Plastic Pelletizing Systems

From Film, Flakes and Regrind to Consistent Recycled Pellets

Complete pelletizing systems that convert film, flakes, regrind and production scrap into filtered, consistent recycled pellets.

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Suitable Materials

What This Plastic Pelletizing System Is Built For

Pelletizing systems that convert films, flakes, regrind and production scrap into consistent, filtered recycled pellets.

  • 01

    LDPE/LLDPE Film

    Low bulk density and printing ink

  • 02

    PP PE Film & Bags

    Moisture and mixed polymer feed

  • 03

    Rigid PE/PP Regrind

    Uneven particle size and fines

  • 04

    HDPE/PP Flakes

    Residual moisture and dirt

  • 05

    Nonwoven & Fiber

    Very low bulk density and entanglement

  • 06

    Production Scrap

    Clean in-house waste streams

Typical Contamination

  • Low Bulk Density
  • Residual Moisture
  • Printing Ink
  • Paper and Labels
  • Fines and Dust
  • Mixed Polymers
  • Degassing Requirement
  • Filtration Requirement

System Overview

A Complete Process for Converting Plastic Waste into Pellets

Controlled feeding, extrusion, degassing, filtration and pellet formation are matched to the bulk density and contamination of your material. Pelletizing systems that convert films, flakes, regrind and production scrap into consistent, filtered recycled pellets.

  • 01

    What is a plastic pelletizing system?

    A plastic pelletizing system is a coordinated production line that feeds, compacts, extrudes, filters and cuts plastic waste into consistent recycled pellets ready for reuse or sale.

  • 02

    How Retech configures the line

    Retech Machine designs pelletizing systems around the material form, bulk density, moisture condition, contamination level, required capacity and target pellet specification.

  • 03

    Typical application range

    The system can be configured for LDPE and LLDPE film, PP/PE film and bags, rigid PE/PP regrind, HDPE/PP flakes, nonwoven and fibre, and clean production scrap.

Input
Film, flake, regrind or production scrap
Main Function
Compaction, extrusion, filtration and pellet formation
Output
Filtered recycled pellets
Next Step
Reuse in production or sale

Input & Output

Input Conditions, Process and Target Output

  • Input

    Input Conditions

    The line is configured around the actual condition of the incoming material.

    • Material form: film, flake, regrind or fibre
    • Bulk density and moisture condition
    • Contamination and filtration requirement
    • Available power, space and labour
  • Process

    Process Route

    The main stages that turn the incoming material into the target output.

    • Feeding
    • Compaction / Densification
    • Extrusion
    • Degassing
    • Melt Filtration
    • Die Face Cutting
  • Output

    Target Output

    Consistent recycled pellets with controlled dimensions and stable processing behaviour, suitable for reuse or sale.

    • Verified through factory testing before shipment
    • Documented for handover and operator training
    • Confirmed against the agreed project scope

Specific capacity, moisture and purity figures are confirmed per project.

Complete Line Layout

The line is engineered as one layout: material flow, machine positions and utility routes are defined together before manufacturing starts.

Complete line layout
Complete line layout

Layout drawings are shown for reference; the final arrangement is engineered per project.

Complete Process Flow

How the Plastic Pelletizing System Works

The exact process depends on the material form, bulk density and contamination. A typical pelletizing system may include the following stages.

  1. 01 Feeding
  2. 02 Compaction / Densification
  3. 03 Extrusion
  4. 04 Degassing
  5. 05 Melt Filtration
  6. 06 Die Face Cutting
  7. 07 Cooling
  8. 08 Pellet Storage
Stage 01

Feeding & Compaction

Feeding → Compaction / Densification

Stabilise low bulk density film, fibre and bag feed so the extruder receives a consistent material stream.

Stage 02

Extrusion & Degassing

Extrusion → Degassing

Melt and homogenise the material, and remove moisture and volatiles before filtration.

Stage 03

Melt Filtration

Melt Filtration

Remove residual contamination that washing cannot eliminate and stabilise the pressure before the die.

