Model number: Repro-Flex
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- PE/PP film roll
- Film scraps
- Bubble Film
- Film Sheet
- Shrink Film
- Waste Bags
- Stretch Film
- Swimming Pool Covers
- Garbage Bag
|Final Product||Plastic pellets/granule|
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||100kg~ 1200 kg/hr *Based on post-industrial LDPE film clean, dry|
|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)|
Single or double vented degassing, Unvented for non-printed film (customized)
Two stage type (mother-baby extruder) for even better degassing
|Cutting Type||Hot die face pelletizing (Water ring pelletizer)|
|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 for customized machine. In stock machines available|
|Technical Assistance||Engineers available to service machinery overseas|
How Repro-Flex works
Cuts, dries and compacts the material which enables a fast and stable feeding from the compactor directly into the extruder
For non-stop operation and prevents material from leaking
Polystar's high efficiency, one-step plastic recycling machine Repro-Flex is designed for the reprocessing of PE polyethylene (HDPE, LDPE, LLDPE) and PP polypropylene flexible packaging material, printed and non-printed. 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 in-house (post-industrial) film waste, the system is also able to process washed flakes, scraps and regrind (pre-crushed rigid plastic waste from injection and extrusion). This equipment is highly recommended for packaging film producers of commercial bags, garbage bags, agricultural films, food packaging, shrink and stretch films, as well as producers in the woven industry of PP woven bags, jumbo bags, tapes and yarns. 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.
The pellets produced by the recycling machine can be put directly back into the production line, in most cases for blown film or pipe extrusion processes.
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 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.
One Step, All-in-One direct recycling
The Repro-Flex plastic recycling machine combines cutting, extrusion and pelletizing into one compact and efficient recycling line. The cutter compactor of the recycling machine prepares (pre-conditions) the material into an ideal condition for the extrusion process and feed the material directly into the extruder with a centrifugal force. Comparing to the conventional recycling machines, this integrated system does not require a separate crusher, andtherefore, eliminates the problem of inconsistent feeding (over-feeding or insufficient feeding)
Easy material feeding without the need for pre-cutting
The waste material enters the machine from the belt conveyor (for film scraps and rigid plastic regrind) and the nip roll feeder (for complete film rolls) at the same time. An extra silo tank can also be added to store and feed pre-washed film flakes. The feeding is controlled automatically based on how full the cutter compactor is. The cutter compactor then cuts, dries and compacts the material into a semi-molten condition (just below the agglomeration point), which is optimal for the extrusion process that follows. The cutter compactor then feeds the material directly and consistently into the extruder screw
Higher output capacity
The integration of the cutter compactor and extruder ensures extremely fast and stable feeding, the tangentially connected extruder is continuously filled with pre-compacted material. This results in a much higher production output comparing to other types of recycling systems on the market
Higher pellets quality
The stable material feeding together with the hot die face pelletizer produce round-sharped, uniformed size plastic pellets that are higher in value and optimal for reproduction (extrusion processes).
- Lower investment cost for a high quality and durable machine
- Low energy consumption with high production output
- Fast machine delivery and installation: Polystar produces on an average of 8 sets of Repro-Flex per month and can deliver the machine faster than most manufacturers. The average delivery time of a Polystar recycling machine is 60 days.
Blown film producers
Leftover waste of edge trim from blown film in the format of scraps (T-shirt bags cut-offs from bag making and punching processes), complete film rolls and sheet can be efficiently recycled in a simple process. The high quality, uniformed sized recycled pellets are almost like virgin material which can be put directly back into the film production line.
PP woven producers
In-house waste generated from the production of PP woven bags, non-woven, jumbo bags, PP raffia, PP woven sacks and tapes. The recycled PP pellets can be reused (100%) for production. In most cases in circular weaving looms and tapelines.
Professional Recyclers who collect both post-consumer and post-industrial waste.
The pellets quality can be improved by direct dosing of masterbatch and additives.
|Output||80-120 Kg/hr||150-250 kg/hr||300-400 kg/hr||400-600 kg/hr||700-800 kg/hr||850-1000 kg/hr||1000-1200 kg/hr|
(With all option)
(With all option)
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.