Industrial Waste Film Washing Production Line

Product Overview

The industrial waste film washing production line is a customized pre-processing equipment for used plastic films, capable of performing integrated crushing–washing–dewatering operations throughout the entire process. Through multi-stage procedures, it thoroughly removes mud, ink, and both light and heavy impurities, ultimately producing clean, dry film material that can be directly fed into subsequent pelletizing processes, meeting the core pre-processing requirements of film recycling. This production line offers a processing capacity ranging from 500 to 2,000 kg/h, with an impurity removal rate of ≥96%, a moisture content of ≤5% after squeezing, and a water recycling rate of ≥88%. It combines multiple advantages—high efficiency, cleanliness, energy and water conservation, and automated operation—making it a key supporting equipment in the plastic recycling field.

Technical Principles and Process Flow

This production line employs a five-stage closed-loop process consisting of “crushing + frictional washing + flotation separation + rinsing + squeezing,” with each step seamlessly connected to achieve thorough washing of waste films:

1. Coarse Crushing Stage: Bulk 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. This effectively breaks down large, bulky materials, preventing bridging issues and ensuring smooth feeding into downstream processes while avoiding material buildup and machine jams.

2. Fine Crushing Stage: The strip-shaped film enters a high-speed pulverizer, which cuts it into small fragments measuring 1–3 cm, greatly increasing the material’s surface area and providing ample contact for subsequent deep washing, thereby enhancing impurity removal efficiency.

3. High-Speed Frictional Washing: The fragments are fed into a horizontal frictional washer, where spiral blades cause the material to collide at high speed and undergo self-friction. Combined with powerful flowing clean water, this process effectively strips away surface mud, dust, and floating ink. Impurities are discharged through side-wall screens along with wastewater, completing the initial impurity removal stage.

4. Flotation Separation and Rinsing: The material flows into a primary flotation tank, where paper labels, airborne dust, and lightweight plastic impurities are carried away with the water flow, while heavier mud and metal debris settle at the bottom for periodic discharge. As the material spirals forward within the tank, it undergoes further intensive rinsing, removing even hidden impurities lodged in crevices.

5. Secondary Clean Water Rinsing + Squeezing: After secondary clean-water rinsing removes any remaining fine impurities, the material is sent to a screw-type dewatering machine. Physical squeezing expels excess water, and a screen filters out residual fine residue, yielding clean dry film material with a moisture content of ≤5%. This material can be directly fed into subsequent pelletizing processes without additional drying.

Key Performance Parameters

1. Processing Capacity: 500–2,000 kg/h; specifications can be customized according to actual customer production needs.
2. Mud and Dust Removal Rate: ≥96%, ensuring the cleanliness of the output material.
3. Moisture Content After Squeezing: ≤5%, meeting the humidity requirements for direct pelletization.
4. Water Recycling Rate: ≥88%, significantly reducing production water consumption costs.
5. Compatible Materials: High-mud agricultural greenhouse films, industrial packaging stretch films, BOPP/CPP waste films, courier plastic bags, adhesive composite films, and other types of film waste.

Core Advantages

1. High Efficiency and Water Conservation: With a water recycling rate of ≥88%, wash water can be extensively reused, reducing water consumption per ton of material by 80% and substantially lowering both water usage and wastewater treatment costs, aligning with environmentally friendly production standards.
2. Automated Operation: The entire process utilizes automated belt conveyors, minimizing manual handling steps. Only two operators are needed to oversee the entire line, cutting labor costs by 65% while also eliminating the instability in cleanliness often caused by manual operations, thus improving overall production stability.
3. Exceptional Durability: The friction chamber and screens are crafted from wear-resistant materials, extending equipment lifespan, reducing maintenance and replacement frequency, and lowering long-term operating costs.
4. Compliance with Cleanliness Standards: With a mud and impurity removal rate exceeding 96%, the resulting clean dry film material can be directly fed into pelletizing processes, reducing mesh-changing frequency in subsequent pelletizing stages by 75% and boosting pelletizing efficiency, while preventing clogging caused by dirty film containing embedded mud.
5. Seamless Process Integration: The final clean dry film material requires no additional processing and can be directly fed into subsequent pelletizing lines, increasing process integration efficiency by 50% and optimizing the overall production workflow.

