An agglomerator is a densification machine that turns light, fluffy plastic scrap \u2014 film, bags, raffia, stretch wrap \u2014 into dense, free-flowing granules using friction heat generated by high-speed rotating blades. Recyclers rely on it because loose film is nearly impossible to feed into an extruder and expensive to store or truck: baled film sits at roughly 20\u201350 kg\/m\u00b3, while agglomerated granules reach 250\u2013400 kg\/m\u00b3 \u2014 a five- to tenfold gain in bulk density.<\/p>\n\n\n\n
This guide explains how an agglomerator works step by step, which materials it handles, the specifications that decide real-world throughput, and where the machine belongs in a recycling line. The process descriptions and spec figures come from the film agglomerators we build and test-run at Energycle for PE and PP scrap.<\/p>\n\n\n\n
In plastic recycling, an agglomerator is a batch machine that densifies thin, lightweight plastics through friction. A set of fixed and rotating knives at the bottom of a steel tank spins at high speed; the friction between blades and material heats the plastic to its softening point \u2014 not its melt point \u2014 so the film shrinks and curls into compact crumbs. A shot of water then quenches the charge, and the crumbs solidify into irregular, popcorn-shaped granules of roughly 5\u201315 mm called agglomerate<\/strong>.<\/p>\n\n\n\n The same machine goes by several names: plastic agglomerator, film agglomerator, or plastic film densifier<\/a>. The terms overlap, though “densifier” is also used more broadly for foam densifiers and screw presses. Agglomerate is an intermediate product: denser and far easier to convey, dose, and extrude than loose film, but not as uniform as finished pellets. You can see tank sizes, motor options, and typical outputs on our plastic film agglomerator<\/a> product page.<\/p>\n\n\n\n Key takeaway:<\/strong> An agglomerator is a friction densifier. All process heat comes from the main motor through the blades \u2014 there are no external heaters to install, power, or maintain.<\/p><\/blockquote>\n\n\n\n An agglomerator works in repeating batch cycles. Each cycle takes about 8\u201315 minutes depending on the material, its moisture level, and the motor size. The operator \u2014 or a PLC on automated units \u2014 runs five stages:<\/p>\n\n\n\n Because the process stops short of full melting, the polymer sees less thermal stress than in an extruder pass. The trade-off is granule shape: agglomerate is irregular by nature, which is why lines that sell finished pellets still run an extruder after the agglomerator.<\/p>\n\n\n\n Agglomerators are built for plastics too light or too thin to feed into other equipment. Typical feedstocks:<\/p>\n\n\n\nHow Does an Agglomerator Work?<\/h2>\n\n\n\n
What Materials Can an Agglomerator Process?<\/h2>\n\n\n\n