Purui PP Film Recycling and Washing Line

Product Overview

The Purui PP 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 employs a five-stage closed-loop process—crushing + frictional washing + flotation separation + rinsing + squeezing—to thoroughly remove sand, ink, and both 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, with outstanding performance characteristics including an impurity removal rate of ≥96%, a moisture content of ≤5% after squeezing, and a water recycling rate of ≥88%. Additionally, it features fully automated process integration and wear-resistant components, effectively addressing multiple pain points in the plastic recycling industry.

Technical Principles and Process Details

This washing line relies on a five-stage closed-loop process to achieve efficient and thorough washing of waste plastic films. Each stage is tightly interconnected, ensuring both effective treatment and high operational efficiency:

1. Coarse Crushing Stage: Loose 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. This step effectively breaks down large, bulky materials, preventing bridging issues and providing a uniform feed for the subsequent fine-crushing stage, thus avoiding equipment blockages or uneven feeding.

2. Fine Crushing Stage: Strip-shaped film material enters a high-speed pulverizer, where it is further shredded into small fragments measuring 1–3 cm. This significantly increases the material’s surface area, enabling more thorough contact between the material and the washing agents during subsequent stages, thereby enhancing overall cleanliness and impurity removal.

3. High-Speed Frictional Washing: Fragmented material flows into a horizontal frictional washer, where spiral blades drive the material through high-speed collisions and self-friction, while flowing clean water provides additional scouring action. This vigorously removes surface sand, dust, and loose ink, with the detached impurities discharged through side-wall screens along with wastewater, achieving preliminary purification.

4. Flotation Separation and Rinsing: After frictional washing, the material enters a primary flotation tank, where differences in density between the material and impurities enable separation of light and heavy contaminants. Paper labels, floating dust, and lightweight plastics are carried away with the water flow, while heavier sand and metal debris settle at the bottom. Regular sludge removal ensures continuous operation, and the material undergoes deep rinsing within the tank via a screw conveyor, further eliminating residual impurities.

5. Secondary Clean-Rinse and Squeezing: Following flotation separation, the material proceeds to a secondary clean-rinse stage, where any remaining fine impurities are thoroughly removed before being sent to a screw-type squeeze dryer. Physical squeezing removes excess moisture, while a screen filters out residual fines, yielding clean, dry film material with a moisture content of ≤5%. This product can be directly fed into the next pelletizing process without additional drying.

Key Performance Parameters

1. Processing Capacity: 500–2,000 kg/h, customizable to meet specific customer production needs.
2. Sand and Dust Removal Rate: ≥96%, ensuring compliance with cleanliness standards.
3. Moisture Content After Squeezing: ≤5%, meeting the moisture requirements for direct pelletizing.
4. Water Recycling Rate: ≥88%, significantly reducing water consumption costs.
5. Labor Requirements: Only two operators needed to oversee the entire line, minimizing labor input.

Core Product Advantages

1. Water Conservation and Cost Reduction: With a water recycling rate of ≥88%, wash water can be extensively reused, cutting water consumption per ton of material by 80%. This not only lowers production water costs but also reduces wastewater treatment pressure, aligning with eco-friendly manufacturing goals.

2. High Degree of Automation: The entire process utilizes automated belt conveyors to handle material transfer, eliminating manual handling and reducing human intervention. This boosts production efficiency while minimizing safety risks associated with manual operations. With just two operators required to maintain stable operation, labor costs are reduced by 65%.

3. Exceptional Durability: The friction chamber and screens are crafted from wear-resistant materials, capable of withstanding prolonged friction and erosion, extending service life, reducing component replacement frequency, lowering maintenance costs, and enhancing the line’s operational stability.

4. Superior Cleanliness: With a sand and dust removal rate of ≥96%, the resulting clean, dry film material can be directly fed into the pelletizing process without additional treatment. This reduces the frequency of screen changes in subsequent pelletizing stages by 75%, significantly improving production efficiency and minimizing downtime due to equipment malfunctions.

