Post-Consumer Film & Woven Bag Recycling, Compounding, and VOC Deodorization Line

This comprehensive turnkey solution provides a fully integrated post-consumer plastic film and bag recycling, thermal devolatilization compounding, and municipal odor abatement system engineered specifically for printed agricultural polyethylene films (LLDPE/LDPE mulch and greenhouse films), PP woven raffia bags, and post-consumer flexible packaging scrap.

Post-consumer film scrap is plagued by low bulk density, extreme fluffiness, trapped surface moisture, printed solvent inks, greasy organic residues, and noxious VOC fumes generated during high-temperature melt extrusion. Attempting to feed fluffy film flakes into conventional extruders causes severe bridging and feed throat starvation. Furthermore, thermal breakdown of ink binders, agrochemicals, and trapped moisture during extrusion generates dense pyrolytic smoke, foul odors, and severe barrel pressure spikes, while escaping VOCs violate municipal environmental regulations and trigger shop-floor worker health complaints. This engineered solution integrates heavy-duty shredding/crushing, force-feed single/twin-screw extrusion with multi-stage high-vacuum degassing, non-stop continuous hydraulic melt filtration, die-face water ring pelletizing, and an engineered multi-stage VOC deodorization and fume abatement system, turning contaminated agricultural and flexible packaging scrap into high-value, odor-free, export-grade recycled pellets.

The problem

What the section changes

Eliminates film feeding bridging, moisture blisters, and foul VOC odors, turning contaminated agricultural film into high-value recycled pellets.

Dónde empieza el cliente

Recycling operators handling printed agricultural films and woven bags suffer from chronic feeding bottlenecks and severe air quality violations. Low-bulk-density film fluff bridges across extruder feed throats, requiring operators to manually ram material into hoppers using wooden poles, which creates extreme mechanical pinch hazards.

Inside the extruder, decomposing ink binders, printing solvents, and trapped moisture boil violently into foul-smelling vapors. Without engineered devolatilization, these gases create hollow, foamed, and brittle pellets with terrible mechanical strength. Uncontrolled extrusion fumes escape freely into the factory, suffocating operators with acrid smoke and triggering immediate environmental shutdown notices from local regulators.

Por qué ocurre el problema

Post-consumer films contain residual solvent-based inks, adhesive laminates, agricultural pesticide residues, and trapped water. Inside the extruder barrel (190°C–240°C), these volatile chemicals crack thermally into low-molecular-weight hydrocarbons, fatty acids, sulfur/nitrogen compounds, and pyrolytic oily mists.

If not removed under powerful vacuum (-0.095 MPa) before extrusion, these gases remain trapped in the molten polymer matrix, generating porous, foamed pellets with terrible tensile properties. Furthermore, when unvented fumes escape into the workshop, waxy aerosol droplets condense onto cold machines and floors, while volatile hydrocarbons create severe occupational safety violations and foul neighborhood odors.

Producción o estado objetivo

Solid, high-density, odor-free recycled pellets suitable for direct blown-film or pipe manufacturing, with total compliance with environmental air discharge standards and a clean, fume-free factory floor.

Process

The steps, in the order the material flows

Film Shredding, Granulating & Metal Separation
Required

Raw Material Preparation

Reduces bulky film bales, loose plastic films, and woven sacks into uniform, manageable flakes suitable for continuous force-feeding.

Función del equipo
Heavy-duty shredder breaks whole film bales into 40–60 mm strips; inline granulator further reduces scrap into uniform flakes, while overband magnets remove tramp metal staples and wire.

Equipos Plastic Shredder Plastic Crusher
Force-Feed Extrusion, Multi-Stage Degassing & Melt Filtration
Required

Extrusion and Melt Processing

Plasticizes low-density film flakes, extracts volatile solvents and moisture, and continuously filters melt contaminants.

Función del equipo
Vertical force-feeder compresses fluffy film flakes into the extruder feed throat. Multi-stage high-vacuum degassing chambers (-0.095 MPa) boil off inks, solvents, and moisture, while continuous hydraulic screen changer filters out residual paper and foil.

Equipos Single Screw Pelletizer Twin Screw Pelletizer
Die-Face Water-Ring Pelletizing & Centrifugal Drying
Required

Pelletizing

Cuts degassed polymer melt at the die face, instantly chills pellets, expels water, and screens out off-spec fines.

Función del equipo
Water ring pelletizer cuts molten strands at the die plate. Pellets are carried by circular water flow into the vertical centrifugal dryer, which expels surface water to ≤ 0.05%, followed by linear screen classification.

