BOPP Film Recycling and Washing Line

Product Overview

The BOPP film recycling and washing line is a customized, end-to-end pre-processing production line for waste plastic films, capable of integrating crushing, washing, and dewatering into a single operation. Through multi-stage processes, it thoroughly removes sand, ink, and both light and heavy impurities from used films, ultimately producing clean, dry film material that can be directly fed into subsequent pelletizing operations. This production line can be tailored to meet specific customer throughput requirements, with processing capacities ranging from 500 to 2,000 kg/h. It is suitable for washing and pre-processing 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, providing an efficient and energy-saving solution for film recycling and processing.

Technical Principles and Process Flow

This production line employs a five-stage closed-loop process—crushing + friction washing + flotation separation + rinsing + squeezing—to ensure thorough removal of contaminants and achieve the required level of material cleanliness. Each stage is specifically designed to address the unique characteristics of waste films:

1. Coarse Crushing Stage: Loose or whole-roll waste film is conveyed by a belt feeder into a twin-shaft shredder, where it is coarsely cut into strips measuring 8–15 cm in length. This effectively breaks up large, bulky clumps, providing a uniform feed for the subsequent fine-crushing stage and preventing equipment blockages or uneven feeding.

2. Fine Crushing Stage: The strip-shaped film enters a high-speed pulverizer, which cuts it into small fragments measuring 1–3 cm. This significantly increases the material’s surface area, enabling more effective contact between the material and the washing process, thereby facilitating the thorough removal of surface impurities.

3. High-Speed Friction Washing: The fragmented material is fed into a horizontal friction washer, where spiral blades cause the material to collide at high speed while being continuously rinsed with flowing water. This powerful action removes surface sand, dust, and loose ink. The detached impurities are discharged through side-wall screens along with wastewater, completing the initial separation of contaminants.

4. Flotation Separation and Rinsing: After friction washing, the material flows into a primary flotation tank, where differences in density between the material and its impurities enable separation. Light impurities such as paper labels, floating dust, and lightweight plastics are carried away with the water flow, while heavier contaminants like sand and metal debris settle at the bottom, ready for periodic discharge and washing. Inside the tank, a screw conveyor performs deep rinsing, further removing any remaining soluble impurities.

5. Secondary Water Rinsing and Squeezing: Following flotation separation, the material proceeds to a secondary water-rinsing stage, where residual fine impurities are washed away. It then enters a screw-type dewatering machine, where physical squeezing removes excess moisture. A screen filters out any remaining fine residue, resulting in clean, dry film material with a moisture content of ≤5%, ready for direct connection to downstream pelletizing operations.

Key Performance Data

1. Processing Capacity: 500–2,000 kg/h; production line specifications can be customized according to actual customer throughput needs.
2. Sand and Dust Removal Rate: ≥96%, ensuring thorough impurity removal and meeting the cleanliness standards required for subsequent pelletizing.
3. Post-Squeezing Moisture Content: ≤5%, preventing issues such as bubbling or broken pellets during wet-material pelletization.
4. Water Recycling Rate: ≥88%, significantly reducing water consumption costs and wastewater treatment burdens.

Core Product Advantages

1. Efficient Water Conservation and Cost Reduction: With a water recycling rate of ≥88%, wash water can be extensively reused, reducing water consumption per ton of material by 80% and substantially cutting water and wastewater treatment expenses, aligning with green manufacturing principles.

2. Full-Process Automation and Reduced Labor: The entire production line uses automated belt conveyors to link each stage, eliminating manual material handling. Only two operators are needed to oversee the entire process, reducing labor costs by 65% while avoiding cleanliness-related instability caused by manual operations.

3. Wear-Resistant Materials for Extended Equipment Lifespan: The friction chamber and screening components are crafted from wear-resistant materials, capable of enduring prolonged friction and impact, thus extending equipment life and minimizing maintenance and replacement costs.

