Thin film crushing and cleaning production line
This production line is a professional recycling system specifically designed for the efficient processing of various waste plastic films (such as PE agricultural film, mulch film, greenhouse film, industrial stretch film, PP woven bag film, daily packaging film, shopping bags, etc.). The film materials possess...It is bulky, has low density, is easy to entangle, and has complex impurities attached to it (mud, pesticides, fertilizers, plant residues).Due to these characteristics, conventional processing lines are inefficient. This system addresses these pain points by innovatively integrating…Anti-tangling and breakage, powerful scrubbing, efficient dehydration and energy-saving dryingCore technologies such as these enable continuous, efficient, and automated production from "waste membrane bundles" to "clean, dried membrane sheets." This line utilizes...Large processing capacity, water and energy saving, high recovery rate, and pure finished product.With its core advantages, it is the preferred solution for investing in the field of thin film recycling.
Core processing materials
Agricultural filmPE agricultural mulch film, greenhouse film, silage film, etc. (high soil content).
Industrial and commercial membranesPE stretch wrap film (pallet film), packaging film, shrink film, etc. (including adhesive and labels).
Living membraneVarious shopping bags, express delivery bags, packaging bags, garbage bags, etc.
Composite membraneIt can handle flexible packaging films with PE/PP as the main component (subject to evaluation).
Core advantages of automated production lines (specifically for thin film characteristics)
Specialized thin film designThe crusher adopts a special blade shape and anti-winding structure, combined with a negative pressure air conveying system, to effectively solve the industry problems of "blade entanglement, material blockage, and bridging" of the film, and ensure continuous and stable crushing.
High-power friction cleaning technologyEquipped with a large-capacity, powerful rotor, the friction cleaner creates a high-intensity water vortex, causing the diaphragm sheets to tumble and rub against each other, powerfully peeling off and removing stubborn mud, sand, and organic stains.
Multi-stage high-efficiency dehydrationThe process combines "screw extrusion" and "centrifugal dehydration" to efficiently remove surface free water, taking advantage of the large surface area and strong water retention of the thin film, resulting in significant energy savings for deep drying.
Energy-saving hot air dryerThe dryer uses a multi-layer mesh belt or duct dryer, which utilizes low temperature and high air volume for penetrating drying, resulting in high heat exchange efficiency, low energy consumption, and ensuring that the film sheets are loose and do not clump together.
Full-process anti-tangling designFrom crushing and discharge to washing and dewatering, the conveying and process flow are all optimized to minimize the risk of material entanglement in the equipment.
High automation and intelligenceThe entire production line is linked and controlled, equipped with automatic feeding, water level and temperature monitoring, reducing manual labor and improving stability.
Standard process flow and equipment composition
A classic thin-film recycling line process is more refined than that for hard materials, focusing on impurity removal and dehydration:
| Process Stage | Equipment Name | Functions and features (for thin films) |
|---|---|---|
| 1. Feeding and Crushing | Automatic feeder/pre-compression device | The loose waste film clumps are automatically and evenly fed into the crusher, with an optional compaction function to improve efficiency. |
| Film-specific crusher | Core membrane breaking equipmentEmploying a V-shaped moving blade, box-type fixed blade, or roller blade design, combined with a unique screen structure, it effectively prevents tangling. (Commonly integrated)Strong magnetic separatorRemove iron impurities. | |
| Negative pressure air delivery system | The broken membrane is pneumatically conveyed to the cleaning tank through pipelines, eliminating the risk of entanglement associated with mechanical conveying, and also serving to pre-cool and remove light dust. | |
| 2. Multi-stage cleaning and separation | Pre-cleaning/Sedimentation tank | Initial soaking and sedimentation of most of the mud, sand and heavy impurities (pebbles, metal shavings). |
| High-power friction cleaning machine | Main decontamination unitThe high-speed rotor generates intense eddies, stripping away most of the attached dirt. | |
| Two-stage friction cleaning/rinsing machine | Fine rinsing unitFurther rinsing in clean water enhances cleanliness. | |
| Hydrocyclone flotation separator/hydraulic separator | Key sorting equipmentBy utilizing water vortex and density difference, it effectively separates membrane fragments (PE/PP, floating) from residual heavy impurities (sand, bottle caps, etc.) and some sinking debris. | |
| 3. High-efficiency dehydration | Screw dryer | Key dehydration equipmentBy using a screw conveyor to compress the film, which has a very high water content, the film is initially and forcefully dehydrated, significantly reducing the subsequent centrifugal load. |
| High-speed centrifugal dehydrator | Core dehydration equipmentBy utilizing the centrifugal force generated by extremely high rotation speed, residual moisture on the surface of the thin film is spun off, reducing the output moisture content to 8-12%. | |
| 4. Energy-saving drying | Low-temperature mesh belt dryer/duct dryer | Core drying equipmentThe process employs layered mesh belts to spread the material thinly, or a pipeline-type suspended conveyor, using a high-volume, low-temperature airflow of 40-70℃ to penetrate the material, achieving efficient, uniform, and energy-saving drying. The final moisture content can reach [amount missing].Less than 1%It is equipped with an insulation layer and a heat recovery system. |
| 5. Intelligent control | Central electronic control system | PLC control integrates monitoring and alarm functions for key parameters such as temperature, water level, and speed, enabling one-button start/stop and intelligent interlocking for the entire production line. |
Optional configurations and upgrades (for thin films)
Color sorting/photoelectric sorting machineRemove discolored films (such as colored printed films) to improve the whiteness and value of recycled materials.
froth flotation systemUsed for deep separation of PE and PP membranes, or to remove specific polymer impurities.
Fine powder removal and recovery systemIt removes fine impurities and powder generated during the cleaning process, improving the quality of the finished product.
Fully automated packaging systemThe dried finished film sheets are automatically weighed and packaged.
Wastewater fine filtration and recycling systemMulti-stage sedimentation and filtration enable water resources to be recycled at a rate of over 95%, meeting environmental protection requirements.
Typical technical parameters (example)
model：RX-Film-1000 / RX-Film-2000
Processing capacity800-3000 kg/h (depending on the compaction degree and contamination level of the raw materials)
Final fragment size12-20mm (Larger size is beneficial for washing and dehydration)
Final moisture content： < 1%
Drying temperature50 - 70°C (Properties of materials protected against low temperatures)
Total powerApproximately 150-400 kW (depending on capacity and configuration)
Water recycling rate： > 90%
AreaLength 30-50m × Width 8-12m (Due to the long process, a large space is required)
Final Products and Applications
productClean, dry, and loose PE/PP recycled film fragments (flakes), the color of which can remain natural or off-white depending on the degree of sorting.
applicationIt is a high-quality raw material for producing high-quality recycled plastic pellets (Pellet), used in the manufacture of:
Recycled packaging film, shopping bags, garbage bags.
Injection molded products such as basins, buckets, and trays.
Blow-molded products such as low-end pipes and hollow products.
Wire-drawn products such as landscaping ropes and shade nets.
Service and Support
We offer fromFrom raw material testing, solution design, equipment customization, factory layout, installation and commissioning, process training to after-sales maintenanceWe provide end-to-end services to ensure that our customers' production lines achieve their designed capacity and product quality targets, thereby maximizing their return on investment.