Equipos Water Ring Pelletizer Vertical Centrifugal Dryer Linear Vibrating Screen
Multi-Stage VOC Fume Abatement & Catalytic Deodorization
Required

Post-Pellet Treatment

Captures all fugitive VOC vapors, oily smoke, and noxious odors from extruder vents and die heads, discharging purified clean air.

Función del equipo
Negative-pressure collection hoods route fumes through a multi-stage VOC deodorization system: stainless demister and electrostatic precipitator capture oil aerosols; deep-bed honeycomb activated carbon and UV photocatalytic oxidation mineralize VOCs before clean stack discharge.

Equipos Plastic VOC Removal Deodorization System

Material

What goes in, what comes out

Condición y requisitos de alimentación

Post-consumer and post-industrial flexible film and bag scrap: agricultural mulch film, greenhouse film, stretch film, shrink wrap, PP woven bags, and printed shopping bags. Flakes or shredded strips (dimensions 20–60 mm), moisture content ≤ 4.0%, free of heavy steel chunks or stones.

Condición y límites de salida

Dense, solid, and completely degassed recycled pellets (bulk density ≥ 0.52 kg/L) with zero internal gas bubbles or voids. Discharged dry, dust-free, and cooled to ≤ 40°C. Factory exhaust stack emissions strictly comply with local environmental limits (NMHC ≤ 20 mg/m³, odorless, zero visible blue/white oil smoke).

400–1500 kg/h

Base de las cifras de capacidad

Based on continuous recycling pelletizing line configurations (single-screw extruder with force-feed compactor or co-rotating twin-screw devolatilizing extruder, screw diameter 100 mm to 180 mm) producing between 400 kg/h and 1,500 kg/h of qualified recycled pellets, paired with a 10,000 to 25,000 Nm³/h VOC deodorization abatement package.

Fit

Where this section belongs — and where it does not

Adecuada cuando

Indispensable for agricultural film recyclers processing post-consumer greenhouse film, PE silage wrap, and mulch films with residual soil and pesticide odors.

Essential for flexible packaging and woven bag recyclers facing strict municipal environmental emission inspections, factory worker odor complaints, or urban zoning compliance mandates.

No adecuada cuando

Not suitable for unwashed, municipal mixed household waste containing over 15% wet food waste, organic sludge, or heavy sand/glass without an upstream industrial washing line.

Not suitable for highly chlorinated hazardous plastics like PTFE or halogenated PVC compounds, which generate hydrochloric or hydrofluoric acid gas that corrodes standard steel ducts and poisons activated carbon beds.

Condiciones pendientes de confirmar

Feedstock specifications assume washed and dried post-consumer or post-industrial PE film flakes (LLDPE/LDPE) or PP raffia flakes with residual moisture ≤ 4.0%, residual paper label content ≤ 0.5%, and mineral soil/ash content ≤ 2.0%.

If processing heavily contaminated unwashed agricultural mulch film containing over 10% soil or sand, an upstream wet-washing pre-treatment plant (friction washer, sink-float tank, squeezer dryer) must be installed prior to the shredding and recycling extruder.

Site and connections

What the section assumes around it

Servicios auxiliares

Suministro eléctrico: 380 V / 415 V / 460 V, 50/60 Hz, 3-phase AC.
Agua: Recirculating cooling water for extruder barrel, vacuum pump, and water-ring tank: 15–30 m³/h at 0.3 MPa.
Aire comprimido: 0.6–0.7 MPa clean, dry compressed air for screen changer hydraulics, water ring pneumatic cutter, and damper actuators (approx. 0.5 m³/min).
Extracción y ventilación: Induced draft centrifugal blower (10,000–25,000 Nm³/h) generating continuous negative pressure across all collection hoods.

Total connected electrical power: 180 kW to 450 kW (depending on extruder drive size and shredder rating).

Limitaciones de la planta

Superficie ocupada: Complete line footprint: approximately 120–180 m² (including shredding, extruder line, and outdoor VOC filtration skid).
Altura libre: Clear vertical ceiling height of 4.5 m to 6.0 m inside the plant; 15 m vertical clearance outdoors for chimney stack.
Entorno: Industrial recycling plant; outdoor concrete pad or reinforced rooftop required for VOC exhaust fan, carbon vessels, and stack.

Ensure explosion-proof wiring and static grounding on all VOC ductwork and carbon vessels.