4. Thorough Impurity Removal Ensuring Pellet Quality: With a sand and dust removal rate of ≥96%, the frequency of screen changes in subsequent pelletizing stages is reduced by 75%, preventing frequent clogging caused by dirty film containing sand. Clean, dry material directly feeds into pelletizing, boosting process efficiency by 50% and ensuring stable, high-quality pellet output.

Core Product Value

1. Deep Impurity Removal Solves Traditional Washing Challenges, Enhancing Recycled Plastic Pellet Quality and Reducing Pelletizing Failure Risks.
2. High Water Recycling Rate Significantly Cuts Water Consumption and Wastewater Treatment Costs, Supporting Green Production and Compliance with Environmental Policies.
3. Fully Automated Operations Reduce Labor Costs and Workload While Improving Production Efficiency and Process Stability.
4. Customizable Capacity Design Meets Diverse Production Needs, Allowing Flexible Adaptation to Different Scale Enterprises and Maximizing Return on Investment.

Target Customer Groups

Film recycling plants, renewable resource industrial parks, large-scale plastic recycling enterprises, and packaging film manufacturers—companies that require pre-treatment washing of waste plastic films, especially those dealing with high-impurity-content film waste and having substantial recycling demands.

Application Scenarios

This production line is suitable for pre-treating various types of waste plastic films. Key application scenarios include: recycling agricultural greenhouse films with high sand content, pre-processing industrial packaging stretch films for reuse, washing and processing BOPP/CPP waste films, recycling courier plastic bags, and removing impurities from adhesive composite films. The cleaned, dry film material produced can be directly fed into pelletizing equipment to manufacture recycled plastic pellets.

Solutions to Industry Pain Points

1. Addressing Frequent Clogging During Pelletization Caused by Contaminated Film: Through the five-stage closed-loop process, sand and dust removal rates reach ≥96%, drastically reducing impurity levels in the material. Consequently, the frequency of screen changes in subsequent pelletizing stages drops by 75%, minimizing equipment downtime and maintenance time, and boosting overall pelletizing efficiency.

2. Solving Low Efficiency and Unstable Cleanliness in Manual Washing: With fully automated belt-driven operations, there is no need for manual transfer or hand-washing. Only two operators are required to oversee the entire process, standardizing and automating the washing procedure to ensure consistent cleanliness across batches while improving washing efficiency.

3. Tackling High Water Consumption and Expensive Wastewater Treatment: With a water recycling rate of ≥88%, most wash water can be reused, reducing water consumption per ton of material by 80% and significantly cutting fresh water usage and wastewater treatment volumes, thereby lowering water-related costs and environmental compliance expenses.

4. Resolving Excessive Moisture in Wet Material Leading to Pellet Bubbling and Breakage: Using the physical squeezing action of a screw-type dewatering machine, the final moisture content of the material is reduced to ≤5%, meeting the strict moisture requirements of the pelletizing process and preventing issues such as bubbling or broken pellets, thus safeguarding the quality of recycled pellets.

Frequently Asked Questions (FAQ)

Q1: What types of waste films can the BOPP film recycling and washing line process?
A: This production line can handle 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. It provides effective pre-treatment washing for materials with varying levels of contamination.

Q2: Can the production line’s capacity be customized?
A: Yes, this product is custom-made with no fixed price. It can be tailored to meet specific customer throughput needs, offering processing capacities ranging from 500 to 2,000 kg/h to suit enterprises of different sizes.

Q3: Is the production line highly water-intensive?
A: The line boasts a water recycling rate of ≥88%, reducing water consumption per ton of material by 80% compared to traditional washing equipment, significantly cutting water usage and wastewater treatment costs.

Q4: Can the processed material be directly used for pelletizing?
A: Yes, the clean, dry film material produced has a moisture content of ≤5% and an impurity removal rate of ≥96%, making it suitable for direct connection to downstream pelletizing operations without additional processing, thereby enhancing the efficiency of the entire production workflow.