Purui Film Recycling and Washing Line

Product Overview

The Purui film recycling and washing line is a customized, full-process pre-treatment production line for waste plastic films, capable of integrating crushing, washing, and dehydration into a single operation. This equipment adopts a five-stage closed-loop processing mode, effectively removing contaminants such as sand, ink, and light and heavy impurities from waste films, ultimately producing clean, dry film material that can be directly fed into the subsequent pelletizing process. The equipment’s processing capacity ranges from 500 to 2,000 kg/h, making it suitable for handling various types of film waste, including high-sand agricultural greenhouse films, industrial packaging stretch films, BOPP/CPP waste films, courier plastic bags, adhesive composite films, and more. It provides efficient, energy-saving solutions for film recycling plants, renewable resource industrial parks, and other enterprises.

Technical Principles and Process Flow

The Purui film recycling and washing line employs a five-stage closed-loop process—“crushing + frictional washing + flotation separation + rinsing + squeezing”—with each step seamlessly connected to achieve fully automated processing of waste films, from coarse crushing to clean, dry material:

1. Coarse Crushing Stage: Bulk or whole-roll waste films are conveyed by a belt feeder into a twin-shaft shredder, where they are coarsely cut into strips measuring 8–15 cm in length. This effectively addresses the bridging issue caused by large, bulky materials, providing an appropriate feed form for the subsequent fine-crushing stage and ensuring stable feeding throughout the entire production line.

2. Fine-Crushing Stage: Strip-shaped film material enters a high-speed pulverizer, where it is further broken down into small fragments measuring 1–3 cm. This significantly increases the material’s specific surface area, facilitating better contact between surface impurities and the washing medium, thereby creating favorable conditions for the subsequent deep-washing stage and enhancing impurity removal efficiency.

3. High-Speed Frictional Washing: The crushed fragments enter a horizontal frictional washer, where spiral blades induce high-speed collisions and self-friction among the particles, while flowing clean water simultaneously washes away sand, dust, and surface ink residues. The detached impurities are discharged through side-wall screens along with wastewater, completing the initial washing process.

4. Flotation Separation and Rinsing: After frictional washing, the material flows into a primary flotation tank, where differences in density allow for effective separation of impurities. Lighter materials such as paper labels, floating dust, and lightweight plastics are carried away with the water flow, while heavier impurities like dense sand and metal fragments settle at the bottom, ready for periodic discharge. Within the tank, a screw conveyor performs thorough rinsing, further removing any remaining impurities.

5. Secondary Clean-Rinse and Squeezing: Following flotation separation, the material proceeds to a secondary clean-rinse stage to remove any residual fine impurities, after which it is sent to a screw-type dehydrator. Physical squeezing removes moisture, while a screen filters out remaining fine residue, ultimately yielding clean, dry film material with a moisture content of ≤5%, ready to be directly fed into the next pelletizing process without additional treatment.

Performance Data

1. Processing Capacity: 500–2,000 kg/h, customizable according to customer production needs to meet the requirements of businesses of varying scales.
2. Sand and Dust Removal Rate: ≥96%, effectively eliminating all types of impurities from waste films and ensuring the cleanliness of the final dry film product.
3. Moisture Content After Squeezing: ≤5%, allowing the dry film to be directly fed into the pelletizing process and avoiding issues such as bubbling or breakage caused by excessive moisture.
4. Water Recycling Rate: ≥88%, significantly reducing water consumption during production and lowering wastewater treatment costs.

Core Advantages

1. Highly Efficient Water Conservation: With a water recycling rate of ≥88%, the equipment enables extensive reuse of wash water, reducing water consumption per ton of material by 80% and substantially cutting both water and wastewater treatment costs, aligning with environmentally friendly production standards.

2. Full-Process Automation: The entire production line uses automated belt conveyors to link each stage, minimizing manual handling. Only two operators are needed to oversee the entire line, reducing labor costs by 65% while also preventing the instability in cleanliness often associated with manual operations, thus improving production efficiency and product quality consistency.

3. Exceptional Durability: The friction chamber and screens are crafted from wear-resistant materials, extending the equipment’s service life, reducing maintenance frequency and parts replacement, and lowering overall equipment operating costs, ensuring continuous, stable production.

4. Thorough Impurity Removal: With a sand and dust removal rate of ≥96%, the equipment effectively eliminates all types of impurities from waste films, enabling the produced clean, dry film to be directly fed into the pelletizing process. This reduces the frequency of screen changes in the pelletizing stage by 75%, boosting both production efficiency and product quality.

