Plastic Film Densifier for PE/PP Film
Struggling with high energy costs and unstable extruder feeding from wet, fluffy film? Our Plastic Film Densifier creates high-density, dry granules that cut operational expense and improve pelletizing stability.
- Mechanically dewaters and compacts washed PE and PP film into free-flowing granules.
- Typical final moisture reaches 1-3%, reducing downstream drying load and pellet defects.
- Supports 300-1500 kg/h lines and integrates directly with washing and pelletizing systems.
Densifier vs. Agglomerator: Which Machine Fits Your Process?
Buyers often search for "densifier" and "agglomerator" interchangeably. Both transform bulky, fluffy plastic films into compact granules — but they serve completely different plant workflows.
| Feature / Requirement | Squeezer Densifier (This System) | Traditional Pot Agglomerator |
|---|---|---|
| Primary Function | Simultaneous mechanical dewatering + continuous densification | Frictional heating and agglomerating only (no dewatering) |
| Inlet Feed Condition | Wet washed film directly from wash line (up to 25–30% moisture) | Clean, dry film & scrap (strictly <5% moisture) |
| Operation Mode | 100% Continuous inline operation (no operator batching) | Batch cycle (5–10 min per batch, operator dependent) |
| Core Mechanism | Heavy-duty alloy screw + slotted dewatering barrel + die cutter | Vertical pot with bottom high-speed rotating blades |
| Final Output Quality | Dense, uniform popcorn granules (1–3% moisture) | Irregular agglomerated flakes/lumps (dry input only) |
| Best Fit For | Post-consumer film washing lines & continuous pelletizing | Dry industrial roll offcuts, clean edge trims, dry fibers |
Note: If your facility processes dry industrial film rolls and specifically requires a high-speed pot agglomerator, Rumtoo manufactures both systems. Contact our technical engineers for tailored recommendations.
What Is a Plastic Film Densifier?
A Plastic Film Densifier mechanically dewaters and compacts washed PE and PP films into dry, free-flowing granules (1–3% moisture) ideal for feeding a pelletizing extruder. By integrating mechanical squeezing and controlled frictional heating, it replaces energy-intensive thermal drying and solves unstable feeding from fluffy film:
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Drastically Lower Energy Costs
Reduce energy consumption by over 40%. The mechanical squeezing process lowers dependence on power-hungry hot-air drying systems.
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Higher Extruder Output
Dense, free-flowing granules feed the pelletizer consistently, reducing clogging and improving throughput.
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Superior Pellet Quality
Lower moisture helps produce bubble-free recycled pellets with more stable melt quality and higher resale value.
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Simplified Workflow
This integrated dewatering and densifying solution replaces separate drying stages, saving floor space and maintenance effort.
Plastic Film Densifier: From Washed Film to Pellet-Ready Granules
Our three-step mechanical squeezing and agglomerating process ensures efficient drying without unnecessary thermal load.
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1. Direct Feeding
Washed film from the recycling line is conveyed into the machine inlet and accepted at high initial moisture.
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2. Mechanical Squeezing
A high-speed screw applies pressure to force water out through the screen in a highly efficient dewatering process.
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3. Frictional Agglomerating
Controlled friction generates heat and forms dense, uniform granules that are easier to feed into the extruder.
The Plastic Film Densifier is designed to work in tandem with washing and extrusion-pelletizing components, helping improve output and efficiency across the full line.
Film Densifier Applications & Materials
The Plastic Film Densifier handles post-consumer and post-industrial streams and prepares them for stable extrusion.
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PE Film & Stretch Wrap
PE film (LDPE/LLDPE), printed film, stretch film, and shrink wrap.
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PP Woven & Jumbo Bags
PP woven bags, raffia, and jumbo bags after proper washing.
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Agricultural & Greenhouse Film
Agricultural film and greenhouse film with residual moisture.
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Label & Packaging Film
Label film offcuts and packaging film reclaim.
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Recycling Line Integration
Integration with Plastic Film Washing Line and Plastic Pelletizers.
Plastic Film Densifier Equipment Overview
Explore the heavy-duty dewatering screw engineering, high-torque reduction drive, and die-face cutting system built for continuous operation.
Heavy-Duty Dewatering Screw & Barrel Assembly
At the core of the squeezer densifier is a high-torque, nitrided alloy screw (38CrMoAlA) operating within a reinforced slotted dewatering barrel. As washed PE/PP film enters the feed hopper with up to 25–30% initial moisture, the progressive compression screw generates intense mechanical pressure, forcing free water out through the drainage screens without thermal degradation.
Driven by a heavy-duty hard-toothed gearbox and high-efficiency motor (90–250 kW), the machine maintains consistent throughput even under challenging film loading variations.
Dense, Free-Flowing Granules (1–3% Moisture)
At the discharge die, controlled friction heat semi-plasticizes the compacted material into high-density strands. An integrated variable-frequency die-face rotary cutter slices the extruded material into uniform, popcorn-like granules.
Bulk density is boosted 5–8x — increasing from 30–50 kg/m³ (fluffy film) to 250–350 kg/m³. This dense, dry form prevents material bridging and screw slippage in downstream pelletizing extruders, boosting overall extrusion throughput by 20–30%.
