Multi-layer Composite Film Granulator

Product Overview

The multi-layer composite film granulator is a specialized film recycling and granulation machine equipped with a densifier–pelletizing feeding system. It is a custom-made product without a fixed price, tailored to meet the specific production capacity requirements of each customer. Designed specifically for the recycling and regeneration of waste films, this equipment efficiently converts loose, bulky waste films into high-quality recycled pellets after compaction and preheating. It is widely applicable to the recycling and reprocessing of agricultural greenhouse films, packaging stretch films, BOPP/CPP industrial films, courier plastic bags, heat-shrink films, and other types of waste films. It serves as essential auxiliary equipment for plastic film manufacturers, waste plastic recycling plants, packaging material companies, and resource recovery enterprises. The equipment originates from NANTONG, under the PURUI brand, and comes with a 13-month quality warranty starting from the date of delivery. The delivery period is approximately 70–80 working days.

Technical Principle

The multi-layer composite film granulator employs an integrated process combining a densifier and a single-screw extruder to achieve efficient recycling and conversion of waste films. The specific workflow is as follows: Waste films first enter the densifier (pelletizing hopper), where they are cut and crushed by high-speed rotating blades. Friction generated during rapid movement produces heat, naturally raising the temperature of the material. The originally fluffy films shrink and compact into uniform pellets, significantly increasing their bulk density before being fed steadily into the extrusion screw. Subsequently, the material undergoes staged heating and shear action within the screw to complete melting and plasticization. After passing through multi-stage filtration to remove impurities and venting to eliminate moisture, the final product is cooled in water and then cut into pellets, yielding high-quality recycled granules.

Key Performance Parameters

1. Standard model capacity: 100–1500 kg/h
2. Screw diameter: φ75–φ200 mm
3. Main motor power: 37–355 kW
4. Bulk density increase: 3–5 times
5. Finished pellet moisture content: ≤0.3%
6. Filtration precision: 80–120 mesh
7. Screw and barrel materials: 38CrMoAlA alloy, bimetallic materials, nitrogen-treated
8. Heating methods: electric heating, electromagnetic heating
9. Heater materials: cast aluminum, cast copper, mica, ceramic heaters
10. Motor brands: Siemens, ABB, Weg, or top domestic brands
11. Pelletizing methods: die-face pelletizing, strand-cutting pelletizing
12. Bearing brands: NSK, SKF, INA, FAG, or top domestic brands
13. Inverter brands: ABB, FUJI, Delta, Siemens

Core Advantages

1. Stable feeding without bridging: Equipped with a densifier–pelletizing feeding system, it ensures more uniform material input, effectively addressing industry challenges such as loose film feed blockages, slippage, and uneven feeding that plague traditional granulators, thus guaranteeing continuous and stable operation.
2. Self-friction preheating saves energy: Material achieves self-heating through high-speed friction, eliminating the need for additional preheating equipment, resulting in higher plasticization efficiency and greater energy savings—up to 15% more energy per ton compared to conventional machines, significantly reducing overall production costs.
3. Eliminates crushing step: The densifier can directly process whole rolls or bundles of film without prior shredding, cutting down on labor needs by 1–2 operators, saving both manpower and processing time while boosting overall productivity.
4. Excellent venting and dehumidification: Multi-stage venting and dehumidification effectively removes moisture and impurities from the material, producing clean, bubble-free pellets with a defect rate kept below 3%, solving the common issues of bubbly pellets and high defect rates associated with wet-material granulation.
5. Highly efficient and controllable capacity: With standard models ranging from 100 to 1500 kg/h, daily output can reach up to 36 tons over 24 hours, meeting the production needs of businesses of various scales. Additionally, production scraps can be fully recycled back into the process, maximizing resource utilization.

Core Value of the Product

1. Simplified processes reduce costs: By eliminating the separate shredding step and minimizing labor input, it lowers both time and labor expenses in the production chain, enhancing operational efficiency.
2. Energy-saving and efficiency-boosting: The self-friction preheating design improves plasticization efficiency, saving over 15% energy per ton processed, leading to substantial long-term energy cost reductions.
3. High-quality output: Excellent venting and dehumidification ensure finished pellets have moisture content ≤0.3%, free of bubbles, and with low defect rates, ensuring strong market competitiveness.
4. Wide applicability: Capable of handling various types of waste films, with flexible capacity ranges to meet the recycling and processing needs of businesses of different sizes, helping them expand their operations.
5. Closed-loop resource management: Production scraps are 100% recycled back into the process, promoting circular resource use and aligning with the industry trend toward environmentally friendly recycling.

Target Customer Groups

The target customers for the multi-layer composite film granulator include plastic film manufacturers, waste plastic recycling plants, packaging material companies, and resource recovery enterprises—all of which have a demand for recycling and regenerating waste films. This equipment helps these businesses efficiently convert waste films, improving resource utilization and production efficiency.

Application Scenarios

This equipment is primarily used in recycling and reprocessing scenarios involving various types of waste plastic films, including agricultural greenhouse films, packaging stretch films, BOPP/CPP industrial films, courier plastic bags, heat-shrink films, and many others. Whether it’s small-scale processing at a boutique recycling plant or large-scale production at a major resource recovery enterprise, the equipment can be customized to suit specific production demands, enabling efficient transformation of waste films into high-quality recycled pellets.

Solutions to Industry Pain Points

1. Solving the issue of loose film feeding: Traditional granulators often encounter problems like bridging, slippage, and uneven feeding when processing loose films, leading to unstable operation and fluctuating capacity. The densifier–pelletizing feeding system of this equipment compacts loose films into uniform pellets, feeding them smoothly into the screw and ensuring consistent, stable material input.
2. Reducing costs by eliminating the crushing step: Conventional waste film granulation requires preliminary shredding, adding extra steps and labor. This equipment can directly process whole rolls or bundles, removing the crushing stage, cutting labor needs by 1–2 operators, and lowering both labor and time costs.
3. Enhancing plasticization efficiency and capacity: Traditional equipment often suffers from insufficient plasticization, resulting in low capacity and high energy consumption. This equipment uses self-friction preheating to boost plasticization efficiency, saving over 15% energy per ton processed, while also achieving a maximum daily output of up to 36 tons over 24 hours, dramatically increasing production capacity.
4. Addressing high defect rates in wet-material granulation: Conventional equipment has poor venting and dehumidification, causing excessive bubbling and high defect rates in wet-material granulation. This equipment employs multi-stage venting and dehumidification, keeping finished pellet moisture content ≤0.3% and limiting defect rates to below 3%, thereby ensuring superior product quality.

Frequently Asked Questions (FAQ)

Q1: Is this multi-layer composite film granulator a custom-made product?
A: Yes, this equipment is custom-designed with no fixed price; it is tailored to meet each customer’s specific production capacity requirements, accommodating businesses of varying sizes.
Q2: What types of waste films can this equipment process?
A: It can handle agricultural greenhouse films, packaging stretch films, BOPP/CPP industrial films, courier plastic bags, heat-shrink films, and many other types of waste films, offering broad applicability.
Q3: What is the delivery timeframe for this equipment?
A: Delivery typically takes 70–80 working days, adjustable based on specific customization needs.
Q4: How long is the equipment’s quality warranty?
A: The equipment comes with a 13-month warranty starting from the date of delivery, during which relevant after-sales services are provided.
Q5: What energy-saving advantages does this equipment offer compared to traditional granulators?
A: Featuring a self-friction preheating design, it eliminates the need for additional preheating equipment, delivering higher plasticization efficiency and saving over 15% energy per ton processed, significantly reducing long-term energy costs.