Core Value of the Product

1. Efficient Impurity Removal, Enhancing Pelletizing Quality and Efficiency: With a sand and dust removal rate exceeding 96%, the frequency of screen changes in the pelletizing stage is reduced by 75%, decreasing downtime and improving the stability of pelletized products while lowering production costs.

2. Water Conservation and Cost Reduction, Lowering Overall Production Costs: With 88% of wash water recycled, water consumption per ton of material is reduced by 80%, significantly cutting water bills and wastewater treatment expenses, thereby enhancing both economic performance and environmental sustainability.

3. Automated Operations, Reducing Labor Costs: With only two operators required to manage the entire line, labor costs are slashed by 65%, while also avoiding the inefficiencies and cleanliness issues inherent in manual washing, thus improving overall operational efficiency and product quality consistency.

4. Seamless Process Integration, Boosting Production Continuity: The clean, dry film can be directly fed into the pelletizing process, increasing process integration efficiency by 50% and reducing material transfer and intermediate handling steps, enabling continuous production from pre-processing to pelletizing and enhancing enterprise production management efficiency.

Target Customer Groups

Film recycling plants, renewable resource industrial parks, large-scale plastic recycling enterprises, packaging film manufacturers, and other companies involved in the recycling and regeneration of waste plastic films—especially those dealing with high-sand agricultural greenhouse films, industrial packaging stretch films, and other waste films with elevated impurity levels—can leverage this equipment to improve recycling efficiency and product quality.

Application Scenarios

This equipment is suitable for the washing and pre-treatment of various types of waste plastic films, with key application scenarios including: recycling and processing high-sand agricultural greenhouse films; regenerating industrial packaging stretch films; washing and recycling BOPP/CPP waste films; resourcefully utilizing courier plastic bags; and removing impurities from adhesive composite films. Whether handling small batches at a small-scale film recycling plant or managing large-scale production at a major renewable resource industrial park, the equipment can be tailored to meet specific capacity requirements.

Solutions to Industry Pain Points

1. Addressing Frequent Screen Clogging Caused by Dirty Films Containing Sand: With a sand and dust removal rate of ≥96%, the equipment effectively eliminates sand impurities from waste films, reducing the frequency of screen changes in the pelletizing process by 75% and minimizing downtime caused by clogged screens, thereby boosting pelletizing productivity.

2. Improving Low Efficiency and Unstable Cleanliness in Manual Washing: With fully automated operations, there’s no need for manual transfer or hand-washing. Only two operators are required to oversee the entire line, dramatically increasing production efficiency, while the standardized washing process ensures consistent cleanliness of the final dry film, avoiding quality fluctuations caused by manual handling.

3. Solving High Water Consumption and Expensive Wastewater Treatment: With a water recycling rate of ≥88% and a reduction of 80% in water consumption per ton of material, the equipment significantly cuts water usage during production while also easing the burden and cost of wastewater treatment, helping enterprises achieve water-saving, environmentally friendly production.

4. Preventing Pelletizing Issues Such as Bubbling and Breakage Due to Excessive Moisture: The screw-type dehydrator keeps the moisture content of the material below 5%, ensuring that the clean, dry film can be directly fed into the pelletizing process, thus avoiding quality problems like bubbling or breakage caused by overly moist material and enhancing the overall quality of pelletized products.

Frequently Asked Questions (FAQ)

Q1: What types of waste films can the Purui film recycling and washing line handle?
A: The equipment can process high-sand agricultural greenhouse films, industrial packaging stretch films, BOPP/CPP waste films, courier plastic bags, adhesive composite films, and other types of film waste, meeting diverse recycling and washing needs for various kinds of used plastic films.

Q2: What is the equipment’s processing capacity range? Can it be customized?
A: The equipment’s processing capacity ranges from 500 to 2,000 kg/h. As a custom-made product, it can be tailored to meet specific customer production requirements, accommodating businesses of different sizes.

Q3: What is the equipment’s water recycling rate? How much can it save in water costs?
A: The equipment boasts a water recycling rate of ≥88%, reducing water consumption per ton of material by 80% and significantly cutting both water and wastewater treatment expenses, thereby enhancing the economic and environmental sustainability of production.

Q4: Can the dry film produced be directly fed into the pelletizing process?
A: Yes. The clean, dry film produced by the equipment has a moisture content of ≤5% and a sand and dust removal rate of ≥96%, so it requires no additional treatment before being directly fed into the next pelletizing stage, with process integration efficiency improved by 50%.