PP/PE Film Shredding & Densifying Line
An integrated washing and densifying solution engineered for recyclers and pelletizing plants. Built for light, contaminated, and wet PE/PP films, it runs shredding, wet granulation, sink-float separation, and squeezing with densifying to raise bulk density and cut residual moisture for steady pelletizer feeding.
- Designed for dirty agricultural film, stretch film, woven bag trims, and post-consumer film scrap.
- Raises bulk density and lowers moisture so feeding becomes more stable and less labor-intensive.
- Available as a standalone densifying upgrade or as part of a complete washing and pre-pelletizing line.
PP/PE Film Densifying Line in Action: Video
Watch how wet, low-density film is converted into denser, lower-moisture output ready for downstream extrusion.
Key Performance & Output Highlights
Engineered to overcome light film feeding bottlenecks and reduce drying power consumption.
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≤ 2–3% Residual Moisture
Continuous mechanical extrusion squeezing and frictional flash-drying slash water content from 25%+ down to under 3%, eliminating energy-intensive thermal pipe drying.
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7–10x Bulk Density Gain
Compacts light, fluffy film flakes into dense, free-flowing semi-molten granules (350–400 kg/m³), ensuring uninterrupted extruder hopper feeding without bridging.
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300–1,200 kg/h Scalable Output
Modular heavy-duty line configurations equipped with SKD-11 alloy rotary knives and nitrided bimetallic screw barrels to match commercial recycling capacities.
How It Works: Four-Step Film Densifying Process
A seamless, continuous conversion cycle takes baled, dirty films through coarse reduction to washed, densified granules.
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High-Torque Shredding
Low-speed, high-torque industrial shredders break compacted film bales and shear bulky packaging wraps down to 40–80 mm strips without rotor entanglement or thermal melting.
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High-Speed Wet Granulation
Water-cooled granulators equipped with scissor-cut D2/SKD-11 blades cut film strips into uniform 12–20 mm flakes while process water pre-washes stubborn mud and debris.
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Multi-Stage Sink-Float Separation
Hydrodynamic floatation tanks exploit polymer specific gravity: polyolefin films (PP/PE, density ~0.91–0.96 g/cm³) float cleanly while heavy stones, sand, metals, and PVC sink for automated purge.
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Screw Squeezing & Densification
A variable-pitch tapered compression screw wrings out surface moisture mechanically, followed by controlled frictional heating that transforms wet flakes into low-moisture agglomerates.
From Waste Film to Extruder-Ready Feedstock
The integrated line converts bulky, contaminated waste films into uniform, dense, extruder-ready feedstocks through four distinct material transformation stages.
Bulk Density: 15–30 kg/m³
Condition: Highly entangled agricultural mulch, stretch wraps, or post-consumer sacks with surface soil and moisture.
Size: 40–80 mm strips
Condition: Bales sheared open to release trapped sand and dirt; free-flowing feed for downstream granulators.
Size: 12–18 mm flakes
Moisture: 20–28%
Condition: Surface contaminants and heavy sinkables purged; high surface moisture remaining.
Bulk Density: 350–400 kg/m³
Moisture: ≤ 2–3%
Condition: Semi-molten popcorn-like agglomerates ready for high-speed extruder feeding.
Core Benefits of Film Densifying System
High-uptime, energy-efficient plastic film washing and densification engineered to maximize throughput while minimizing maintenance costs.
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High-Efficiency Densification
Reduces fluffiness and raises bulk density for steadier, more uniform feeding.
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Low Final Moisture
Mechanical squeezing with heat exchange minimizes secondary drying and shortens the process.
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Energy Efficient
Optimized process design and motor selection deliver lower kWh per ton.
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Modular Configuration
Integrates with existing washing lines and combines shredding, granulation, separation, and densifying modules.
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Built to Last
Wear-resistant contact surfaces handle high-contamination films with reduced downtime.
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Smart Controls
One-touch start, stop, and interlocks reduce manual intervention and simplify maintenance.
Solving Film Moisture & Bulk Density Challenges
Target the chronic bottlenecks in film recycling with a process engineered to stabilize feeding, moisture, and contamination before pelletizing.
