Pelletising polypropylene: Applied Machinery

Daniel Fisher, Applied Machinery Project Manager, wants to revive domestic plastic recycling through sustainable Polystar pellets. 

The recycling conversation is becoming more layered and complex by the day, with notoriously problematic plastic often taking centre stage. While the problem of plastic waste is widely understood, manufacturing processes still heavily rely on the material.

Daniel Fisher, Applied Machinery Project Manager, says responsibly processing plastic while keeping up with demand requires straightforward remanufacturing options. He adds that one such option is recycled plastic pellet production.

Daniel says to implement a wider uptake of recycled pellets in the manufacturing industry, resource recovery operators need simple-to-use equipment.

“When dealing with a difficult waste stream such as plastic, it’s common for operators to think that a more complex system will perform better,” Daniel says.

“But as the exclusive Australian distributor of Polystar Machinery, Applied Machinery is committed to supplying customers with straight forward and cost-effective solutions.”

Applied Machinery has worked with the Taiwan-based recycling equipment manufacturer for four years.

Polystar manufactures a range of one-step machines designed to reprocess multiple waste streams, notably polyethylene and polypropylene flexible packaging material.

Polystar technology is designed to be simple to operate and easy to maintain.

“The recycled output result is high-quality plastic pellets that can be repurposed back into manufacturing straight away,” Daniel explains.

“The pellets save waste disposal costs by producing a saleable product, while also offering an alternative to raw material extraction.”

Applied Machinery can offer customers the full suite of Polystar products, including the Polystar HNT and the Polystar Repro-Flex.

“HNT machines are typically suited for flexible, post-industrial film and have the added benefit of being able to produce quality pellets from even the most heavily printed packaging material.”

Daniel says the Polystar Repro-Flex is suited to multiple recycling applications including plastic bags, film scraps, bubble wrap, shrink film and laminated film.

“Repro-Flex machines also work well for post-industrial film waste, as the system can process washed flakes, scraps and pre-crushed rigid plastic waste from injection and extrusion,” he adds.   

Both the HNT and Repro-Flex feature an integrated cutter compactor, which removes the need for pre-cutting.

“The cutter compactor, which generates frictional heat during the compacting process, also helps remove moisture from the material.”

According to Daniel, eliminating moisture is a particularly significant feature when generating recycled plastic pellets, as even minimal water can render a whole batch unusable.

Daniel says the integrated Polystar system also eliminates the need for separate crushers and the common problem of inconsistent feeding.

“The integration of the cutter compactor and extruder ensures extremely fast and stable feeding, as the tangentially connected extruder is continuously filled with pre-compacted material.”

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POLYSTAR film recycling line

POLYSTAR’s Repro-Flex was designed for reprocessing polyethylene (HDPE, LDPE, LLDPE) and PP polypropylene flexible packaging material, printed and non-printed.

As the exclusive distributor for POLYSTAR equipment, Applied Machinery can offer a compete film recycling line designed to produce pellets that are ready to insert back into the start of the manufacturing process, while at the same time dramatically cut on film waste that was previously destined for landfill.

POLYSTAR has worked with plastics producers across the globe and is used in more than 102 countries worldwide. The cutter integrated pelletising system eliminates the need for pre-cutting materials, taking up minimal space, while producing plastic pellets at a productive rate. The machine aims to have an output that is 20 per cent higher when compared to traditional feeding methods, with 10 per cent less power consumption. By being able to reprocess plastic materials themselves, producers can reduce their own production costs.

The extruder specialises in post-industrial waste, with blown and cast film producers (HDPE, PP shrink, stretch film), raffia and woven (PP woven bags, non-woven, jumbo bags) and rigid regrind (bottles, pipes, containers) just a few materials that can be reprocessed. A filtration system aims to reduce machine downtime.

The machine offers multiple degassing and filter options, including triple degassing to remove ink and extra humidity from the material, a dosing device for colour masterbatches  and compounds added during the process, filter re-positioning prior to degassing for higher quality pellets and an unvented extruder to ensure minimal change in material property and a higher output.

POLYSTAR’S recycling line also offers a range of other solutions, including the two-stage HNT-VS for heavy printed material, the air-cooled RP120 for PE in-house waste and the TR-B for pre-washed film flakes and a range of other materials.

Product in Focus: 

Model: HNT-65V

Application: HDPE, LDPE, LLDPE, PP

Extruder screw diameter: 65

Power consumption: 40 kilowatts

Output: 120 kilograms per hour

Product in Focus: 

Model: POLYSTAR Repro-Flex65

Application: Polyethylene (HDPE, LDPE, LLDPE) and PP polypropylene flexible packaging material, printed and non-printed

Power consumption: 40 kilowatts

Output: 80 to 100 kilograms per hour

www.appliedmachinery.com.au

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