Film Recycling Solutions: full process guide for plastic film recycling, washing and pelletizing

Plastic film has become an indispensable material in modern industry. From packaging and agriculture to logistics and consumer goods, millions of tons of polyethylene (PE), polypropylene (PP), and multilayer composite films are consumed globally each year.

However, plastic film waste is one of the biggest challenges facing the plastic recycling industry. Due to its lightweight and flexible properties - often contaminated by dirt, labels, moisture, or organic residues - plastic film is much more difficult to process than rigid plastic.

With increasingly strict global sustainable development regulations and the growing demand for recycled plastics, efficient film recycling solutions have become a key investment project for recycling companies, waste management companies, and plastic manufacturers.

This guide delves into the complete film recycling process, common film types, challenges faced in recycling, processing techniques, and successful recycling solutions.

Plastic film recycling is the process of collecting, sorting, washing, shredding, drying, and pelletizing post-industrial (PIR) or post-consumer (PCR) plastic film to produce reusable plastic pellets.

Recycled pellets can be used to manufacture:

Packaging film
Trash bags
Agricultural film
Construction film
Plastic sheets
Injection-molded products
Extruded products

A complete film recycling production line typically includes:

Shredding, crushing, washing, dewatering/drying, and pelletizing processes.

PE film is the film material with the highest recycling rate.

Typical applications include:

Stretch wrap film
Shrink film
Agricultural film
Greenhouse film
Packaging film
Industrial wrap

Characteristics:

✔ High recycling value
✔ Stable pelletizing performance
✔ High market demand

Low-density polyethylene (LDPE) film is commonly used for:

Shopping bags
Packaging bags
Industrial liners

LDPE film is soft and tough, making it highly suitable for recycling and reprocessing.

Linear Low-Density Polyethylene (LLDPE) stretch wrap film is widely used in logistics, transportation, and pallet wrapping. 

Key characteristics:

High elasticity
High toughness
High-quality recycled granules

Although it is not strictly classified as traditional film, woven bags and raffia materials are typically processed using film recycling systems.

Applications include:

Fertilizer bags
Cement bags
Bulk bags (FIBCs/ton bags)
Industrial packaging bags

Agricultural film recycling is one of the fastest-growing areas in the recycling industry.

Typical materials:

Mulch film
Greenhouse film
Silage film

These materials often contain:

Sand
Soil
Moisture
Organic contaminants

Consequently, reliable washing systems are required.

Film recycling presents unique challenges compared to rigid plastics.

1. High Contaminant Levels

Post-consumer film often contains:

Soil
Sand
Food residue
Labels
Adhesives

Inadequate washing directly impacts granule quality.

2. Material Tangling

Film materials tend to tangle around rotating parts.

This creates challenges for:

Feeding
Conveying
Shredding

Specialized shredders and compactors are usually required.

3. Low Bulk Density

Loose film occupies significant storage and transport space.

Pre-shredding or densification is typically required prior to washing and pelletizing.

4. Moisture Content

Moisture easily adheres to the film surface. Without an efficient drying system, excessive moisture can lead to:

Granule defects
Reduced output
Unstable extrusion pressure

Collected film is fed into:

Belt conveyors
Chain plate conveyors
Screw feeders

The specific equipment used depends on material characteristics.

A film shredder/crusher reduces the material size to facilitate subsequent washing and processing. 

Advantages include:

Uniform material size
Improved cleaning efficiency
Reduced labor requirements

The washing system removes:

Dirt
Sand
Organic contaminants
Labels

Typical equipment includes:

Low-speed Friction washers
Float-sink tanks
Hot washing systems

Efficient drying is crucial for ensuring granule quality.

Typical equipment:

Mechanical dewatering machines
Squeezers
Hot air drying systems

Target moisture content is typically below 5%.

The washed film flakes are processed into recycled granules. Main technologies include:

Single-stage compacting-extrusion pelletizing
Two-stage compacting-extrusion pelletizing

The resulting granules are ready for direct use in manufacturing.

Manufacturers seek recycled granules for:

Flexible packaging
Industrial packaging
Construction materials
Consumer goods

Advantages include:

Lower raw material costs
Reduced carbon footprint
Compliance with regulatory requirements
Enhanced sustainable brand image

ACERETECH offers complete turnkey film recycling systems covering: shredding, crushing, washing, and pelletizing.

Advantages include:

✔ Customized engineering solutions
✔ Stable production performance
✔ Energy-efficient operation
✔ High-quality recycled pellets
✔ Global installation and maintenance services
✔ Comprehensive professional technical support

Whether processing clean industrial waste or heavily contaminated agricultural film, ACERETECH provides customized recycling solutions to maximize recycling efficiency and profitability.

PE Film Recycling Systems

PE film washing solutions
PE film size reduction solutions
PE film pelletizing solutions


PP Woven Bag Recycling Systems

PP woven bag washing solutions
PP woven bag shredding solutions
PP woven bag pelletizing solutions

LDPE Film Recycling

LDPE film washing solutions
LDPE film pelletizing solutions

PP film pelletizing solutions
BOPET film pelletizing and recycling solution
LLDPE stretch film pelletizing solutions
PA film shredding solutions
LCP film shredding solutions

Please contact us for more case studies.