Core Product Value

1. Cost Reduction and Efficiency Gains: By leveraging a high water recycling rate to lower water consumption, automating operations to reduce labor costs, and using durable components to cut maintenance expenses, this line comprehensively compresses production operating costs. Meanwhile, improved process integration boosts efficiency by 50%, shortening production wait times and increasing overall productivity.

2. Quality Assurance: A high sand and dust removal rate ensures consistent cleanliness of the output material, while a moisture content of ≤5% prevents issues such as bubbling or breakage during pelletizing, thereby enhancing the quality of recycled plastic pellets and guaranteeing stable downstream product quality.

3. Customization: The line can be tailored to meet specific customer production needs, adapting to various scales and scenarios to satisfy the personalized requirements of different plastic recycling enterprises.

Target Customer Groups

The Purui PP film recycling and washing line primarily serves film recycling plants, resource regeneration industrial parks, large-scale plastic recycling companies, and packaging film manufacturers. These customers typically have substantial demands for processing waste plastic films, and the equipment’s efficiency, water conservation, and automation perfectly align with their operational needs, helping them improve both the efficiency and quality of their recycled plastic processing.

Application Scenarios

This equipment is widely applicable for the pre-treatment washing of various types of waste plastic films, including agricultural greenhouse films heavily contaminated with sand, industrial packaging stretch films, BOPP/CPP waste films, courier plastic bags, adhesive composite films, and other similar materials. Whether the material contains significant amounts of sand or is coated with ink, glue, or other impurities, the five-stage closed-loop process ensures thorough washing, providing high-quality raw materials for subsequent pelletizing processes.

Addressing Industry Pain Points

1. Solving the problem of frequent screen clogging caused by dirty films containing sand: With a sand and dust removal rate exceeding 96%, the equipment dramatically reduces impurity levels in the material, cutting the frequency of screen changes in subsequent pelletizing stages by 75% and minimizing downtime due to clogging, thereby enhancing the continuity and efficiency of the pelletizing process.

2. Improving low-efficiency manual washing and inconsistent cleanliness: Fully automated operations eliminate the need for manual washing, boosting washing efficiency while standardizing processes to ensure consistent cleanliness across batches, thus avoiding quality fluctuations caused by human error.

3. Alleviating the issue of excessive water consumption during washing and high wastewater treatment costs: With a water recycling rate of ≥88% and a reduction in water usage per ton of material by 80%, the equipment significantly cuts production water consumption while easing the burden and cost of wastewater treatment, aligning with eco-friendly production goals and reducing enterprises’ environmental investment.

4. Resolving the problem of excessive moisture in wet materials causing pelletizing defects such as bubbling or breakage: The screw-type squeeze dryer controls moisture content to ≤5%, allowing the resulting dry film material to be directly fed into the pelletizing process, thereby avoiding defects caused by overly moist materials and improving the quality of recycled plastic pellets.

Frequently Asked Questions (FAQ)

Q1: Can the capacity of this Purui PP film recycling and washing line be customized?
A: Yes, this equipment is custom-made and can be tailored to meet specific customer production needs, covering a processing capacity range of 500–2,000 kg/h to suit various production scales.

Q2: Can the material processed by this equipment be directly used for pelletizing?
A: Yes, after undergoing the five-stage process, the resulting clean, dry film material has a moisture content of ≤5% and a sand and dust removal rate of ≥96%, making it ready for direct use in subsequent pelletizing processes and improving production efficiency.

Q3: Does the equipment’s high water recycling rate affect its washing performance?
A: No. The equipment employs a multi-stage washing design, and the recycled water, after filtration, can be reused in subsequent washing stages. Combined with high-speed friction and flotation separation, it still maintains a sand and dust removal rate of ≥96%, ensuring effective washing while conserving water.

Q4: Is this equipment suitable for processing adhesive composite films?
A: Yes. The equipment’s high-speed frictional washing stage can powerfully strip off adhesive layers and other surface impurities, while flotation separation and rinsing further remove residual adhesives and other contaminants, producing clean, dry film material that meets required standards.