Equipment
Heavy-duty single screw extrusion pelletizing system for cost-effective melting, vacuum degassing, and recycling of post-industrial rigid flakes and regrind.
Overview
Plastifies, melts, degasses, and pressurizes post-industrial and post-consumer plastic regrind flakes into clean, filtered melt for pelletizing.
The Single Screw Pelletizer (single screw recycling and extrusion pelletizing line) is engineered for cost-effective, continuous melting, homogenization, filtration, and pelletizing of post-industrial and post-consumer thermoplastic waste. Widely applied across rigid scrap regrind (HDPE/PP containers, ABS/PS e-waste flakes, PVC profiles) and pre-densified plastic scrap, the single screw extruder provides stable, high-pressure melt delivery with lower mechanical shear and power consumption compared to twin screw compounding systems.
Equipped with a deep-flighted nitrided or bi-metallic screw, optimized barrier shearing sections, multi-stage ceramic barrel heating, and an extended high-vacuum devolatilization zone, the single screw pelletizer efficiently extracts entrapped moisture, ink residues, and low-boiling polymer volatiles. It pairs flexibly with hydraulic screen changers and either the complete Strand Pelletizer System, water ring hot-die face cutters, or underwater pelletizers, transforming bulky reclaimed scrap into uniform, high-bulk-density recycled plastic pellets.
Key features
Each picture names one part of the machine and what it does for the material and the batch.
Deep-flighted screw featuring dedicated feed, compression, barrier melting, devolatilization, and metering zones. Precision-engineered flight clearances and Maddock shear elements deliver stable, surge-free melt pressure and complete plastification at low melt temperatures.
Heavy-duty helical-bevel parallel shaft gearbox engineered with a high service factor (SF ≥ 1.5). Features precision carburized and ground alloy gears, an integrated high-capacity roller thrust bearing assembly, and an independent forced-oil cooling circuit.
High-efficiency ceramic band heaters enclosed in insulated stainless steel shrouds. Paired with low-noise centrifugal blowers on each barrel zone, PID microprocessor temperature controllers maintain temperature stability within ±1.5°C.
Extended barrel vent opening equipped with a high-capacity liquid-ring vacuum pump skid. Rapidly pulls down vacuum to -0.096 MPa to extract volatile monomer odors, residual moisture, and printing ink gases, preventing gas pores and foamed pellets.
Integrated PLC control architecture featuring an intuitive color touchscreen HMI. Monitors barrel temperatures, screw RPM, motor amperage, melt pressure, and safety interlocks, complete with cold-start safety prevention and recipe memory.
Material and process
Read the conditions together: a machine is selected for the material and the output, not from its name alone.
Designed for post-industrial and post-consumer plastic recycling plants, scrap washing facilities, and masterbatch dilution pelletizing lines.
Excellently handles clean and pre-washed rigid thermoplastic regrind, including Polypropylene (PP), High-Density Polyethylene (HDPE), Low-Density Polyethylene (LDPE), Acrylonitrile Butadiene Styrene (ABS), High-Impact Polystyrene (HIPS), and rigid PVC flakes. Converts crushed bottles, pipe offcuts, automotive battery cases, electronic appliance housings, and injection molded runner scrap into clean, high-density, reusable plastic pellets.
Linear melting and pressure-building extruder; operating boundaries include:
Accepts clean, washed, or post-industrial thermoplastic rigid regrind flakes, crushed caps and closures, injection molding runner scrap, thermoforming skeleton regrind, and pre-densified plastic agglomerates.
Compatible with PP, HDPE, LDPE, ABS, HIPS, and rigid PVC regrind with particle sizes typically between 6 mm and 14 mm and moisture content ≤ 1.0% (higher moisture materials require pre-drying or double vacuum venting). Input must be free of tramp metal, stones, and foreign non-polymeric contaminants.
Delivers a thoroughly plasticized, filtered, gas-free continuous polymer melt flow at consistent pressure and temperature.
Discharges through a hydraulic screen changer directly into downstream strand water bath dies or water-ring cutting die plates, producing solid, uniform recycled plastic granules ready for re-manufacturing.
Throughput
Read a figure together with the basis below it: the same machine reaches different numbers on different materials.
Hourly pelletizing capacity ranges from 100 kg/h up to 1,500+ kg/h depending on screw diameter (ranging from 65 mm to 200 mm), screw L/D aspect ratio (typically 30:1 to 38:1), and main drive motor power (30 kW to 315 kW).
Throughput is fundamentally governed by feedstock bulk density, particle size uniformity, and polymer melt flow index. Free-flowing rigid regrind flakes (bulk density 0.45–0.65 kg/L) feed smoothly and achieve maximum nominal output, whereas light fluffy un-densified flakes require forced crammer feeding or derating by 25%–40%.
Scope of supply
The quotation states the scope for the confirmed configuration; the groups below describe how a supply is normally split.
Installation planning
These are the connections the machine and the line around it have to agree on before the layout is fixed.
Mechanical: Bolted base frame anchored to factory concrete floor; discharge flange standard round hydraulic clamp connection (DN100–DN200) for coupling to hydraulic screen changers and pelletizing die heads.
Electrical & Automation: Three-phase industrial power supply to the electrical drive and control cabinet (380V/415V/460V, 50/60 Hz). Control panel provides digital I/O contacts for upstream conveyor/crammer speed coordination and downstream pelletizer speed synchronization.
The buyer provides a reinforced level concrete floor slab capable of supporting the static and dynamic operating weights of the extruder, motor, gearbox, and pelletizing line. Buyer supplies primary electrical power cabling terminated at the main control cabinet disconnect switch, continuous industrial cooling water with filtration to the heat exchangers and water baths, clean dry compressed air, and external exhaust ducting from the vacuum pump and barrel covers.
Spare parts
The parts that wear in normal service, and the spares worth keeping on site. How often a part is replaced depends on the material and the duty the machine runs, so the basis is confirmed for each machine.
Inspect flight outer diameter annually; replace or laser-rebuild when radial clearance to barrel exceeds 0.7–1.0 mm or when output drops by > 20%.
Continuous one-piece screw. The primary wear component of the extruder. Keep one spare finished screw machined to exact flight geometry to prevent extended production downtime during scheduled overhauls.
Inspect wiring and amp draw during quarterly PM; replace immediately if heater band burns out or thermocouple drifts.
High-wattage ceramic heating bands and dual J/K type thermocouples installed along the barrel and die head adapter zones.
Inspect pump vacuum level quarterly; replace mechanical seals and internal impeller vanes if vacuum fails to reach -0.09 MPa.
Internal maintenance kit for the barrel vacuum degassing pump station. Protects vacuum integrity against acidic or solvent vapors.
Calibrate annually; replace if diaphragm is mechanically damaged or electrical zero/span signal fails to respond accurately.
Installed in the barrel metering section before the screen changer to monitor internal melt pressure and prevent equipment overpressurization.
Inspect blower bearings and clean air inlet grilles monthly; replace motor assembly upon abnormal vibration or winding failure.
Low-noise cooling fans mounted beneath each barrel heating zone shroud for zone temperature control.
Blades, screens and other normal consumables are outside the standard warranty. How a spare part is identified and ordered is set out under Warranty & Spare Parts.
Selection
Work through what you already know. The rest is settled in the conversation, not before the first message.
Select the optimal single screw recycling pelletizer configuration based on material type, contamination level, and target production volume:
Request a Quote A model name, a material or a drawing is enough to start.
Indíquenos el material, el proceso y el resultado que necesita lograr. Los detalles técnicos se pueden completar más adelante junto con nuestro equipo de ventas.
