PVC compound pelletizing
Heat-sensitive PVC scrap or compound is processed carefully to avoid HCl release.
PELLET PRODUCTION
How Recycled Plastic Pellets Are Made
From scrap film, bottle flake and industrial waste to uniform reprocessed pellets.
Plastic scrap is bulky, wet, contaminated and inconsistent. Pelletizing converts it into dense, uniform pellets that feed reliably into downstream extrusion, injection or compounding lines.
What recycled pellets are used for
The right pelletizing process depends on the input material. PE film behaves very differently from PET bottle flake or PVC scrap, so washing, drying, feeding and filtration must be selected around the waste stream.
PE/PP film recycling
Low bulk density film needs densifying before stable feeding into the extruder.
Bottle flake re-pelletizing
Washed flake is filtered and cut into uniform pellets for reuse.
Industrial scrap reclaim
Edge trim, purge and rejected parts can be converted into reusable feedstock.
Input materials and their challenges
PE film has very low bulk density, often only 30-50 kg/m3, so it bridges in hoppers and must be compacted or force-fed. PET bottle flake loses intrinsic viscosity if moisture is above about 0.02%, so it needs crystallising and drying. PVC scrap cannot be overheated because decomposition releases HCl gas. PP industrial scrap often contains labels, dust or mixed polymers and may require washing before extrusion.
- Pre-processing normally includes shredding, washing, centrifugal drying and forced feeding.
- Film lines often use a compactor-feeder or agglomerator to densify material before extruder intake.
- Melt filtration is essential when paper, metal, sand or label contamination is present.
Production process
Pelletizing is a cleaning and homogenising process as much as a cutting process. The line must turn irregular scrap into stable melt, remove contaminants and cut pellets with controlled size and moisture.
Shredding and washing
Scrap is reduced to manageable size and washed if contamination is present. Cleaner input reduces screen changer load and improves pellet quality.
Drying and forced feeding
Centrifugal drying removes surface water. Film requires compaction so the extruder can receive a consistent mass flow.
Extrusion
A single or twin screw melts and homogenises the plastic. PVC needs low temperature control; PE/PP film needs strong feeding and degassing.
Melt filtration
A screen changer removes paper, metal, stones and unmelted particles. Hydraulic automatic screen changers allow continuous operation without stopping the line.
Pellet cutting
Strand pelletizing is simple and low cost for clean materials. Underwater pelletizing cuts at the die face and is better for sticky, flexible or high-output PE/PP materials.
Drying and screening
Centrifugal dryers remove pellet surface water after underwater cutting. A vibration screener removes fines and oversize pellets before silo storage.
Finished pellet requirements
Finished pellets should be uniform, dry and free from visible contamination. Pellet size is typically 2-5mm and moisture should be below 0.1% for most downstream extrusion. Bulk density, melt flow index, colour, contamination level and odour are often checked before the pellets are sold or reused in production.
Machines required
These are the core machines for a recycling pelletizing line. The exact screw type, degassing system and pelletizer depend on whether the input is film, rigid regrind, bottle flake or PVC compound.
Forced Feeder or Compactor
Densifies low-bulk scrap so the extruder can run steadily.
Twin or Single Screw Extruder
Melts, degasses and homogenises the waste stream.
Melt Filter
Removes solid contamination before pellet cutting.
Underwater or Strand Pelletizer
Cuts melt into uniform pellets by the selected method.
Centrifugal Dryer & Screener
Removes water and separates fines or oversize pellets.
Technical reference
Planning reference only. Final configuration depends on your target spec — share it with the engineering team for a matched proposal.
| Output rate | 100-800 kg/h |
|---|---|
| Pellet size | 2-5mm |
| Final moisture | <0.1% |
| Materials | PVC / PE / PP / ABS |
| Cutting method | Strand or underwater pelletizing |
| Typical feedstock | Film, bottle flake, industrial scrap, regrind |
Ready to produce recycled plastic pellets?
Tell us your scrap type, contamination level, washing status, target pellet size and output rate. We will configure feeding, filtration, pelletizing, drying and screening for your material.
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