ZHANGJIAGANG BOXIN MACHINERY CO., LTD.

Plastic film recycling lines combine a series of equipment for crushing, washing, drying, and re-pelletizing plastic materials, enabling waste plastic films to be converted into clean, reusable plastic pellets.

These specialized recycling lines are essential for processing flexible PE (polyethylene) and PP (polypropylene) films—materials commonly used in plastic bags, packaging films, shrink films, agricultural mulch films, and more.

What is a Plastic Film Recycling Line?

A plastic film recycling line (also known as a plastic film washing pelletizing line) is a complete set of equipment designed to recycle post-consumer or post-industrial plastic films into clean flakes or pellets for reuse.

The line takes in dirty or mixed plastic film waste and processes it through a series of steps—shredding, washing (with water and friction), density separation, drying, and pelletizing—to remove contaminants such as paper labels, dirt, food residues, and metals, ultimately producing uniform plastic pellets that can be used in new products.

Crucially, a film recycling line is not a single machine but a fully integrated system of coordinated machinery. Each component in the line plays a vital role in addressing the unique challenges of film recycling.

Boxin Machinery has developed a complete solution that covers the entire process—“shredding → washing → dewatering → extrusion → conveying.” This system reduces plastic films into manageable flakes and ensures thorough cleaning before any melting or extrusion takes place.

By cleaning the films first, the system prevents issues such as foaming during extrusion, inconsistent pellet quality, and unstable melting caused by residual moisture or dirt.

How Does a Plastic Film Recycling Line Work?

A plastic film recycling line follows a step-by-step process. While exact configurations may vary, the workflow is fairly standardized across the industry. Below are the key stages of a typical recycling line and the machinery used at each stage:

1. Collection & Sorting

The process begins with collecting and sorting plastic film waste. It is essential to separate film plastics (such as PE/PP film) from other materials and remove large non-plastic contaminants like metals, glass, and heavy debris.

In many cases, waste plastics are first separated into films and rigid plastics, since each requires a different recycling line.

2. Shredding / Crushing

Sorted films are fed into a shredder or crusher, which reduces them into smaller flakes (typically 10–50 mm). This size reduction makes cleaning easier and prevents downstream tangling.

Many modern lines use a wet granulator at this stage, where water is sprayed into the cutting chamber. Wet shredding both pre-washes the material and reduces heat buildup from friction, preventing melting or smearing of the film.

3. Friction Washing

The shredded plastic film flakes enter high-speed friction washers (also called friction scrubbers). These are powerful rotating machines with paddles or a high-speed shaft spinning around 1200 RPM.

The intense spinning action forces flakes against perforated screens and against each other, scrubbing off dirt, sand, labels, and residues.

Some lines use multiple friction washers in sequence for heavily contaminated films. Anti-wrapping designs help keep films from tangling on the shaft while maintaining cleaning efficiency.

4. Float-Sink Separation

Next, the material passes through a float-sink tank. This process relies on density differences: PE and PP films are lightweight and float on water, while contaminants such as metals, glass, sand, and higher-density plastics (e.g., PVC, PET) sink to the bottom.

Light flakes are skimmed off and carried forward, while heavier contaminants settle and are removed, usually by a screw conveyor at the bottom. This step is critical for achieving purity.

5. Dewatering & Drying

Moisture removal is vital, as excess water causes extrusion issues like pellet foaming, splashing, or hydrolysis.

Drying is typically a two-stage process:

Mechanical Dewatering: A centrifugal dryer (similar to a washing machine spin cycle) removes the bulk of free water efficiently.
Thermal Drying: Hot-air dryers (pneumatic drying systems) evaporate remaining moisture, targeting below 5% moisture content (often <2%).

Some systems use a screw press dewatering machine, which physically squeezes water from the flakes. This method can compact or even partially plasticize the film, creating warm, semi-molten material that feeds well into extrusion pelletizers.

6. Pelletizing (Re-granulation)

The final step is pelletizing, where the clean, dry flakes are melted and converted into plastic pellets.

This is done with a pelletizing system, usually consisting of an extruder and pelletizer (such as a water-ring cutter or strand pelletizer).

Flakes are fed into the extruder hopper, melted, and pushed through a screen filter to remove fine impurities.
The molten plastic is then cut into uniform pellets—water-ring pelletizers solidify and cut pellets in a water chamber, producing high-quality recycled granules.

