BOPP and stretch film scraps and film on-roll can be turned into high quality pellets for reprocessing. Polystar’s advanced cutter-compactor system can process material that is typically more difficult to recycle due to its special property, such as printed BOPP and stretch film that one normally faces problem with the traditional recycling systems.

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.

Leftover waste of edge trim from blown film and cast 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.

Post-industrial waste generated from PE, PP and PPR pipe production (defected products) can be reused again in pipe extruders when recycling is done correctly.
After shredding, the rigid regrind goes directly into the POLYSTAR pelletizing line for immediate reprocessing. The Repro-Direct 150 processes 700kg/hr for the Turkish pipe producer.
Since it has started in-house recycling, the valuable secondary raw material has significantly reduced the use of virgin and material, with the quality of the pipe remaining just as high.

Production waste from thermoformed PP trays, cups, spoons and PS utensils.
The largest plastic producer located in Bolivia with over 2,000 employees is currently recovering all of its industrial waste with two POLYSTAR recycling machine HNT-120V, processing in total of 1,000 kg/hour.
The recycling machine can flexibly handle both PP and PS thermoformed product, in addition to some of the PE and PP film waste

The Nitra-based recycler acquired a POLYSTAR HNT-85 to work in-line with its existing washing and drying units to complete the turnkey, government-funded recycling project.
The dirty material is collected from city waste. After a quick sorting, the post-consumer waste first goes through the washing and drying lines.
The washed and dried film flakes with 3~5% water moisture content is then fed directly into the POLYSTAR HNT-85V machine for further degassing, filtration and pelletizing.

Stretch and cling film producer in Taiwan with monthly production of 3,000 tons (achieved with several 5-layer cast film machines from Germany) have high standards for its in-house recycling. The defected film-on-rolls are fed automatically via the nip roll feeder. After a quick cutting and compacting process it goes directly into the recycling extruder for further processing and pelletizing. The rest of the occasionally generated scraps are fed via the conveyor belt. The two-way feedings are controlled automatically and simultaneously to prevent over-feeding or insufficient feeding of material into the machine. The high quality, uniform sized recycled pellets can be used 100% back into the cast extrusion lines.

The A-B-A 3 layer blown film machine is mainly used for T-shirt and garbage bag production. The biggest advantage of the A-B-A is that a high percentage of calcium carbonate compound can be used in the middle (B) layer. Besides reducing a significant amount of virgin raw material used in the formula, another advantage of the ABA machine is that the 3-layer film that it produces is 30% stronger than the film produced by a monolayer extruder with the same thickness.
In some markets where T-shirt bag production has become extremely competitive, film producers are replacing their existing monolayer extruders with ABA 3 layer blown film machines to reduce production cost.

When producing film rolls suitable for T-shirt bag and bottom-sealed bag conversions (ranges from 200~600mm in width), it is difficult to achieve higher output by using a bigger extruder for such small film width unless an IBC (internal bubble cooling) is used. Polystar’s double (twin) head blown film machine provides an economic alternative and has a much faster return on investment comparing to a blown film machine equipped with IBC. In the double head blown film machines, one can reach much higher output with bigger extruders even when producing at smaller film width. It is especially effective for T-shirt bag makers who are looking for less expensive machines with higher output. This type of twin head film extrusion line is very popular amongst T-shirt bag makers.

Polystar’s classic 55mm and 65mm monolayer extrusion machines are prevalent throughout the European market for packaging film application. It provides a flexible solution for general packaging; suitable for both HDPE and LDPE film production by simply changing the die head and air ring. Polystar designs and customizes each and every machine based on customer’s requirement to produce a wide variety of products. Examples are hole-punched bags, soft loop handle bags, courier bags, T-shirt bags, supermarket bag, flat bags and many others. Good output, mixing and thickness control can be easily achieved.

The mulch (agricultural) film producer located in Santiago, Chile has been working with Polystar for years and has recently added two more lines to expand its production capacity. The two-layer (AB) film line is mainly used for LDPE agricultural film production. The company also produces other products such as construction film, furniture cover, detergent bags, heavy-duty bags, shopping bags, consumer packaging and many others. The film line is equipped with automatic winding, cutting, and offloading as well as a 4 component dosing system. A specially designed screw allows the producer to work with recycled material in the mixture.

The Vietnamese bag producer with monthly production of 1,500 tonnes doing 100% export to mainly European and Japanese markets.
HDPE thin T-shirt bags with virgin material for the Japanese market and LDPE thicker garbage bags (bag on rolls and draw tapes) with recycled material for the European markets can both be produced on the same DM55-750 machine.
The switch between producing HDPE/LDPE can be done simply by changing the die heads and air rings of the machines. Space saving, lower energy consumption, higher productivity are the reasons why the company continues to invest in POLYSTAR every year for both quality product and manufacturing efficiency.

The garbage bag producer with more than 15 sets of POLYSTAR mono layer extruders produce mainly garbage bag on rolls. The special screw design provides flexibility for producing blown film from different resins.
According to the owner of the bag producer, “we can switch between using virgin, recycled or mix with calcium carbonates on the POLYSTAR HA55-1000 and still manage to obtain very good film quality and thickness variation.
Besides, the POLYSTAR blown film extrusion lines are compact and simple to operate.

Sharjah-based bag producer who manufactures LDPE two layer (AB) carrier bags, DHL bags, high quality shopping mall bag, soft loop handle and many others.
Load cell tension control, edge position control, 4 component gravimetric dosing and fully automatic double winding and cutting are equipped to improve manufacturing efficiency and automation.
Film thickness from 40 micron to 150 micrones, and film width from 700 ~ 1300mm can be achieved in this machine depending on the product requirement.

DM45-500 model with twin die head can produce film from 100mm ~ 400mm, which is ideal for HDPE flat bags and glove production.
The Thai based producer is producing a wide range of thickness from 7 to 15 microns of HDPE gloves, vegetable and fruit bags with the machine DM45-500.
Good film thickness control, stable output and superior film quality is the reason why the Thai based producer continues to grow its business overseas.