There isn’t a universal plastic recycling machine. Equipment that works well on rigid HDPE regrind can struggle with thin LDPE film, and a line sized for clean factory scrap can fail quickly on dirty post-consumer bales.
The most reliable way to select equipment is to start with your material audit (what the plastic is, what shape it’s in, how dirty it is), then design the line around the output spec you need (clean flake, densified feedstock, or pellets).
Conclusiones rápidas
- Polymer type affects separation method (float/sink vs hot wash vs dry separation).
- Form factor determines feeding and size reduction (film needs densification; rigids need torque).
- Contamination level drives washing intensity and melt filtration requirements.
- “Flake vs pellet” output changes which downstream modules you need.
- Ask suppliers to quote “saleable output per hour” under a defined feedstock condition.
Step 0: Define the Output You Sell (Because It Determines Everything)
Before you choose machines, define what you will sell and how it is tested:
- Copos limpios (buyer tests: moisture, contamination, size distribution, color/specks)
- Pellets (buyer tests: melt flow, odor, gels/specks, consistency lot-to-lot)
If you do not define the output spec up front, suppliers will size equipment around assumptions—and quotes will not be comparable.
Your Material Audit Template (Use This Before You Request Quotes)
| Audit Item | Qué grabar | Por qué es importante |
|---|---|---|
| Polymer(s) | Target polymer + common “look-alike” contaminants | Separation strategy (sorting, float/sink, hot wash) depends on polymer mix. |
| Form factor | Film, bottles, pipes, purge lumps, injection parts | Drives feeding, torque needs, and size-reduction concept. |
| Contamination window | Paper/labels, sand, metals, food residue, oils | Determines washing intensity, wear package, and filtration approach. |
| Humedad | Moisture at inbound and after washing | Controls drying design and extrusion stability. |
| Throughput reality | Average and worst-case kg/h + working shifts | Prevents undersizing and sets your true capex/opex trade-offs. |
Step 1: Define the Polymer and What Must Be Removed
Start by listing your target polymer and your most common contaminants.
Typical separation logic: – PE/PP often float in water; PET/PVC/ABS often sink (use float/sink tanks as one tool, not the only tool). – PVC in PET is a high-risk contaminant because it can damage rPET quality at low levels; plan sorting and QC accordingly.
If your input is mixed or inconsistent, plan for sorting up front (manual + metal removal + optical where justified).
Step 2: Identify the Form Factor (This Drives the Front End)
Flexible waste (film, bags, woven)
Key challenge: low bulk density and “wrapping” behavior.
Common modules: – wet or dry pre-shredding / cutting (depending on the line concept) – intensive washing (film carries high surface contamination) – dewatering and densification before extrusion (often via squeeze drying or agglomeration)
If you are processing post-consumer film, start by reviewing a proven process flow like Energycle’s PE/PP film recycling process design to align equipment terminology.
Rigid waste (bottles, crates, pipes, injection parts)
Key challenge: thick sections and variable geometry.
Common modules: – primary size reduction with a trituradora de un solo eje when parts are bulky – secondary sizing with a granulador de plástico – washing/separation matched to the polymer mix
Step 3: Score Contamination and Choose the Cleaning Strategy
Think in three contamination types:
- Physical dirt (sand, stones, paper): friction washing + separation + water management
- Other polymers (PVC in PET, PA in PP, etc.): sorting and density/electrostatic separation where needed
- Chemicals/odors (oils, food residue): hot wash and process control
If you expect heavy contamination, start from a full sistema de lavado de reciclaje rather than trying to “upgrade later.”
Step 4: Decide Your Output (Clean Flake vs Pellets)
Clean flake output – Typically targets stable size, low dirt, and manageable moisture for storage/transport. – Works well if you sell flakes to compounders or pelletizers.
Pellet output – Adds extrusion and filtration requirements. – Requires tighter control of moisture and contamination to protect the extruder and screen changer.
Energycle’s peletizadores de plástico and turnkey soluciones de reciclaje are typically configured around the output you sell, not just the input you receive.
Step 5: Build the “Minimum Viable Line” (And Then Add Options)
Many projects fail because buyers start with an overbuilt line or an underbuilt line. A better approach is to define a minimum viable configuration that can hit your output spec, then add optional modules that protect quality and uptime.