These pellets are the final recycled product, which can be sold or reused in manufacturing just like virgin resin.

Pelletizing is considered an optional add-on for film washing lines. Some facilities stop at producing clean, dry film flakes, especially if they plan to sell or directly use the flakes.

However, integrating pelletizing into the recycling line provides a one-stop solution: it enables recyclers to convert dirty films into finished plastic pellets in a continuous process. Many buyers prefer this approach, since pellets are more standardized and better suited for feeding into molding or extrusion equipment.

Types of Plastic Film Recycling Lines (by Material & Contamination Level)

Not all plastic film recycling lines are the same. In fact, based on the source and type of film being processed, recycling lines can generally be divided into two sub-categories: agricultural film recycling lines and packaging/industrial film recycling lines. Equipment configurations are typically adjusted to meet specific needs. For pre-consumer (factory scrap) films, a direct pelletizing machine is often sufficient.

Agricultural Film Recycling Line

Agricultural films include greenhouse covers, crop mulching films, silage wraps, and other farm plastics usually made from LDPE (low-density polyethylene) or LLDPE (linear low-density polyethylene).

These films are often heavily contaminated—covered in soil, sand, mud, and crop residues (e.g., plant material). Recycling lines designed for agricultural films focus on heavy-duty preprocessing and intensive washing.

A twin-shaft shredder may be used for pre-shredding large, muddy film bundles into strips, as these films are tougher and dirtier than packaging films.
After initial size reduction, additional equipment such as desanders or rotary screens can be used to shake off or wash away large amounts of sand and soil.
The washing stage typically includes extra friction washers or extended washing tanks to handle the high level of contamination.

As a result, agricultural film recycling lines form a distinct category tailored specifically to high-contamination, mud-laden film waste.

Packaging & Industrial Film Recycling Line

Packaging films cover a wide range of applications: stretch wrap for pallets, shrink wrap, grocery and retail bags, food packaging film, bubble wrap, courier mailing bags, and various factory films from manufacturing and distribution centers. These films are generally made from LDPE, HDPE, or PP.

Contamination here is usually lighter—mainly labels, tape, adhesive residues, and minor dirt or dust picked up during use.

These lines don’t require as much heavy-duty machinery as agricultural systems but must still address contaminants such as printing inks and adhesives.
Output from packaging film recycling is typically high-quality pellets, which can often be reused directly in new film production or other plastic goods.

A notable sub-category is PP woven bag recycling line, designed to process woven polypropylene bags and jumbo bags. These lines follow similar shredding, washing, and drying steps as film lines but are modified for thicker, woven materials. Since the main focus here is thin plastic films (sheets and bags), Boxin also provides dedicated solutions for PP woven bag recycling.

Installing a plastic film recycling line offers numerous benefits—both environmental and economic. Below are some of the key advantages:

1. Waste & Pollution Reduction

The primary benefit is diverting plastic film waste away from landfills and the natural environment, reducing litter and long-term pollution.

2. Lower Greenhouse Gas Emissions

Producing new plastics from petroleum requires significant energy and results in high greenhouse gas emissions. Recycling films into new materials dramatically reduces energy use and carbon footprint.

3. Regulatory Compliance & Sustainability Goals

Governments worldwide are setting higher recycling targets and stricter waste regulations, especially for plastic packaging. For example, the EU mandates that by 2025, 50% of plastic packaging waste must be recycled. Installing a recycling line helps companies stay compliant and aligned with sustainability initiatives.

4. Economic Benefits & Cost Savings

Properly recycled plastic films gain economic value. Instead of paying for disposal or incineration, companies can repurpose film waste or even generate revenue by selling recycled pellets.

5. Higher Quality of Reprocessed Products

For manufacturers reusing recycled materials, having clean, dry, and uniform flakes or pellets is essential for consistent product quality. Specialized film recycling lines deliver higher-quality recyclates compared to ad-hoc or informal recycling methods.

Factors to Consider When Purchasing a Plastic Film Recycling Line

Not all recycling lines are the same—the best choice depends on your specific needs: the type of film, level of contamination, expected capacity, and budget. Below are the key factors that influence the selection and cost of a film recycling line:

1. Capacity

Typical capacities range from small systems (around 500 kg/h) to large industrial setups (over 4000 kg/h). You should evaluate the daily or monthly volume of materials to be processed and select a line with sufficient throughput.

