From Waste Burden to Production Asset
Facing tightening environmental regulations and fluctuating raw material costs, a leading packaging manufacturer in China encountered growing challenges in managing production waste.
Large volumes of HDPE film scrap—including edge trims and post-industrial waste—were accumulating daily, resulting in increased storage pressure and rising outsourcing costs for disposal.
To address these issues, the company implemented an in-house recycling strategy using the ACS-H 800-120 cutting & compacting pelletizing system, transforming film waste into reusable, high-quality PE pellets directly within the factory.
What This Case Demonstrates
This project highlights how an in-house HDPE/LDPE film recycling system can:
- Convert production waste into valuable raw material
- Reduce dependency on virgin resin
- Improve cost control and operational efficiency
- Support long-term sustainability and ESG goals
Implementation Results & Business Impact
1. Strong Return on Investment
By shifting from outsourced disposal to internal recycling, the manufacturer significantly improved its cost structure.
- Achieved full ROI in less than 18 months
- Reduced virgin material consumption by approximately 15% per month
- Turned waste handling from a recurring cost into a value-generating process
2. Stable Output and Reusable Pellet Quality
Operating under continuous 24/7 production conditions, the system delivers:
- Stable output of 500 kg/h
- Consistent pellet quality suitable for direct reuse
- Maintained film properties, including tensile strength and transparency
The recycled pellets are successfully reintroduced into the blown film production line without negatively affecting final product performance.
Before vs After Implementation
| Category |
Before Implementation |
After Implementation |
| Waste Handling |
Outsourced disposal |
In-house recycling |
| Cost Structure | Continuous expense | Cost reduction + value creation |
| Raw Material Usage | 100% virgin material | Partial replacement with recycled pellets |
| Production Stability | Variable supply | Stable internal material loop |
Why the ACS-H System Was Selected
After evaluating multiple recycling solutions, the client selected the ACS-H system due to its ability to handle film-specific challenges:
- Efficient feeding and processing of low bulk density film
- Integrated compacting and pelletizing design
- Reliable performance in continuous operation environments
- Proven capability in handling printed and post-industrial film waste
Project Specifications
| Item |
Details |
| Location |
China |
| Material | HDPE film scrap, post-industrial waste film |
| Machine Model | ACS-H 800-120 |
| Output Capacity | 500 kg/h |
| Final Product | High-quality recycled PE pellets |
| Process Flow | Conveying → Compacting → Extrusion → Double Degassing → Filtration → Water Ring Pelletizing |
Client Testimonial
“Aceretech’s solution exceeded our expectations. The system operates with excellent stability and is very easy to manage. More importantly, it has helped us turn waste into a valuable resource and move closer to our green manufacturing goals.”
— Production Director
Evaluate If This Solution Fits Your Operation
Every manufacturing setup has different material conditions and production requirements. Understanding whether an in-house recycling system is suitable depends on factors such as scrap volume, material type, and reuse targets.
👉 Explore the full technical guide to evaluate this system for your production
See How You Can Achieve Similar Results
Manufacturers with high volumes of film waste can significantly improve profitability and sustainability through in-house recycling.
👉 Speak with our engineers to assess your film recycling strategy