Examples of optional modules that often pay back:
- metal removal and pre-sorting to protect knives and pumps
- stronger dewatering to stabilize drying load
- additional separation stages to reduce label/paper carryover
- melt filtration upgrades (if pelletizing) to handle real contamination spikes
A Practical Decision Matrix (Examples)
Use this as a starting point—final configuration depends on your spec, throughput, and local contamination patterns.
| Your Waste Stream | Typical Front-End | Typical Downstream Goal |
|---|---|---|
| Clean in-house film scrap | Cutting + densification feeding | Direct pelletizing or densified feedstock |
| Dirty agricultural film | Size reduction + intensive washing | Clean flakes, then pelletizing with strong filtration |
| HDPE/PP rigid containers | Shredder/granulator + washing and separation | Clean flakes or pellets depending on end market |
| Botellas de PET | Sorting + hot wash + rinsing + drying | Clean flakes for fiber/packaging applications |
What to Ask Before You Buy
- What is my worst-case contamination scenario, and can the line handle it?
- What moisture level do I need for storage/extrusion?
- Do I need flake, densified feedstock, or pellets?
- What QC checks will I run (PVC detection, melt filtration pressure, ash content, etc.)?
Preguntas frecuentes (Preguntas reales sobre adquisiciones)
1) How do I avoid buying a line that only works on “clean demo material”?
Define the feedstock condition in your RFQ and require suppliers to quote performance under that condition. Specify a contamination window (labels/paper/sand/metal), moisture at feed, and polymer mix. Then ask each supplier to state throughput as saleable output per hour and to include assumptions about downtime (screen changes, cleaning, knife service). Without those definitions, two “500 kg/h” lines can deliver very different saleable output. If possible, run a trial with your own material or a documented surrogate. The goal is not a perfect trial; it is to prove the line behavior when contamination spikes and moisture drifts.
2) What is the fastest way to choose between “flake output” and “pellet output”?
Follow your customer spec and your logistics. If you already have buyers for washed flakes, flake output can reduce capex and simplify operations. Pellet output can increase market flexibility, but it adds extrusion, filtration, and tighter moisture control—plus more process know-how. Ask your potential buyers what tests they use (appearance, specks, moisture, melt flow) and what penalties they apply for drift. Then price the full system: washing, drying, and pelletizing, not only the extruder. If you need help mapping outputs to equipment, Energycle’s peletizadores de plástico overview is a useful reference for pelletizing terminology.
3) What equipment matters most for post-consumer film compared with rigid plastics?
Film lines succeed when they stabilize feeding and drying. Low bulk density makes feeding unstable, and film carries surface contamination that drives washing and separation requirements. Rigid plastics are easier to feed and shred, but they often require stronger size reduction torque and consistent granulation for washing. In film projects, densification/compaction, dewatering, and filtration (if pelletizing) often decide saleable output. In rigid projects, rotor power, knife maintenance, and separation performance often decide uptime. Start with a proven film flow like Energycle’s PE/PP film recycling guide before you compare quotes.
4) What minimum documents should I require from a recycling equipment supplier?
Ask for a process flow diagram, a scope-of-supply list, electrical and utility requirements, and a performance definition tied to your feedstock condition. Then require a wear parts list with lead times and a recommended spares package. If pelletizing is included, ask for the filtration configuration and the expected screen-change interval at your contamination window. For washing lines, require a water management plan (filtration, sludge removal, and discharge/recirculation concept). Clear documents reduce commissioning surprises and make quotes comparable. If you are collecting proposals from multiple suppliers, standardize your RFQ template so each seller responds to the same assumptions.
5) How do I decide whether I need hot washing?
Hot washing is justified by the contaminants you must remove and the buyer spec you must meet. If labels, adhesives, oils, or food residue drive odor and appearance complaints, hot washing can improve cleanliness—but it increases wastewater treatment needs. Decide with a trial: wash a representative batch with and without hot wash, then check the tests your buyers use (visual contamination and odor). If buyers accept cold-washed flakes, invest more in sorting and rinsing instead. Ask suppliers to define temperature, residence time, and water-loop assumptions.
If you want help turning your material audit into a complete equipment list, share photos, bales, and target output with Energycle via its página de contacto.
