waste, the system is also able to process post-consumer (PCR) plastic waste. This equipment is highly recommended for packaging film recyclers of medical plastic bags, waste plastic bags, agricultural films, food packaging, shrink and stretch films, etc. Other types of material such as PS sheet, PE and PS foam, PE net, EVA, PP mixed with PU are also applicable on this machine.

For processing using PCR plastic recycling machine

Cutter compactor
Cutter compactor shredder Easy material feeding
Easy material feeding by belt conveyor Higher output
30% higher output and higher quality pellets

1. Filtration before degassing

The re-positioning of filtration before degassing ensures a superior degassing effect, producing excellent quality pellets from heavily printed material.

2. Triple Degassing

In addition to the double degassing in the first extruder, the venting area (the connection between the first and second extruder) serves as a third degassing section to further remove the ink and extra humidity level from the material.

3. Higher pellets quality

The stable material feeding together with the hot die face pelletizer produce round-shaped, uniformed size pellets that are higher in value and optimal for reproduction (extrusion processes).

Model Comparison

Model Repro-Flex65 Repro-Flex85 Repro-Flex100 Repro-Flex120 Repro-Flex150 Repro-Flex165 Repro-Flex180
Output 80-120 Kg/hr 180-250 kg/hr 300-400 kg/hr 450-600 kg/hr 700-800 kg/hr 850-1000 kg/hr 1000-1200 kg/hr
5250 5950 6600 7550 8550 8800 9100
(With all option)
6000 7000 8000 9000 10000 11000 12000
7300 8200 9400 15000 16000 17500 18000
(With all option)
10000 12000 12000 15500 16500 18000 19000
C 2900 3100 3200 3400 3500 3600 3700

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.
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