User-friendly, high-performance recycling line
With BKC Plastik's Repro-Flex recycling line, plastic waste that goes through the recycling process is converted into granule form in accordance with high quality standards. These granules can be directly reintroduced into production in many different production lines, especially blown film and pipe extrusion lines, without the need for any additional processing. In this way, production efficiency is increased and environmental impact is minimized by contributing to sustainability goals.
Generally, 5% or more of the total production capacity results in production waste. Today, in-house recycling provides a great advantage in raw material costs. Granules obtained from production waste are almost like virgin material and can be used in production without compromising product quality.
Repro-Flex is also designed for the recycling of used plastics and agricultural films. The friction-induced heating effect during the compactor's agglomeration process removes moisture from washed materials, ensuring they dry (materials that have passed through a washing line). Recycled granules can be used up to 100% in LDPE pipe or garbage bag production, or can be added to virgin material at certain ratios to reduce material costs. Granule quality can be improved by adding masterbatch or additives through a dosing unit.
The Repro-Flex plastic recycling line is a compact and efficient line that combines crushing, extrusion and granule cutting. The compactor of the recycling line prepares the material and brings it to the ideal condition for the extrusion process. Compared to conventional old-type recycling lines, this integrated system does not require a separate crusher and eliminates inconsistent feeding problems such as overfeeding or underfeeding.
Film scraps and crushed rigid plastic waste materials are transferred to the machine by belt conveyor, while roll films are fed by a nip roll feeder. Crushed and washed film materials coming from the washing line can be collected in an additional silo and fed from there. Automatic controlled material feeding is done depending on the filling level of the compactor. The compactor cuts, dries and agglomerates the material in a semi-molten state (slightly below the agglomeration point). This means optimum condition for the subsequent extrusion process. The compactor then feeds the material directly to the extruder screw continuously and evenly.
The integration of the compactor into the extruder provides perfectly regular feeding. Thanks to the tangential connection to the extruder, the agglomerated material is fed continuously to the extruder. This gives much higher extruder output compared to other recycling systems.
Thanks to this regular feeding and hot-face cutting (water ring granule cutting), perfectly shaped and evenly sized granules are obtained every time. Thus, reusing the granules in the extruder becomes much easier and under optimum conditions.
POLYSTAR's highly efficient, one-step production Repro-Flex model is designed to process printed and unprinted HDPE, LDPE and LLDPE derivatives as well as PP flexible packaging materials. This compactor-integrated granulation line eliminates the need for pre-crushing of the material while producing high-quality granules, occupies less space, saves energy and delivers high output. In addition to in-house production waste, this system is also suitable for washed, crushed films and crushed flash materials from injection, blow molding and extrusion. This system is also very suitable for packaging film, garbage bag, agricultural film, food packaging, shrink film, stretch film producers as well as PP woven fabric, big bag, tape, strapping and rope producers. Other materials such as PS sheet, PE and PS foam, PE net, EVA, PU with PP additives can also be easily processed with this machine.
