Flexible film (LDPE/LLDPE) is one of the hardest high-volume plastic streams to recycle well. When capacity grows, it usually means the market has found ways to manage contamination, moisture, and odor—at an operating cost that still makes sense.
Industry reporting from European trade groups points to sustained growth in installed recycling capacity for flexible polyethylene. For example, Packaging Europe summarized Plastics Recyclers Europe’s estimate of a “nearly 10% increase” in installed flexible film recycling capacity in 2020, despite COVID-era disruption. That growth trend is supported by better Prozessdesign für das Recycling von PE/PP-Folien and tighter policy pressure on packaging waste.
Kurzgefasste Erkenntnisse – Film recycling economics depend on wash quality and drying as much as on shredding or extrusion. – “Film-to-film” output requires cleaner input streams and tighter melt filtration than low-grade applications. – When you evaluate a project, define feedstock quality and product spec first, then size the equipment.
What “Capacity Growth” Means (And What It Doesn’t)
Installed capacity growth is a sign that investors and brands expect demand for recycled polyethylene. It does not automatically mean every line can make high-grade film resin. In film recycling, quality often collapses because of: – contamination and moisture swings (post-consumer film is variable) – odor and volatiles (especially in household streams) – unstable feeding and filtration downtime
If you’re building a line, treat “capacity” as a starting point and then design for saleable output per hour.
What’s Driving Growth (Beyond Headlines)
Two forces usually move capacity: – Demand pull: recycled-content commitments and packaging waste policy pressure. – Technology push: better washing, separation, and filtration that makes film output more consistent.
Drivers of Growth: Technology and Policy
Two main factors are fueling this expansion: the “pull” of legislation and the “push” of technological capability.
1. The Policy Framework
In Europe, packaging policy and recycled-content expectations push demand for recycled polymers. The European Commission’s overview of the Packaging and Packaging Waste Regulation (PPWR) is a useful reference point for understanding why brands are planning for more recycled content and why recyclers are investing in capacity (see the European Commission’s PPWR overview).
2. Technological Evolution
Historically, post-consumer film was difficult to recycle (smelly, wet, and highly contaminated). Today, advanced machinery has changed the equation: * Heißes Waschen: Industrial film washing and recycling lines can remove organics and reduce odors, supporting higher-value end uses compared with downcycling. * Improved filtration strategies: Better melt filtration and screen-change control reduce downtime and improve pellet consistency on real-world feedstock.
What Equipment Improvements Actually Matter for Film Recycling
Film lines succeed when they stabilize three things: feed, moisture, and contamination. This table maps “what changed” to “why it matters.”
| Line challenge | What improves results | Why buyers care |
|---|---|---|
| Unstable feeding (low bulk density) | Better feeding and densification/compaction concepts | Stable melt pressure and fewer stops |
| Moisture after washing | Stronger dewatering and drying design | Less steam/foaming risk, steadier extrusion |
| Adhesives, paper, and fines | Washing + separation tuned for film streams | Cleaner pellets and fewer customer rejections |
| Filtration downtime | Filtration strategy sized for real contamination load | Higher saleable output per hour |
Challenge: The “Film-to-Film” Imperative
While capacity is growing, the quality of the output remains the industry’s central challenge. Historically, much of the recycled film was used for low-value injection molding applications (e.g., flower pots).
The new goal is circularity: * Current state: Much recycled film still goes into lower-demand applications when contamination and odor are not controlled. * Directional trend: Buyers are increasingly asking for cleaner rPE suitable for film applications, which raises the bar on washing, drying, and filtration.
Achieving this requires a strict adherence to Design für Recycling principles. Multi-layer barrier films (e.g., PE + PA/EVOH) remain a contaminant in the stream. The industry is aggressively moving toward mono-material PE structures that maintain barrier properties without compromising recyclability.
Strategic Outlook
Europe’s growth is also a reminder that policy, infrastructure, and buyer specs move together. If your end market expects tighter specs, your equipment must be designed around those tests—especially washing, drying, and filtration.
