H.R. PLASTIC MACHINERY PVT. LTD.

HDPE & LDPE Recycling Plant

October 10, 2025

HDPE & LDPE Recycling Plant

HDPE & LDPE Recycling Plant Manufacturer in India | Washing, Extrusion & Pelletizing Lines

HDPE & LDPE Recycling Plant â€“ Washing, Extrusion and Pelletizing Solutions

An HDPE LDPE recycling plant converts post-consumer and post-industrial films, carry bags, liners, and flexible packaging into quality reprocessed granules. A robust line integrates size reduction, contamination removal, intensive washing, moisture control, melt filtration, and pelletizing. When evaluating vendors, compare throughput (kg/hr), kWh/kg, filtration fineness (in microns), moisture targets at feed and before extrusion, and after-sales coverage across India.

Working Principle and Process Flow of HDPE/LDPE Recycling

Material flow typically starts with manual/automated sorting, followed by shredding and granulation. Film flakes pass through floatâ€“sink separation to remove heavies, then friction/hot washing to dislodge inks and organics. High-speed dewatering and thermal dryers reduce moisture before the extruder. In the extruder, multi-zone heating with vacuum degassing removes volatiles; automatic screen changers filter fines; die-face or strand pelletizers cut uniform granules. SCADA or PLC systems log energy, temperature, and throughput for traceability. Learn more about solutions on www.hrplasticindia.com.

Types of HDPE/LDPE Recycling Plants

Compact film recycling modules (120â€“300 kg/hr) for decentralized aggregators and MSMEs handling clean LDPE liners and carry bags.
Medium capacity lines (400â€“800 kg/hr) with forced-feed extruders for mixed film streams, ideal for regional converters and recyclers.
High-throughput twin lines (900â€“1500 kg/hr) providing redundancy, lower changeovers, and continuous operation during maintenance.
Washed-flakes to pellet systems with hot caustic wash, friction washers, and multi-stage filtration for high-quality rLDPE/rHDPE.
Odour-control and water-recycling add-ons for urban plants targeting stringent EPR and audit requirements.

Key Features and Specifications

Energy-efficient drives with VFDs; documented kWh/kg benchmarks for films and mixed poly streams.
Automatic screen changers (80â€“200 Î¼m), multi-zone heating, and vacuum degassing for stable melt and fewer black specks.
Stainless steel wetted parts in wash sections; closed-loop water circuits with filtration to cut consumption.
Recipe-based PLC control, alarm logs, preventive maintenance prompts, and remote diagnostics.
Die-face pelletizers for films; strand pelletizers for rigid mixes; bolt-on capacity expansions and standardized spares.

Applications of rHDPE/rLDPE Granules

Blown film for garbage bags, liners, mulch films, and secondary packaging with defined MFI, dart impact, and haze specs.
Sheets for thermoforming trays, separators, and protective packaging with consistent thickness and gel control.
Injection moulded crates, caps, hangers, and non-critical components blending rHDPE/rLDPE with virgin for balanced properties.
Pipes and conduits for non-pressure applications, drip laterals, and corrugated drainage with target stiffness and UV stabilisation.

Benefits of an HDPE LDPE Recycling Plant

Lower raw material costs through dependable recycled feedstock and improved scrap monetisation.
Consistent quality from controlled washing, moisture reduction, vacuum degassing, and fine filtration.
Higher productivity via automatic dosing, recipe control, quick screen changes, and efficient conveying.
Improved compliance with EPR, audit-ready traceability, and safety guarding for Indian shop-floor conditions.

Manufacturers & Suppliers in India

India hosts experienced manufacturers of HDPE/LDPE recycling lines offering layout engineering, installation, commissioning, operator training, and remote support. While comparing proposals, ask for guaranteed throughput at stated contamination, moisture after drying, filtration rating, pellet bulk density, and energy benchmarks. Typical service hubs include Ahmedabad, Mumbai, Delhi-NCR, Coimbatore, and Hyderabad. Upgrades may include water-recycling modules, odour scrubbing, metal separation, and advanced SCADA reporting.

Maintenance and Safety Tips

Check knives, screens, bearings, and belts daily; track vibration, temperature, and unusual noise.
Maintain wash chemistry and replace contaminated water; clean tanks, pipes, and nozzles on schedule.
Monitor extruder pressures, MFI targets, and zone temperatures; calibrate sensors and load cells periodically.
Train crews on lockout-tagout, hot surfaces, confined spaces, and emergency stops.
Stock critical spares like heaters, thermocouples, seals, screens, and gear-pump elements.

FAQs â€“ HDPE LDPE Recycling Plant

1. What capacity should I choose for my film recycling plant? +

Base capacity on consistent scrap availability, planned shifts, polymer mix, and downstream demand. Modular lines allow stepping up without compromising washing or filtration performance.

2. Can one line handle mixed HDPE and LDPE films? +

Yes, with effective sorting, floatâ€“sink separation, and flexible extruder feeding. Separate recipes and filtration settings help maintain stable MFI and colour across different film grades.

3. What moisture is acceptable before extrusion? +

For films, target low residual moisture after thermal drying and dewatering to avoid melt instability, gels, and porosity. Proper dryer sizing and airflow are critical.

4. How do I improve pellet quality and reduce odour? +

Use hot/friction washing, multi-stage filtration, and strong vacuum degassing. Add odour-control modules and maintain water-recycling hygiene to limit microbial growth.

5. Which after-sales terms should be included? +

Seek defined response times, preventive maintenance schedules, operator training, remote diagnostics, guaranteed spares, and performance guarantees tied to throughput, moisture, and filtration metrics.