You want to recycle LDPE and PP films profitably. A full recycling line lets you take dirty plastic film waste, clean it thoroughly, and turn it into pellets that packaging plants and manufacturers pay good money for. At Rumtoo, we have helped operators across the United States set up and run these lines for years. This guide gives you every detail you need to plan, build, and operate your own system so you start making money instead of guessing.
What LDPE and PP Films Are and Why They Matter
LDPE stands for low-density polyethylene. You see it in grocery bags, stretch wrap for pallets, shrink film, and agricultural covers. Manufacturers mark it with resin code #4. PP means polypropylene. You find it in woven feed sacks, some retail bags, and flexible packaging. It carries resin code #5.
Both materials stay flexible and lightweight, which makes them perfect for packaging but terrible for landfills. They take up huge space and break down very slowly. The U.S. Environmental Protection Agency reports that in 2018 Americans generated about 4.2 million tons of plastic bags, sacks, and wraps. Only 420,000 tons got recycled, or roughly 10 percent. That leaves a massive opportunity for anyone who builds an efficient line.
Why You Can Make Strong Profits Right Now
Brands and governments push for more recycled content in packaging. Buyers pay premium prices for clean, consistent pellets. Industry sources show clear post-consumer LDPE pellets trade between $0.40 and $0.80 per pound depending on color and purity. You buy or collect baled film at low cost or even free through partnerships, process it, and sell the output at a markup.
A mid-size line that runs 500 kilograms per hour can process 1,000 tons of film per year with steady operation. At an 85 percent yield you sell around 850 tons of pellets. Even at the lower end of market prices you generate healthy revenue after covering labor, energy, and maintenance. Many of our clients recover their full investment inside two to three years.
Find Reliable Feedstock That Keeps Costs Low
Start with post-industrial scrap. Factories and warehouses throw away clean stretch wrap and off-cuts every day. Contact local manufacturers and offer to haul it away. You pay little or nothing and receive material that needs minimal cleaning.
For post-consumer film, partner with grocery stores, distribution centers, and farms. Retailers already collect stretch film and bags through store drop-off programs. Visit plasticfilmrecycling.org to learn exactly which films qualify and where collection points operate. Bale the material tightly so one truck carries more weight and you cut transport costs by half. Inspect every load on arrival and reject anything with too much dirt or mixed plastics. Consistent quality feedstock directly raises your pellet price and profit margin.
Choose the Right Location and Handle Permits
Pick an industrial-zoned site near your suppliers and pellet buyers. You need space for incoming bales, the processing line, water treatment, and finished pellet storage. A 1,000-square-foot building works for a starter line, but plan for 3,000 to 5,000 square feet as you grow. Make sure you have three-phase power, good drainage, and room for water recycling.
Check with your city or county for business licenses and environmental permits. In California you also follow SB 54 rules on plastic packaging. The process usually takes two to four months. Budget extra for any required stormwater or air-quality plans. We supply layout drawings that meet most inspector requirements and speed up approvals.
Build Your Full Recycling Line Step by Step
You need machines that work together without bottlenecks. Here is the exact flow we recommend and that our clients use every day.
Step 1: Bale breaking and shredding
Operators feed baled film into a single-shaft shredder or pre-shredder. The rotor cuts the material into 40- to 60-millimeter flakes without wrapping or jamming. A good shredder handles wet or dirty film and runs continuously.
Step 2: Washing and separation
Flakes move to a high-speed friction washer that scrubs off labels, adhesives, and grease. Next comes a sink-float tank where sand, stones, and heavier contaminants drop out while the plastic floats. Hot washing at 60-80°C removes stubborn oils. Our PP PE recycling washing line combines these stages in one efficient module and recycles 90 percent of the water.
Step 3: Dewatering and drying
A film squeezer or centrifugal dryer squeezes out most water and brings moisture down to 3-5 percent. A hot-air dryer then finishes the job to below 1 percent. Dry flakes prevent steam pockets in the extruder and give you stronger pellets.
Step 4: Pelletizing
Clean, dry flakes feed into a single- or double-stage extruder. The machine melts the plastic, removes any remaining volatiles through vacuum degassing, and pushes it through a screen changer that catches tiny impurities. A water-ring or strand pelletizer cuts the melt into uniform pellets that cool quickly and store easily.
Step 5: Quality control and bagging
Operators check melt flow index, color, and contamination on every batch. Automatic bagging machines fill 25-kilogram sacks or one-ton super sacks ready for sale.
A complete line for 300- to 1,000-kilogram-per-hour capacity costs between $150,000 and $450,000 depending on automation and options. We deliver, install, and train your team on site.
Run the Line Efficiently Every Day
Train two or three operators per shift. They check incoming material, monitor water pH and temperature, and clean screens on schedule. Run a small test batch whenever you change feedstock so you adjust settings fast. Recycle process water through a simple settling and filtration system to cut your utility bill by 70 percent. Keep spare wear parts on hand so downtime stays under one hour per month.
Calculate Your Numbers and Protect Your Margins
Here is a realistic example for a 500-kilogram-per-hour line running 8 hours a day and 250 days a year:
- Input: 1,000 tons of film per year
- Yield after losses: 850 tons of pellets
- Average selling price: $1,000 per ton (mid-range for mixed-color material)
- Revenue: $850,000
Operating costs break down roughly as:
- Labor (3-4 people): $180,000
- Electricity and water: $120,000
- Maintenance and parts: $40,000
- Transport and misc.: $60,000
- Total: $400,000
You clear about $450,000 before taxes in the first full year. Subtract your initial investment and you reach positive cash flow quickly. Higher-purity clear pellets push revenue even higher.
Track every cost in a simple spreadsheet. Sell pellets to local extruders who make new film or trash bags. Some clients also blow their own film and sell finished products for extra margin.
Avoid the Mistakes That Kill Profits
Too many new operators accept dirty loads and spend extra hours and chemicals cleaning them. Reject anything with more than 5 percent non-plastic. Another common error is skimping on drying. Pellets with hidden moisture create bubbles and weak product that buyers reject. Invest in the right dryer from day one. Finally, lock in offtake agreements before you start so you never sit on inventory when pellet prices dip.
Stay Compliant and Grow
Follow all federal, state, and local rules on waste handling and wastewater discharge. Join the Association of Plastic Recyclers at plasticsrecycling.org to stay current on design guidelines and market trends. Many states offer grants or tax credits for recycling equipment. Check your local economic development office.
Take the Next Step Today
You now have the complete roadmap to recycle LDPE and PP films profitably. Start by auditing your local feedstock supply and contacting us for a free material test and customized line proposal. Our team will review your space, volume goals, and budget, then deliver a turnkey system that works from day one.
Hubungi Rumtoo sekarang. Turn plastic film waste into steady income while you help keep landfills cleaner. Your profitable recycling line is ready to build.