If you’re designing a film wash project, Energycle’s Recycling-Waschsystem page can help align terminology for wash loops, separation, and water management.
Buyer Checklist: What to Verify Before You Invest
1) What is your inbound film stream (household vs industrial), and what is the contamination range?
2) What is the required output spec (film grade vs downcycling applications), and how is it tested?
3) What moisture target is required at extruder feed, and how is it measured?
4) What is the filtration strategy and expected screen-change interval at your contamination load?
5) What is the plan for odor/volatiles, and how will it be validated with trials?
Häufig gestellte Fragen (FAQ) (Echte Fragen zum Beschaffungsprozess)
What’s the single biggest reason film wash projects miss quality targets?
Moisture and contamination variability. Film streams can look “clean” and still carry detergent residue, labels, paper fibers, and grit that load the wash system and later overload filtration. If moisture after washing is not controlled, extrusion becomes unstable and pellets drift lot-to-lot. The fix is not one machine—it’s a tuned system: washing, separation, dewatering/drying, and filtration matched to your stream. Before you buy, define the acceptance tests your buyer uses and run a material trial that measures wash quality, moisture at feed, and filtration behavior at production rates.
Do I need hot washing for post-consumer film?
Often, but not always. Hot washing can help remove organics, adhesives, and residue that contribute to odor and quality issues, but it adds energy and water treatment needs. The decision should be driven by your buyer’s spec and your inbound stream. If you target film-grade applications, you usually need tighter cleanliness and more stable output, which can justify more aggressive washing. If your market accepts lower-grade output, a simpler line may be viable. Ask suppliers to show reference data on similar film streams and to define what contaminants their line is designed to handle.
How should I compare “kg/h capacity” numbers between suppliers?
Ask for saleable pellets per hour at a defined feedstock condition. Provide a contamination and moisture range, then require suppliers to define the wash quality, moisture at extruder feed, filtration approach, and expected screen-change interval. Capacity claims without those definitions are not comparable. Also ask how many operators are assumed and what downtime is expected for cleaning and maintenance. Film recycling lines can show impressive “mechanical capacity” and still produce low saleable output if filtration downtime and restart scrap are high.
What policy documents should I read first if I’m investing in Europe?
Start with official EU sources that explain the Packaging and Packaging Waste Regulation context and how packaging policy is evolving. The European Commission’s PPWR overview is a practical starting point for understanding why recycled content and packaging waste rules influence demand. Then confirm the compliance path for your customers and your country. Policy sets direction, but buyers set acceptance tests. Your equipment selection should still be driven by your customer’s spec and your feedstock reality.
What moisture level should I target before extrusion for washed film flakes?
Ask your pelletizing supplier what moisture range their extruder can tolerate without steam bubbles, unstable melt pressure, or pellet quality drift, then work backward to define your drying specification. Mechanical dewatering removes free surface water, but film flakes still hold water in folds and fines. In practice, the moisture target depends on polymer, melt temperature, and how sensitive your customer is to gels and voids. Do not accept “dry enough” as an answer—require a measurable moisture target, where it is measured (after dewatering, after hot-air drying, at extruder feed), and what happens to throughput when moisture rises.
Which two pieces of equipment make the biggest difference in film-to-film quality?
First is the washing/separation train, because film-to-film quality fails when adhesives, paper fibers, and grit carry through and overload filtration. Second is the melt filtration strategy, because film lines often face contamination spikes that create downtime and pressure instability. Shredders and densifiers matter, but they rarely fix quality problems caused by poor washing or undersized filtration. Ask suppliers to show how their line handles a defined contamination window, including screen-change behavior, restart scrap, and the maximum acceptable dirt load. Energycle’s film washing and recycling line page is a useful reference for process terminology when comparing proposals.
Referenzen
- Packaging Europe — Flexible film recycling capacity “grows by almost 10%” in 2020 (citing Plastics Recyclers Europe)
- Plastics Recyclers Europe — Research & reporting on European plastics recycling capacity
- European Commission — Packaging and Packaging Waste Regulation overview
- PlasticsEurope — The Circular Economy for Plastics (European analysis, 2024)