Problem to Solution
Light, Tangled Film Causes Unstable Feeding
Inline shredding, wet granulation, and densifying lift bulk density so films convey smoothly and feed extruders without surging.
Problem to Solution
High Moisture Ruins Filtration and Pellets
Mechanical squeezing and controlled heat exchange deliver pelletizer-ready moisture levels, cutting bubbles and improving surface quality.
Problem to Solution
Dirt, Paper, and Sand Overload Downstream
Wet granulation plus sink-float separation remove fines and organics early, easing filtration load and lowering consumable spend.
Problem to Solution
Footprint, Energy, and Manpower Constraints
Modular layouts, high-efficiency drives, and centralized controls shrink footprint, reduce kWh per ton, and simplify operator routines.
Target Film Materials & Applications
Tailored processing solutions for flexible post-consumer, agricultural, and industrial polyolefin streams.
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Agri Film / Greenhouse Film
Light films with high dirt content such as mulch and greenhouse films.
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Packaging / Stretch / Shrink Film
Common warehouse and logistics films can be densified and fed directly to pelletizing.
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Woven Bags / FIBC Trims
PP/PE mixes benefit from separation and densifying to improve purity and feeding stability.
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Shopping / Garbage Bags
Thin, wet post-consumer films fit the wash and densify process well.
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Washing Line Upgrades
Use as a standalone densifier to upgrade dewatering and feeding on existing lines.
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Plant Offcuts
Clean production offcuts can be densified directly to boost throughput.
PP/PE Film Densifying Line Specifications
Standard engineering configurations for commercial post-consumer and agricultural film processing lines. Capacities and motor ratings can be customized to match your plant requirements.
| Specification Parameter | RUM-300 Line | RUM-500 Line | RUM-1000 Line |
|---|---|---|---|
| Throughput Capacity | 300–400 kg/h | 500–700 kg/h | 1,000–1,200 kg/h |
| Infeed Moisture Range | Up to 25–30% | Up to 25–30% | Up to 25–30% |
| Discharge Moisture Level | ≤ 2.0–3.0% | ≤ 2.0–3.0% | ≤ 2.0–3.0% |
| Output Bulk Density | 320–380 kg/m³ | 350–400 kg/m³ | 360–420 kg/m³ |
| Squeezer Motor Power | 55 kW (IE3) | 90 kW (IE3) | 132–160 kW (IE3) |
| Screw & Barrel Metallurgy | 38CrMoAlA (Nitrided, HV ≥ 950) | Bimetallic Tungsten Carbide Coating | Bimetallic Tungsten Carbide Coating |
| Granulator Rotary Knives | SKD-11 / D2 (HRC 58–60) | SKD-11 / D2 (HRC 58–60) | SKD-11 / D2 (HRC 58–60) |
| Automation & Controls | Siemens S7-1200 PLC + Touch HMI | Siemens S7-1500 PLC + Touch HMI | Siemens S7-1500 PLC + Touch HMI |
| Installed Line Footprint | Approx. 18 × 3.5 × 4.0 m | Approx. 24 × 4.0 × 4.5 m | Approx. 32 × 5.0 × 4.8 m |
Note: Parameters can be customized. Final configuration and throughput depend on your material and process goals.
System Comparison: Densifying Line vs. Conventional Methods
How our continuous mechanical squeezing and densifying technology compares against traditional centrifugal dewatering and thermal hot-air pipe drying runs.
| Performance Dimension | Rumtoo Continuous Densifying Line | Centrifugal Drying + Thermal Air Pipes |
|---|---|---|
| Final Moisture Level | ≤ 2–3% (Direct Extruder Ready) | 8–15% (Requires high-kW electric/gas heater pipes) |
| Bulk Density Output | 350–400 kg/m³ (Dense agglomerates) | 40–80 kg/m³ (Fluffy, causes hopper bridging and screw surges) |
| Specific Energy Draw | ~0.12–0.18 kWh/kg (Mechanical efficiency) | ~0.28–0.42 kWh/kg (Continuous heating blowers draw high power) |
| Plant Floor Space | Compact inline layout (10–14 m) | Extensive footprint (30–45 m cyclone towers & pipe loops) |
| Operational Safety | Fully enclosed compression chamber | Airborne fine dust hazard and thermal duct fire risks |
| Downstream Output Gain | Extruder intake capacity increased by 20–35% | Extruder screw starved; frequent operator manual poking |
Frequently Asked Questions
Find clear, practical answers to common technical, capacity, and operational questions regarding PP/PE film shredding and densifying systems.
