PS Chip Tray Washing Recycling Line | (IC) Packaging Tray Recycling

What Is an Integrated Circuit (IC) Packaging Tray?

Polystyrene IC trays (PSIC trays) are specialized packaging trays designed for storing, transporting, and protecting integrated circuit (IC) chips. Typically made from anti-static polystyrene (PS), these trays feature standardized dimensions, precise positioning slots, and excellent anti-static properties. They are widely used in semiconductor manufacturing, chip packaging, and electronic component production, effectively preventing static and mechanical damage during transportation and production, ensuring chip quality and reliability.

Why Recycle IC Trays?

The semiconductor plastic IC tray market is experiencing robust growth, driven by semiconductor industry expansion, increasing global electronics demand, and advancements in packaging technology.

Environmental regulations are pushing for the development of more sustainable and recyclable tray options. Companies like Samsung actively integrate recycled materials into their products, including semiconductor trays, and are committed to significantly reducing plastic packaging use.

Surprisingly, polystyrene (PS), known for its low cost, rigidity, transparency, and insulation properties, is ubiquitous in packaging, electronics, and consumer goods, yet its global recycling rate is below 5%. Its non-degradable nature and tendency to break down into microplastics severely exacerbate landfill burdens and marine pollution.

Key Challenges in IC Trays Recycling: Why is it Difficult to Recycle?

Recycling polystyrene (PS) appears straightforward but involves numerous challenges. Many recycling facilities underestimate PS’s material complexity and precise processing requirements, leading to frequent production line clogs and unstable product quality.

(1) Material Brittleness During Mechanical Processing

Polystyrene is highly rigid but extremely brittle (impact strength only 0.6–1.5 kJ/m²), easily breaking into fine particles under mechanical stress. Traditional recycling equipment (such as crushers, high-speed friction washers, and dewatering machines) generates high shear forces that create significant amounts of fine dust. These fine particles clog screens and filters, accelerate equipment wear, escalate maintenance costs, and severely affect product purity and market value.

Specific issues include:

Frequent equipment blockages: Fine particles clog filtration systems, causing frequent downtime.

Rising production costs: Frequent blockages and wear significantly increase maintenance costs and production losses.

Reduced product quality: Contaminants carried by fine particles degrade the quality of recycled material, limiting high-end applications.

(2) Density-Based Separation Difficulties

PS density (1.04 to 1.09 g/cm³) is only slightly higher than water (~1.0 g/cm³), theoretically causing it to sink. However, PS often remains suspended mid-layer during processing due to "neutral buoyancy," posing significant separation challenges for traditional float-sink tanks.

Reasons for mid-layer suspension include:

Variations in particle size and shape: Irregular PS particles created by mechanical processing neither settle nor float consistently.

Complex additives and modified materials: Electronic waste PS often contains various fillers, complicating density-based separation.

Traditional float-sink tanks can only effectively handle clearly floating or sinking materials. Persistent mid-layer suspension complicates material capture, transportation, and discharge, causing:

Significant reduction in transport efficiency: Suspended materials disrupt stable conveyance, reducing throughput.

Dramatic decrease in washing efficiency: Accumulation of suspended particles deteriorates water quality, compromising material cleanliness.

Lower material purity and value: Incomplete separation leaves impurities, significantly reducing the recycled material’s market value.

Comparative Density of Common Plastics and Water in Recycling Processes

Project Case Study Video

Boxin’s Innovative Solution: Advanced Recycling Processes for Trays

Addressing PS recycling’s "suspension dilemma" and "brittleness challenge," Boxin surpasses traditional methods through material and process innovation, offering industry-leading solutions.

(1) Innovative Float-Sink Separation Technology: Solving the Suspension Problem

Conventional float-sink tanks struggle with capturing suspended mid-layer PS particles. Boxin has developed an innovative float-sink solution by deeply understanding PS material characteristics:

Precise water flow control: Optimizing fluid dynamics to stabilize suspended particle movement.

Patented scraper and specialized conveying mechanism: Efficiently capturing and discharging suspended mid-layer particles.

Optimized tank design: Minimizing internal eddies and dead zones to prevent material accumulation, ensuring high-purity separation.

This groundbreaking technology significantly enhances PS separation efficiency, improving subsequent washing stages and recycled material quality.

(2) Gentle Washing and Dewatering Technology: Reducing Particle Generation from the Source

Addressing PS’s high brittleness and dust generation causing equipment blockages, Boxin introduces gentle processing techniques:

Customized mechanical design: Specialized blades and crushing chambers minimize harsh impacts and shear forces on materials.

Precise speed control and optimized water flow: Removing contaminants effectively without generating dust or thermal degradation.

Advanced dewatering and drying: Employing hydraulic filter presses or customized centrifugal dryers for gentle moisture removal, avoiding mechanical damage.

These innovations drastically reduce dust generation and equipment maintenance, ensuring stable quality, high purity, and greater market value for recycled PS materials.