2. Contamination Level (Input Material)

The dirtier or more complex the film feedstock, the more robust and sophisticated the line must be. Heavily contaminated films (e.g., agricultural films or mixed municipal films) may require extra equipment, which adds to cost and complexity.

Suppliers often ask for detailed input specs—film type, contamination percentage, and moisture content—to design the right configuration.

3. Washing vs. Pelletizing (Scope of Line)

Decide whether you need just a washing & drying line or a complete washing + pelletizing line (with pellet output as the final product).

4. Automation Level & Energy Consumption

Modern recycling lines range from semi-automated to fully automated.

Higher automation (central control systems, feedback loops, automatic dosing of chemicals, etc.) ensures consistency and reduces labor needs.
However, it comes with a higher upfront cost.

5. Manufacturer Experience & Build Quality

The build quality and reputation of the manufacturer are critical. A recycling line is a major investment, so it should be reliable for years of continuous operation. Well-designed machines—using wear-resistant alloys, durable gearboxes, and strict quality control—may cost more initially but save money by reducing downtime and maintenance.

6. Cost & ROI Considerations

Finally, evaluate the total cost of ownership (TCO) and return on investment.

In addition to purchase price, factor in:

Shipping and import duties (if buying overseas)
Installation and commissioning costs
Ongoing expenses: energy, water (and water treatment if required), labor, spare parts, and maintenance.

Customization & Choosing the Right Supplier

The best results usually come from tailoring a recycling line to your specific needs—which is why selecting the right supplier/manufacturer is crucial. A capable supplier will work with you to customize equipment, layout, and support services. Below are key considerations regarding customization and supplier support:

1. Customized Equipment Configuration

Leading manufacturers (such as Boxin Machinery in China) emphasize that every film recycling project is unique. Factors such as film source, contamination level, space limitations, and output quality requirements vary.

That’s why process flow and equipment setups should be customized accordingly.

When evaluating suppliers, check if they are open to discussing component-level adjustments. This shows professionalism and flexibility. A one-size-fits-all approach rarely delivers the best performance.

2. Modular Design & Scalability

High-quality recycling lines are often designed with a modular structure, allowing you to add or remove certain processing units as needed. Modular design is a hallmark of well-engineered lines.

A trustworthy supplier will not try to sell unnecessary equipment just to boost sales. Instead, they’ll help you identify which modules are essential for your quality goals and which ones can be omitted or added later. This consultative approach ensures your budget is invested wisely.

3. Facility Layout Planning

Integrating the line into your facility is another area where top suppliers add value. Installing a recycling line isn’t only about the machines themselves—it’s also about how they fit into your available space, how materials flow through your building, and how utilities (water, electricity) are connected.

Experienced suppliers assist in creating an optimal equipment layout. Often, you can send them a simple workshop floor plan or dimensions, and their engineers will prepare a layout drawing showing machine positions, piping, wiring, and required infrastructure (platforms, concrete pads, drainage near washing tanks, etc.).

This planning support saves time, prevents installation issues, and ensures you’re fully prepared before equipment arrival. Always ask whether suppliers provide layout and installation planning assistance—it’s a hallmark of comprehensive service.

4. Training, Commissioning & After-Sales Support

Commissioning (assembly and startup at your site) and ongoing support are critical for long-term success.

Good suppliers provide on-site training and commissioning services, often sending engineers to your facility during delivery.
During commissioning, they assist with assembly (working with your electricians and mechanics), calibrate settings, and run test batches to fine-tune performance. They also train your staff on safe, efficient operation and routine maintenance.

After startup, look for suppliers who promise fast after-sales support, including:

Remote troubleshooting (via phone, email, WhatsApp, or WeChat)
Quick spare parts delivery
Warranty coverage

Boxin Machinery, for example, maintains an inventory of spare parts and offers rapid-response support to minimize downtime. It’s wise to obtain a recommended spare parts list (e.g., crusher blades, screens, bearings) and keep essential items in stock.

Bottom line: Choose a supplier known for backing their equipment with ongoing service and reliability. This relationship shouldn’t end with the sale—it should continue throughout the entire lifecycle of your recycling line.

Plastic Film Recycling Lines: Process, Equipment, and Benefits