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).

Other benefits

• 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.