H.R. PLASTIC MACHINERY PVT. LTD.

Two Stage Plastic Recycling Plant Supplier in Gujarat

November 11, 2025

Two Stage Plastic Recycling Plant Supplier in Gujarat

Two Stage Plastic Recycling Plant Supplier in Gujarat | Double Degassing Extruder Lines

Two Stage Plastic Recycling Plant Supplier in Gujarat

Choose a Gujarat-based partner for two stage plastic recycling plants that deliver stable output from highly contaminated film and rigid scrap. Double-degassing, dual filtration, and optimized melt residence time help remove inks, moisture, and volatiles while protecting downstream quality. Get correct line sizing, utility mapping, and lifecycle cost clarity for continuous production across Ahmedabad, Morbi, Rajkot, Surat, and Vapi.

Working Principle and Process Flow of Two Stage Lines

A two stage recycling plant combines a primary extruder for intensive plastification and venting with a secondary extruder for fine filtration and final devolatilization. Typical flow: sorting, crushing, hot wash, friction wash, drying, agglomeration or force-feed, primary extruder with vacuum, melt filtration or screen changer, second extruder with vacuum, pelletizing, cooling, and drying. Recipe control, energy and kWh/kg logging, and alarm history are managed via PLC-SCADA. Learn about modular upgrades on hrplasticindia.com.

Two Stage Plant Configurations

Force-feed film lines for LDPE/LLDPE carryover with high moisture and paper labels, tuned for 250â€“900 kg/hr output.
Rigid regrind lines for HDPE and PP drums, crates, and caps with metal separation and intensive wash sections.
PET in-line compactor plus twin-vent configuration for stable IV and reduced acetaldehyde in textile and strapping use.
Odour-reduction packages with deep vacuum, multi-zone heating, and high-efficiency degassing ports for post-consumer waste.
Die-face cutter or strand pelletizer options matched to MFI range, colour masterbatch dosing, and downstream needs.

Key Features and Specifications

Double vacuum degassing with calibrated leak-proof seals, delivering low moisture pellets and reduced smell.
Automatic screen changers, multi-stage filtration up to fine mesh ratings for fewer black specks and gels.
Energy-efficient motors with VFDs and documented kWh/kg benchmarks for Gujarat DISCOM audits.
PLC-SCADA with recipe library, trend charts, preventive maintenance prompts, and remote diagnostics.
Stainless steel contact parts for wash modules, water recycling skids, and closed-loop cooling options.

Applications Served in Gujarat

Flexible packaging converters using rLDPE/rLLDPE for liners, carry bags, and film blends with target MFI and printability.
Moulders consuming rPP and rHDPE for crates, caps, buckets, pallets, and non-critical automotive trim.
Textile and strapping units using rPET chips and pellets for fibres, yarns, and PET straps with tensile consistency.
Municipal and industrial waste handlers converting mixed post-consumer streams into saleable pellets for regional demand.

Benefits of Choosing a Two Stage Recycling Plant

High tolerance to contamination and moisture with stable output quality, reducing rejections and downtime.
Improved devolatilization and odour control via dual-vent, deep vacuum, and optimized melt path design.
Lower operating cost per kg with efficient motors, heat insulation, and logged kWh/kg benchmarks.
Scalable, modular design with bolt-on wash upgrades, additional filtration stages, and dosing automation.

Manufacturers and Suppliers in Gujarat

Experienced suppliers support site layout, utility planning, installation and commissioning, operator training, and spares. Typical deliverables include performance guarantees on throughput, filtration fineness, pellet quality, and energy norms. Service coverage across Ahmedabad, Sanand, Changodar, Vapi, Dahej, Halol, and Dholera enables faster response times and preventive maintenance scheduling for higher uptime.

Maintenance and Safety Tips

Track vacuum levels, melt temperature, and pressure; investigate deviations with a calibrated checklist.
Maintain wash chemistry, replace contaminated water on schedule, and clean friction washers and tanks.
Inspect screen changers, heaters, thermocouples, and sealing elements; stock critical spares with part codes.
Train operators on lockout-tagout, hot surfaces, confined space entry, and emergency stop drills.
Record kWh/kg and output MFI by batch to optimize recipes and validate cost per kg.

FAQs â€“ Two Stage Plastic Recycling Plant

1. When should I choose a two stage line over a single stage? +

Select two stage when input contamination and moisture are high, odour reduction is critical, or when you need finer filtration and consistent pellets for demanding applications such as film extrusion or fibre.

2. What capacities are common for Gujarat processors? +

Popular ranges are 250â€“900 kg/hr for films and 400â€“1200 kg/hr for rigids. Final sizing depends on scrap availability, shift planning, product mix, and quality targets like MFI and ash content.

3. Can the plant handle mixed film with paper labels and moisture? +

Yes. With hot wash, friction wash, proper drying, force-feed, and dual degassing, two stage lines can handle labelled, damp films while maintaining pellet quality and odour control.

4. Which pelletizing option should I use? +

Die-face cutting suits lower MFI film grades and continuous production; strand pelletizing is preferred for higher MFI and when narrow pellet size distribution is required. Selection depends on downstream process.

5. What documentation should I ask for at purchase? +

Seek layout drawings, utility charts, FAT protocols, performance guarantees, preventive maintenance schedules, spares lists, and training manuals, along with warranty and response time commitments.