Core Value of the Product

1. Addressing Core Pain Points in Plastic Recycling: Effectively resolves industry challenges such as frequent clogging during pelletizing due to dirty film containing mud, low efficiency and unstable cleanliness in manual washing, excessive water consumption and high wastewater treatment costs, and excessively high moisture content in wet materials leading to bubble formation and broken pellets, thereby enhancing the stability and efficiency of recycled plastic production.
2. Significant Cost Reduction and Efficiency Gains: By conserving water, reducing labor, and improving process integration, it dramatically lowers production operating costs while simultaneously elevating product quality and production efficiency, creating greater economic value for enterprises.
3. Customized Adaptability: As a tailor-made product, it can be precisely configured to meet specific customer production needs, accommodating diverse scales and scenarios in waste film pre-processing.

Target Customer Groups

This production line primarily serves film recycling plants, renewable resource industrial parks, large-scale plastic recycling enterprises, and packaging film manufacturers, providing them with professional solutions for pre-processing waste film and helping businesses enhance the automation level and economic benefits of their recycled plastic production.

Application Scenarios

This production line is suitable for pre-processing various types of film waste, including high-mud agricultural greenhouse films, industrial packaging stretch films, BOPP/CPP waste films, courier plastic bags, adhesive composite films, and more. Whether it’s agricultural film laden with substantial mud or industrial packaging films and courier bags coated with ink or adhesive layers, all can undergo thorough washing via the five-stage closed-loop process, providing high-quality raw materials for subsequent pelletizing operations.

Addressing Industry Pain Points

1. Solving the Problem of Frequent Clogging During Pelletizing Caused by Dirty Film Containing Mud: With an impurity removal rate exceeding 96%, the amount of impurities in the pelletizing process is significantly reduced, decreasing mesh-changing frequency by 75% and shortening downtime for mesh changes, thereby boosting pelletizing efficiency.
2. Resolving Low Efficiency and Unstable Cleanliness in Manual Washing: With fully automated operation, minimal manual involvement in washing tasks, not only reducing labor costs but also ensuring consistent cleanliness across every batch, eliminating errors introduced by manual operations.
3. Tackling High Water Consumption and Expensive Wastewater Treatment: 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 fresh water usage and wastewater treatment volumes, thus lowering both water-related costs and environmental treatment expenses.
4. Mitigating Bubble Formation and Broken Pellets Caused by Excessively High Moisture Content: With a moisture content of ≤5% after squeezing, the material meets the humidity requirements of the pelletizing process, preventing quality issues such as bubble formation and broken pellets caused by overly moist raw materials, thereby improving the quality of recycled plastic pellets.

Common Questions FAQ

Q1: Is this industrial waste film washing production line available in fixed specifications?
A: No, it is a custom-made product with no fixed price. It can be tailored to meet specific customer production needs and adapt to different-sized manufacturing environments.
Q2: Can the material processed by this line be directly used for pelletizing?
A: Yes, the clean dry film material produced at the end of the line has a moisture content of ≤5% and an impurity removal rate of ≥96%, satisfying the raw material requirements for pelletizing and allowing direct connection to subsequent pelletizing processes.
Q3: Is the water consumption of this production line high?
A: Not at all. With a water recycling rate of ≥88%, wash water can be extensively reused, reducing water consumption per ton of material by 80% and effectively lowering overall water costs.
Q4: How many workers are required to operate this line?
A: Only two operators are needed to oversee the entire line. The entire process relies on automated belt conveyors, minimizing manual handling steps and significantly reducing labor costs.
Q5: What types of waste film can this line process?
A: It can handle high-mud agricultural greenhouse films, industrial packaging stretch films, BOPP/CPP waste films, courier plastic bags, adhesive composite films, and other types of film waste, offering broad applicability.