Interfaces

Mecánico: Airtight exhaust collection hoods fitted over vacuum vent ports, hydraulic screen changer, and water-ring cutter chamber connected via spiral stainless ducting (DN300–DN600).
Control: PLC interlock between VOC exhaust fan and extruder: extruder heaters and main drive cannot engage unless the VOC exhaust system is running under positive negative draft.
Aguas arriba y aguas abajo: Upstream: scrap film bale breaker / belt conveyor. Downstream: pneumatic pellet conveying blower to storage silo or bagging station.

Targets

What the section is judged on

VOC Abatement Efficiency (NMHC Removal Rate): ≥ 95.0% % Certified third-party EPA stack gas chromatography testing
Exhaust Chimney Odor Concentration: ≤ 30 OU (dimensionless) Standard dynamic olfactometry odor sensory testing (ASTM E679 / EN 13725)
Pellet Internal Void/Bubble Ratio: 0.00% % Cross-sectional optical microscopy analysis on 500 randomly sliced pellets

Cómo se evalúa la aceptación

Acceptance testing requires an 8-hour continuous commercial recycling run processing post-consumer printed agricultural PE film scrap or printed PP raffia woven bag regrind at ≥ 95% rated capacity. Extruded pellets must be solid, dense (bulk density ≥ 0.52 kg/L), and 100% free of internal gas blisters, voids, or moisture foaming.

Exhaust stack emissions from the VOC deodorization system must pass municipal environmental compliance testing: Total Non-Methane Hydrocarbons (NMHC) ≤ 20 mg/m³, TVOC removal efficiency ≥ 95%, and stack exit odor concentration ≤ 30 OU (dimensionless odor units), ensuring zero pungent odors in the surrounding plant neighborhood.

Scope of supply

What is in the delivery — and what is not

Incluido en el alcance del suministro

Heavy-Duty Single/Twin-Shaft Plastic Shredder High-torque shredder with solid alloy rotor, hydraulic ram pusher, DC53 wear blades, and tramp metal magnetic separator.
High-Torque Devolatilizing Recycling Extruder Unit Equipped with vertical force feeder / side stuffer, bimetallic screw/barrel, multi-vent vacuum degassing chambers, and high-vacuum liquid ring pumps.
Continuous Hydraulic Screen Changer (Dual-Piston Non-Stop) Continuous melt filtration unit allowing screen replacements under high melt pressure without halting line production.
Water Ring Die-Face Pelletizing & Dewatering Skid Direct-coupled water ring cutter hood, pneumatic blade adjustment, stainless slurry pipe, vertical centrifugal dryer, and classification screener.
Integrated Multi-Stage VOC Removal & Deodorization System Grease demister pre-filter, electrostatic oil-mist precipitator (ESP), honeycomb activated carbon adsorption beds, UV photolysis/catalytic deodorizer, and 15m exhaust stack.

No incluido en el alcance del suministro

Upstream film washing and dewatering wash-line Crushers, sink-float tanks, friction washers, and mechanical squeezers belong to wet-washing pre-treatment scope.
Outdoor chimney stack guy wires and civil foundation concrete pad Reinforced civil concrete pads and rooftop load support structures are on the customer side.
Spent activated carbon disposal or off-site thermal regeneration Disposal or thermal regeneration of saturated carbon media by certified environmental contractors is customer scope.
Mains electrical feeder cables to control cabinets High-voltage cabling from plant substation to master control disconnect switches is on customer side.

Before a price

What we confirm before this becomes a quotation

01 Scrap plastic feedstock profile and contaminant data Film type (LLDPE greenhouse, LDPE packaging, PP raffia), estimated residual moisture (%), printing ink coverage (%), and presence of pesticides or labels.
02 Site environmental discharge limits (EPA / Local EPA) Local municipal limits for NMHC (mg/m³), TVOC (mg/m³), maximum odor units (OU), and minimum required exhaust stack height (m).
03 Factory floor layout and outdoor stack staging area Plant architectural drawings showing extrusion bay, duct routing path, and outdoor concrete pad for VOC carbon vessels and chimney stack.
04 Water supply and drainage infrastructure Available industrial process water flow (m³/h) for cooling tanks and water ring pelletizer, plus wastewater discharge connections.

Request a Quote Send these points with your inquiry; the section can then be quoted against your line, not against an assumption.

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Photos

The section in the workshop

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Placeholder · 1200 × 900 px (4:3)（占位图） Replace with an approved section photos, real workshop or installation views at this size.（按此尺寸替换为正式图片。）

Details

Further details

Problema de producción principal

Blockage and bridging
High surface moisture on the material
Odor and VOC acceptance target not defined
Residual odor and VOC