The ACSS Two-Stage Cutter Compactor Pelletizing System is an advanced recycling solution that integrates material feeding, cutting, compacting, two-stage extrusion, filtration, pelletizing, cooling, drying, and packing into one complete system.
Compared with conventional single-stage pelletizing systems, ACSS adopts a two-stage single screw extrusion design to provide enhanced plasticization, homogenization, degassing, and filtration performance. It is especially suitable for challenging plastic waste materials with high moisture content, heavy printing ink, poor flowability, and higher contamination levels.
Material Feeding System
Belt Conveyor Feeding
The standard feeding system uses a belt conveyor to continuously transport plastic waste materials into the cutter compactor.
Materials such as films, filaments, raffia, and woven bags can be automatically conveyed into the compaction chamber. For roll-shaped materials, a roll haul-off device is available as an optional feeding solution.
The conveyor speed and roll haul-off speed are automatically adjusted according to the filling level of the compactor chamber, ensuring stable and continuous material feeding.
Metal Detection System
A metal detector can be integrated with the belt conveyor and connected with the control system.
When metal contaminants are detected in the incoming material, the system automatically sends an alarm signal and stops operation to protect the equipment from potential damage.
Cutter Compactor System
Cutter Compactor System
The cutter compactor is the key pre-processing unit of the ACSS system, combining cutting, size reduction, pre-heating, drying, and compaction into one integrated process.
The system improves material bulk density and feeding stability, making it especially suitable for lightweight plastic waste such as films, raffia, filaments, and woven bags.
Sliding Gate with Servo Motor
The servo-controlled sliding gate precisely regulates the residence time of materials inside the compaction chamber.
By controlling material retention time, the system improves pre-drying and compaction performance before extrusion. The PLC-controlled feeding system automatically adjusts material input according to production requirements, ensuring stable output.
Inspection Window
The LED inspection lamp allows operators to monitor material distribution inside the compaction chamber and adjust feeding conditions easily, ensuring stable operation.
Compaction Chamber and Rotary Blades
The rotating blades on the knife disc and fixed blades installed on the chamber wall cut plastic materials into smaller flakes.
The friction heat generated during high-speed rotation pre-heats and dries the material, reducing volume and increasing material density.
The arc-shaped guide plates direct the compacted material into the extruder smoothly, ensuring stable feeding performance for low bulk density plastics.
Two-Stage Single Screw Extrusion System
Two-Stage Single Screw Extrusion System
The core advantage of the ACSS system is its two-stage single screw extrusion design.
The first extrusion stage focuses on melting and plasticizing the material, while the second stage further homogenizes the melt, improves degassing performance, and provides more stable extrusion conditions before pelletizing.
This design is especially suitable for demanding recycling applications involving:
• Heavy printed films
• High moisture materials
• Poor flowability plastics
• Materials requiring higher melt quality
Wear-Resistant Screw and Barrel
The extruders are equipped with high-quality wear-resistant screw and barrel components.
The bimetallic treatment provides excellent wear resistance and corrosion resistance, ensuring reliable long-term operation under continuous recycling conditions.
Vacuum Degassing System
Vacuum Degassing System
The ACSS system is equipped with natural venting and dual-zone vacuum degassing as standard.
The vacuum degassing system effectively removes moisture, volatile substances and low molecular weight compounds from the melt, improving pellet quality and processing stability.
It is particularly suitable for heavily printed materials and high-moisture plastic waste.
Melt Filtration System
The ACSS system provides different filtration solutions according to material contamination levels and production requirements.
Standard Options: Non-stop Piston Type Filter
A single-plate or piston double-station screen changer can be installed at the extruder head.
For higher filtration requirements, a non-stop double-plate piston four-station filter is available.
Advantages:
• Large filtration area and long screen lifetime
• Reduced screen replacement frequency
• Quick and easy screen change without stopping production
• Lower operating cost
Standard Options: Plate Type Filter
The continuous plate-type filter uses two filter plates, ensuring that at least one filtration area remains active during screen replacement.
The ring-shaped heating system provides consistent and stable temperature control.
Optional Advanced Filtration Solution: Self-Cleaning Filter
The self-developed SCF self-cleaning filtration system enables continuous recycling extrusion without production interruption.
It is especially suitable for highly contaminated plastic waste.
The system can remove up to 5% contamination from the melt stream, including:
• Paper
• Wood
• Aluminum
• Unmelted plastics
• Rubber contaminants
Pelletizing System
ACSS offers multiple pelletizing options according to customer requirements, including water-ring pelletizing, water-strand pelletizing, and underwater pelletizing.
The optimized pelletizing process produces uniform recycled pellets with stable shape and quality, suitable for reuse in various plastic production applications.
Die Head
Its core feature is that the die head surface does not contact with the cooling water directly. This design ensures that the die head temperature is uniform, and even if the output is low, the discharge can be maintained normally. Specially suitable for handling materials with low melt index.
Water Ring Pelletizing System
The self-adjusting water ring pelletizing system ensures consistent pellet quality and long operating time.
Features:
• Automatic blade pressure adjustment
• Automatic blade speed adjustment according to melt pressure
• Fast and easy blade replacement without additional adjustment
Strand Pelletizing System
The molten plastic strands are cooled and solidified in a water tank before being cut into uniform pellets.
This method provides gentle pelletizing conditions for different recycling applications.
Underwater Pelletizing System
The underwater pelletizing system provides a highly automated pelletizing solution.
It is suitable for materials with high melt flow index and high production capacity requirements.
The system includes:
• Pelletizer
• Valve system
• Conveying pipeline
• Dewatering vibrating screen
• Storage silo
Cooling, Drying and Pellet Collection
After pelletizing, the recycled pellets are cooled, dehydrated, and transported to the storage silo through an integrated drying and conveying system.
The efficient drying process reduces residual moisture and ensures clean, dry pellets ready for packaging or direct reuse.
Vibration Sieve +Centrifugal Dryer
The advanced dewatering vibration sieve combined with horizontal centrifugal drying provides efficient pellet drying performance with reduced energy consumption.
The sieve plates are fixed by screws instead of welding, making future replacement and maintenance easier.
Packing System
The qualified recycled pellets are collected and stored in the product silo.
The drying system ensures low moisture content, while the online capacity monitoring and quantitative weighing system provide accurate production measurement and efficient packaging.
Intelligent Control System
Remote Monitoring and Data Transmission
The ACSS system can be equipped with remote monitoring and information transmission functions.
The system supports remote program monitoring and Bluetooth communication, enabling convenient equipment management and technical support.
Intelligent Start and Stop Control
The intelligent control system provides one-button operation.
• Intelligent Start:
All machine modules automatically start according to the preset sequence and material processing requirements.
• Intelligent Stop:
Each module can be safely stopped through a coordinated shutdown process.
• Emergency Stop:
Emergency stop functions are available to ensure operator safety during unexpected situations.
European Standard Electrical Control Cabinet
The electrical control cabinet is designed and manufactured according to European standards, featuring professional wiring, clear layout and reliable protection design. High-quality electrical components and standardized assembly processes ensure safe, stable and efficient equipment operation with reduced maintenance requirements.
