300th Shredder - Plastic Recycling Machine goes to India

As a milestone, the?Repro-One 85?was the 300th?all-in-one (shredder + extruder + pelletizer) plastic recycling machine that POLYSTAR has sold worldwide. In July 2021, this shredder integrated recycling line already started operation in India.

Machine number 300: An increasing demand for raffia and woven recycling worldwide

Amongst these 300 worldwide installations of this machine model, 75 machines are installed in the states of Gujarat, Kolkata, Bangalore, and Raipur, India, where the demand for higher quality recycling machines is increasing, particularly for PP raffia, FIBC, woven sacks, and HDPE non-woven in-house waste.

What makes Repro-One superior?

The recycling machine has a heavy-duty shredder built-in, which is designed specifically to turn different forms of production waste generated during the woven bag making process (extruder start-up lumps, winding, weaving, bag making, and printing) back into high-quality recycled pellets which can be reused again in tape extrusion lines.

This special machine design with a single-shaft shredder integrated allows woven bag producers to handle this difficult-to-process material in one step at higher efficiency and lower cost.

5 Machines for the Indian raffia and woven producer

One of the Indian producers has already installed 5 sets of?Repro-One?at 5 different factory locations since the first installation back in 2015.

“It is cost saving and our operators find it very easy to run and maintain the machines,” said Mr. Kumar, director of Kolkata-based jumbo bag producer,?“the shredder integration is definitely the best choice for raffia and woven application,”?he added, explaining the reason why they decided to add the second, third, fourth and fifth machine in 2017, 2018, 2019 and 2020.

“We produce all types of products with different sizes and shapes, including cement bags, sugar bags, fertilizer bags, mesh bags (for packing onion, ginger, garlic, potato), the machine can handle it all with ease. As our production capacity increases, we also see a higher demand for recycling.”

Powerful yet gentle – A new combination

What makes the Repro-One special is that the built-in shredder is capable of reprocessing materials with high strength such as pp raffia, tapes, filaments, fabrics, and lumps directly without the need to pre-crush. The high-quality recycled pellets ensure easy reuse back in the production process for raffia, non-woven, and Ad*Star block bottom heavily printed bags. The reusability of the PP recycled pellets is particularly high with the Repro-One recycling machines, raffia producers can use between 20% to 100% recycled pellets back into the production line depending on the final product requirement.

The system is different from the recycling machine with a rotating-cutter/cutter compactor built-in, which is used mainly for recycling light-weighted material such as plastic film and bags.

The ideal recycling solution for PP woven bag producers worldwide

In the Repro-One machine, the waste material is fed without pre-cutting into the plastic crusher by a conveyor belt. A hydraulic “pusher” presses the material against the rotor where the material is shredded and cut in between at a low processing temperature. After shredding, the material is fed directly into the extruder for further filtration and degassing before pelletizing.

The combination of shredder, extruder, and pelletizer into one machine is the ideal solution for raffia and woven bag producers who need to process their internal waste, as the powerful (shredder) yet gentle (low processing temperature) process produces the best possible pellets quality at the lowest operation cost.

Many PP raffia and woven bag producers have already seen the great benefits of doing in-house recycling using the?Repro-One, including producers in Argentina, Azerbaijan, Congo, Ethiopia, India, Indonesia, Mexico, Myanmar, Philippines, Saudi Arabia, Sudan, Swaziland, Thailand, Türkiye, Kenya, Kuwait, USA, and many others.

This article originally appeared on POLYSTAR.

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