Compaction Pelletizing System

Product Overview

The URIDGE Compaction Pelletizing System is designed for recycling lightweight, low-bulk-density plastic waste into reusable pellets. It is intended for fluffy and hard-to-convey materials that cannot be fed into a conventional extruder directly.

Typical materials include PE and PP film, PET film, BOPP and BOPET film, PP woven bags, PET fiber waste and EPS foam. The integrated compaction chamber cuts, densifies and continuously feeds this lightweight material into the extruder, so the line can run steadily on bulky feedstock.

The standard model range covers nominal capacities of approximately 100–1,000 kg/h. Actual output depends on the material, bulk density and configuration rather than being fixed for every material.

Suitable Materials and Applications

The system is mainly designed for lightweight and low-bulk-density thermoplastic waste, including:

• PE film
• PP film
• PET film
• BOPP film
• BOPET film
• PP woven bags
• PET fiber waste
• EPS foam

Feed material can be supplied as rolled film, loose material or pre-shredded material. Typical customers include packaging factories, film blowing and film production plants, printing factories, plastic recycling companies and other operations that generate lightweight plastic waste.

How the Compaction Pelletizing Process Works

A typical line follows this process flow:

Belt Conveyor → Compaction Chamber → Extrusion and Melt Mixing → Vacuum Degassing → Melt Filtration → Pelletizing → Cooling → Dewatering → Pellet Screening → Pneumatic Conveying → Storage.

Belt Conveyor

The belt conveyor transfers film and other lightweight material into the compaction chamber.

Compaction Chamber

The compaction chamber cuts, densifies and compacts film, fiber and foam material, then feeds it continuously into the extruder.

Extrusion and Melt Mixing

The extruder melts and mixes the compacted plastic into a homogeneous melt.

Vacuum Degassing

The vacuum system removes moisture, gases and volatile components released during processing.

Melt Filtration

The filtration system removes solid contamination from the melt before pelletizing.

Pelletizing, Cooling and Dewatering

The melt is cut into pellets, which are then cooled and dewatered.

Pellet Screening

A vibrating screen separates oversized and undersized pellets to improve pellet size consistency.

Pneumatic Conveying and Storage

The finished pellets are pneumatically conveyed to the storage silo.

Compaction Chamber and Feeding Control

The compaction chamber is the core of this system. It performs three functions in one section: cutting the lightweight material, compacting and densifying it, and feeding it into the extruder.

The feeding logic is interlocked with the chamber load. If the compaction chamber current becomes too high, the belt conveyor can automatically stop feeding to prevent overloading. This is a current-based protective interlock rather than an autonomous control system.

Extrusion and Vacuum Degassing

The extruder melts and mixes the compacted plastic. The vacuum system removes moisture, gases and volatile components released during processing, helping to stabilise the melt before filtration.

Flexible Melt Filtration Options

Different feedstocks require different filtration strategies. Filtration configurations can include:

• Plate Screen Changer
• Column-Type Screen Changer
• Screenless Filtration System
• Laser Filtration System
• Automatic Backflush Filtration System
• CPF Filtration System

A melt pressure sensor can be installed at the front end of the filtration system to monitor filter loading and blockage. Selected automatic filtration options can reduce manual screen changes. Filtration reduces contamination; it does not remove all contamination from the recycled pellets.

PET Pelletizing Configuration

For PET pelletizing applications, the line can be configured with a melt pump and CPF filtration system according to process requirements.

Pelletizing Options

Water-ring pelletizing is the standard configuration for this system. Strand pelletizing and underwater pelletizing can also be configured according to the material, process and pellet requirement.

Automation and Process Control

The line can be equipped with a Siemens PLC and an HMI operator interface. PID temperature control and adaptive temperature control are used for extrusion temperature management. A closed-loop linkage between die pressure, feeding and the main motor helps maintain stable extrusion.

The control system can also include:

• Motor overcurrent protection
• Overvoltage protection
• Recipe storage
• Network communication module
• Remote diagnostics

Remote monitoring and program adjustment are carried out only with customer authorization.

Standard Line Configuration

A typical standard line includes:

• Belt Feeding Conveyor
• Compaction Chamber
• Extruder
• Vacuum Degassing System
• Melt Filtration System
• Water-Ring Pelletizing System
• Cooling System
• Centrifugal Dewatering System
• Vibrating Screen
• Pneumatic Conveying System
• Storage Silo

A metal detector can be added on the belt conveyor where required. The filtration system is selected according to the material.

Technical Specifications

The following URCS models are the standard mass-production series for this system.

Notes:

• Capacities are nominal values and may vary depending on material type, bulk density, moisture level, contamination level, filtration configuration and pelletizing method.
• Water-ring pelletizing is the standard configuration.
• Screw, vacuum, filtration and pelletizing configurations can be adjusted according to the material.
• PET applications can be configured with a melt pump and CPF filtration system where required.

Flexible Configuration

The system is based on standardised mass-production models, and the main platform is common across the range. At the same time, key process sections can be configured according to the material. Configurable items can include screw configuration, vacuum system, melt filtration system, pelletizing method, capacity, electrical standard, automation level and plant layout. Different materials do not all use the identical configuration.

Pellet Quality

The system is designed to produce uniform recycled pellets with consistent size, stable shape and reduced contamination. Final pellet quality depends on the feed material, contamination level, degassing, filtration and process settings.

Factory Testing

Each production line can be tested with material before shipment. Customers can provide their own raw material for trial production so that machine configuration and processing conditions can be evaluated before delivery.

Installation and Technical Support

URIDGE provides installation, commissioning, operator training, remote technical support and spare-parts support.

• Warranty period: 1 year
• Typical production lead time: approximately 2 months
• Typical installation period: approximately 1 week

Before installation, customers should prepare a level floor and ensure that electricity, water, supporting personnel and operators for training are available. During machine configuration, locally available and easy-to-maintain parts can be considered to simplify future service and replacement.

Project Experience

URIDGE has supplied compaction pelletizing equipment to customers in markets including Egypt, the Middle East, Peru, Brazil, Argentina, Hungary, Nigeria, Turkey and Russia.

Frequently Asked Questions

What materials can the compaction pelletizing system process?

It is designed for lightweight, low-bulk-density thermoplastic waste such as PE and PP film, PET film, BOPP and BOPET film, PP woven bags, PET fiber waste and EPS foam.

What is the available production capacity?

The standard URCS model range covers nominal capacities of approximately 100 to 1,000 kg/h. Actual output depends on the material and configuration.

What filtration systems are available?

Options can include plate screen changers, column-type screen changers, screenless filtration, laser filtration, automatic backflush filtration and CPF filtration systems.

How is moisture removed from the plastic melt?

A vacuum degassing system removes moisture, gases and volatile components released during processing.

What is the standard pelletizing method?

Water-ring pelletizing is the standard configuration. Strand and underwater pelletizing can also be configured according to the material and pellet requirement.

Can PET be processed on this line?

Yes. For PET applications, the line can be configured with a melt pump and CPF filtration system according to process requirements.

Can the system be customized for different materials?

Yes. Screw configuration, vacuum system, filtration, pelletizing method, capacity, electrical standard, automation level and plant layout can be selected according to the material and production requirements.

Tell Us About Your Material

To configure a suitable compaction pelletizing system, please send us:

• Material type
• Material form
• Bulk density
• Moisture level
• Contamination level
• Required output
• Required pellet quality
• Available factory space
• Local voltage and frequency

URIDGE will recommend the machine configuration based on your actual material. You can request a quote or use the WhatsApp contact on this page to start.