Plastic film is extremely light and fluffy, with an apparent bulk density of only 20 to 50 kg/m³. Feeding loose, voluminous film directly into an extruder hopper causes severe bridging, auger starvation, and erratic melt pressure. Densifying compacts flakes into dense, free-flowing agglomerates (350 to 400 kg/m³) while reducing residual moisture below 2 to 3%, allowing extruders to operate at maximum stable throughput.
Traditional tub agglomerators operate in batches, consume high peak electrical surges, and rely on manual operator guesswork to inject water during the compaction cycle. A continuous screw squeezer densifier operates inline with automated variable-speed feeding, mechanically wringing out water before applying kinetic frictional heating. This results in consistent moisture control, continuous steady output, and up to 40% lower specific energy consumption.
Yes. Our lines feature heavy-duty low-speed shredders and water-injected granulators paired with deep hydrodynamic sink-float tanks. Sand, soil, and heavy foreign matter sink to the bottom and are discharged automatically, preventing abrasive wear on the downstream squeezer screw and extruder barrel.
The squeezer densifier consistently achieves final moisture levels of 1.5% to 3.0%. Mechanical screw compression removes the vast majority of free water, while kinetic frictional heat evaporates the thin residual film layer as material discharges, eliminating the need for high-kW hot air pipe ducts.
Yes. Many recyclers install our squeezer densifier as a standalone dewatering upgrade immediately after their existing friction washer or centrifugal dryer to replace bottlenecked hot-air drying tubes and boost pelletizer intake volume.
The system efficiently processes LDPE agricultural mulch and greenhouse films, LLDPE stretch film and pallet wrap, HDPE shopping bags, PP woven bags and FIBC jumbo bag trims, printed packaging scrap, and factory blow-molding offcuts.
Granulator knives and cutting rotors use premium Japanese SKD-11 or D2 tool steel (vacuum hardened to HRC 58–60). Squeezer screws feature deep nitrided surface hardening (HV ≥ 950) with optional bimetallic tungsten carbide flight hardfacing, and the compression barrel is lined with replaceable wear sleeves.
Yes. Rumtoo delivers full plant engineering support including CAD foundation layout drawings, electrical load specifications, water recirculation piping diagrams, and on-site dispatch of mechanical engineers for installation, testing, and operator training worldwide.
Customer Testimonials
Verified feedback from commercial recyclers and pelletizing facilities operating our film washing and densifying lines.
Recycled Pellets Producer
Plant Operations Director
Once feeding stabilized, filtration pressure held steady. Moisture control is far easier and pellet quality is more consistent across shifts.
Agricultural Film Recycler
Washing Line Supervisor
The wash and densify configuration finally lets us handle post-harvest films with mud and sand, and downstream extruders run without clogging.
Compounding Plant
Project Engineering Manager
Turnkey delivery, on-site training, and the recommended screen packs boosted uptime. Integration with legacy equipment was smooth.
Warranty & Global Commissioning Support
Every Rumtoo recycling line is backed by comprehensive structural warranties, worldwide on-site installation, and long-term technical support to protect your capital investment.
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12–24 Month Core Warranty
Full structural and mechanical protection covering gearboxes, main shafts, screw barrels, and weld integrity against manufacturing defects.
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Worldwide On-Site Installation
Experienced field engineers deployed globally for foundation checks, equipment alignment, electrical commissioning, and trial-run validation.
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Lifetime Fast-Track Spare Parts
Guaranteed availability for all high-wear parts including D2/Cr12MoV blades, extruder screws, screen changers, and heating bands with rapid international dispatch.
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SOP Manuals & Crew Training
Comprehensive bilingual schematics, CE maintenance manuals, and rigorous on-site training for plant operators to ensure safe, maximum-yield continuous operation.
Get a PP/PE Film Densifying System Quote
Share your material mix, contamination level, and capacity goals. Our engineers will map the optimal shredding, washing, and densifying modules with timelines and budget.
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