1. Customer Background

JPFL Films Pvt. Limited is a large-scale, indigenous Indian manufacturer of functional plastic films. Its core products include BOPP and BOPET packaging films, serving downstream industries such as food packaging, printed laminates, and industrial packaging, making it an important film supplier in northern India. In its daily slitting and production processes, the company generates substantial amounts of film trimmings and non-conforming scrap. Previously, it had long relied on low-cost overseas sales to dispose of these waste materials, resulting in extremely low resource utilization.

2. Core Pain Points

1. The existing outdated recycling equipment has a single-line capacity of only 500 kg/h, unable to keep pace with the rate of waste generation. As a result, waste has been accumulating on-site for extended periods, occupying valuable warehouse space.

2. The old equipment suffers from poor temperature control accuracy and insufficient filtration stages, producing granules with numerous crystallization points and high impurity levels. Consequently, these granules cannot be reused in the company’s high-end film production lines and must be sold at low prices.

3. With the continuous rise in the price of virgin plastic raw materials in India, the company’s external procurement costs remain stubbornly high, creating an urgent need to reduce costs through in-house recycling.

3. Our Solution

We customized a comprehensive solution consisting of the **ML160 BOPP Film-Specific Pelletizing Line + ML180 BOPET Film Recycling Pelletizing Line**, both equipped with:

• A fluffy-film forced-feed system that resolves bridging and slipping issues during film feeding;

• A five-stage precision temperature-controlled extrusion system ensuring melt stability for films with varying melting points;

• A dual-stage high-precision filter system that thoroughly removes impurities and crystallization points from the melt;

• A closed-loop water-cooling pelletizing system that guarantees uniform particle size and excellent appearance.

4. Quantified Business Outcomes

1. Each unit achieves a stable throughput of 1,000 kg/hour, supporting 24/7 continuous operation. Daily output includes 20 tons of recycled BOPP granules and 24 tons of BOPET granules, doubling waste-processing efficiency.

2. Finished granules boast a purity of 99.2%, with crystallization point content reduced by 85%, enabling direct reuse in the company’s mid-to-high-end film production lines.

3. The defect rate of granules has dropped from the original 18% to 2.5%, significantly cutting rework losses.

4. Annual procurement of virgin film raw materials has been reduced by over 13,000 tons, lowering raw material costs by 27%.

5. Project Value

This solution has established a fully closed-loop production cycle—“raw material–product–waste–recycled material–raw material”—helping the customer comply with India’s domestic environmental solid-waste management regulations while substantially reducing production costs and enhancing the market competitiveness of its products.