Plastic Film Densifier Specifications
Engineered for performance and reliability. Specifications can be adjusted according to material condition and target output.
| Parameter | Specification |
|---|---|
| Applicable Materials | Post-consumer PE film, LDPE/LLDPE stretch film, PP woven bags, jumbo bags, agricultural film. |
| Inlet Feed Moisture | Up to 25% – 30% initial moisture straight from recycling washing lines. |
| Final Moisture Content | 1% – 3% typical (guaranteed <5%). |
| Bulk Density Increase | 5× – 8× increase (from ~30–50 kg/m³ fluffy film to ~250–350 kg/m³ dense granules). |
| Throughput Capacity | 300 – 1500 kg/h (model-dependent). |
| Main Motor Power | 90 – 250 kW (premium efficiency motor options). |
| Screw & Barrel Metallurgy | 38CrMoAlA alloy steel with deep nitriding treatment (HV ≥ 950) / optional bimetallic wear layer. |
| Cutting System | Die-face rotary hot cutter with Variable Frequency Drive (VFD) speed regulation. |
| Downstream Integration | Direct inline feeding to single-screw and twin-screw pelletizing extruders. |
| Warranty & Service | 12-month quality warranty, global on-site commissioning, overseas engineer dispatch. |
Model Options
Choose a model that matches your washing line and pelletizer throughput.
| Model | Capacity (kg/h) | Main Motor | Final Moisture | Notes |
|---|---|---|---|---|
| RT-D300 | 300-500 | 90 kW | 1-3% | Compact, fits small lines. |
| RT-D500 | 500-800 | 132 kW | 1-3% | Best-seller for PE film. |
| RT-D800 | 800-1200 | 185 kW | 1-3% | High-throughput, stable feeding. |
| RT-D1200 | 1200-1500 | 220-250 kW | 1-3% | Large line integration. |
Why Densifier vs. Centrifugal or Thermal Drying?
A Plastic Film Densifier combines dewatering and densifying in a single step, cutting energy demand and simplifying the line.
| Method | Energy Use | Moisture | Feeding Behavior | Notes |
|---|---|---|---|---|
| Plastic Film Densifier | Low | 1-3% typical | Stable, free-flowing granules | Replaces two machines. |
| Centrifugal Dryer | Medium | 5-10% typical | Fluffy, bulkier | Often needs thermal stage. |
| Thermal Hot-Air Dryer | High | 3-5% typical | May remain fluffy | Higher OPEX and larger footprint. |
See the Plastic Film Densifier in Action
Watch how washed flexible film is squeezed into dense, pellet-ready granules for more stable extrusion feeding.
Related Equipment & Systems
Build a complete film recycling and pelletizing solution around your densifier.
Upstream
Plastic Film Washing Line
Shredding, washing, and separation to prepare film for densifying.
View Washing LineDownstream
Plastic Pelletizers
Stable feeding and high output with densified film granules.
View PelletizersAlternative
Plastic Film Squeezing Machine
Standalone squeezing machine for specific dewatering and densifying tasks.
View SqueezerPart of a Complete Drying System
The film densifier serves as a high-efficiency alternative within a broader plastic drying system for film recycling lines. Unlike a standalone centrifugal dryer or thermal dryer, it combines dewatering and densification in one step — reducing energy costs by over 40%. Compare all options on our drying systems hub page to determine the best fit for your production requirements.
Frequently Asked Questions
Clear answers to common questions about film densifiers, operating principles, and recycling line integration.
This machine is a continuous screw-type mechanical squeezer dryer that combines dewatering and densification in one step for wet washed film (up to 30% moisture). Unlike batch-type pot agglomerators that rely strictly on dry friction heat, it runs continuously inline with the washing line, delivering stable output moisture (1–3%) and over 40% energy savings.
Yes. The densified, free-flowing granules (bulk density 250–350 kg/m³, moisture 1–3%) feed consistently into single-screw and twin-screw pelletizing lines, eliminating material bridging and screw slippage in the extruder feed throat.
In typical operations, final moisture is reduced to 1–3% (we guarantee under 5%), while bulk density increases 5–8x from 30–50 kg/m³ to 250–350 kg/m³.
It is designed to handle material coming directly from a thorough washing line. The alloy screw resists abrasion from residual surface dirt and ink, though thorough washing is still recommended for premium pellet quality.
The screw segments and dewatering screen barrels are manufactured from wear-resistant alloy steels. Regular inspection of the discharge die and lubrication of the reduction gearbox ensure long service life.
We recommend installing an inline metal detector and magnetic separator on the feeding conveyor before the densifier inlet to prevent tramp metal from damaging the screw assembly.
Yes. If your recycling facility reprocesses dry industrial film rolls, clean edge trims, or fiber waste that do not require dewatering, we also build high-speed vertical pot agglomerators. Contact us to discuss your raw material specifications.
Warranty & Global Installation Support
Each system includes installation guidance, commissioning support, and practical service planning for continuous operation.
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12-Month Quality Warranty
Covers core structural parts and mechanical assembly. Wearing parts excluded.
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Global Engineering Service
Experienced technicians available for overseas installation, commissioning, and operator training.
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Rapid Spare Parts Dispatch
High-wear components like screw tips and dewatering screens kept in stock for fast international shipping.
Get a Plastic Film Densifier Quote
Each machine includes a 1-year limited warranty and installation support. Tell us your material, moisture level, and target throughput for a tailored recommendation.