Stage 04

Pelletizing & Cooling

Die Face Cutting → Cooling → Pellet Storage

Cut, cool, dewater and classify the pellets for storage, reuse or sale.

Main Equipment Configuration

Main Stages of a Plastic Pelletizing System

The line is configured as a coordinated system, with each stage supporting the performance of the next.

Feeding System

Screw feeders and compaction units that stabilise low bulk density material.

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Machines in This System

Each unit below is built for one duty in the line rather than sold as a stand-alone machine.

Single-shaft shredder
Laser filter
Water chiller

Optional Process Modules

Options That Can Be Added to the Line

  1. 01

    Single-stage or two-stage extrusion

  2. 02

    Continuous or plate-type filtration

  3. 03

    Die face or strand pelletizing

  4. 04

    Melt pump for pressure stability

  5. 05

    Additive dosing

  6. 06

    PLC control and data logging

Material-Specific Engineering

Different Materials Require Different Pelletizing Routes

The pelletizing route is adjusted according to material form, bulk density, contamination and the required pellet specification.

Material Main Challenge Process Focus Possible Output
LDPE / LLDPE Film Very low bulk density and printing ink Compaction, degassing and filtration Filtered recycled pellets
PP Woven Bags & Raffia Dust, printing and coatings Shredding, compaction and filtration Filtered recycled pellets
Rigid PE / PP Regrind Uneven particle size and fines Controlled feeding and melt filtration Consistent recycled pellets
Nonwoven & Fibre Waste Very low bulk density and entanglement Shredding, compaction and degassing Filtered recycled pellets

The Line in Production

Engineering Detail

Capacity, Layout and Control

These three areas define how the system fits your site and how it is operated day to day.

Capacity Options

  • Compact units for lower throughput lines
  • Mid-range systems for general production
  • High-output systems with melt pump and continuous filtration

Layout & Utility Requirements

  • Platform height and access for the extruder
  • Cooling water supply and pellet handling routes
  • Installed electrical load and cabinet position
  • Clearance for filter changes and screw maintenance

Control & Automation

  • PLC control of temperatures, speeds and pressure
  • Closed-loop control of pellet dimensions
  • Filter differential pressure monitoring
  • Alarm logging and optional remote support

Delivery

From Material Review to Stable Pellet Production

Retech coordinates the process route, equipment configuration, layout, utilities and project delivery as one complete pelletizing system.

Manufacturing & Factory Test

  • Extruder heating and alignment checks
  • Trial run with your material where available
  • Pellet sample inspection and documentation
  • Acceptance testing per the agreed project scope

Installation & Commissioning

  • Layout, foundation and utility requirements
  • Installation supervision and alignment
  • Commissioning, pellet quality verification and training
  • Spare parts guidance and technical support

Project Delivery Flow

  1. 01Material Review
  2. 02Process & Layout Design
  3. 03Manufacturing
  4. 04Factory Acceptance Test
  5. 05Installation & Commissioning

Real Production

See Plastic Pelletizing Systems in Operation

Systems of this type running in real production, and a video of the line in operation.

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Frequently Asked Questions

Plastic Pelletizing System FAQs

Single-stage or two-stage extrusion?

Single-stage suits cleaner material. Two-stage is used when degassing and filtration demand is higher, or when film bulk density is very low.

Why is a melt filter needed?

Filtration removes residual contamination that washing cannot eliminate and protects the pellet quality.

Can the system run different polymers?

Often yes, but screw geometry, temperatures and filtration are configured around a defined material range.

What should I send before quotation?

Material form, bulk density, contamination level, required capacity and target pellet specification.

How is moisture handled before extrusion?

Mechanical dewatering upstream and vacuum degassing on the extruder remove moisture before the melt reaches filtration and the die.

Does the pelletizing line need a washing stage?

Only if the material carries soil, labels, adhesives or oil. Clean in-house scrap and washed flakes can normally go straight to pelletizing.

Ready to review your material?

Tell Us About Your Project. Get a System Proposal.

Share your material, contamination level, required capacity and target output. Retech will recommend a process route and system configuration.

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