Recycling defective and off-spec reels
Start-up scrap and off-spec rolls are an inevitable part of film production. Instead of storing them or selling them at a loss, convert them automatically into value. Plasmac’s integrated solutions allow you to recycle full reels of printed, multilayer and packaging films directly back into your production line
Turn production losses into raw material
Managing defective reels is often a logistical nightmare. They are bulky, difficult to handle, and dangerous to cut manually. Plasmac technology transforms this problem into an opportunity by allowing you to reprocess the material without pre-cutting or heavy manual labor.
Safety and automation
Traditional methods require operators to slice reels with knives to feed granulators, a major safety hazard. Our approach automates the intake of the film, pulling the web directly from the reel into the recycling system. This protects your workforce and ensures a consistent feed rate for superior pellet uniformity.
Handling complex film specifications
Not all reels are the same. From heavy ink coverage to incompatible polymer layers, we have the engineering expertise to handle your specific waste stream.
Printed film
Heavily printed films present a unique challenge: ink volatiles can cause gassing, leading to porous pellets. Our recycling systems are equipped with high-efficiency vacuum degassing zones that actively remove ink solvents and moisture.
Packaging film
Standard LDPE, LLDPE, and stretch films are valuable resources. Whether it’s shrink wrap or stretch hooding, our systems maintain the material’s high melt flow index and clarity. By reprocessing these reels in-house, you recover pure polyolefin material that can immediately replace virgin resin in your blend.
Multilayer film
Barrier films (PA/EVOH/PE) are notoriously difficult to recycle due to differing melting points and polymer incompatibility. Our technology utilizes specialized screw geometries to homogenize these materials at low temperatures. This prevents the degradation of sensitive layers and creates a consistent blend that can be used for non-critical applications or injection molding.
Why reprocess reels in-house?
Sending off-spec rolls to an external recycler means losing money on logistics and buying back material at a premium.
Preserve material properties
Our low-shear processing ensures that the polymer chains are not stressed excessively during recycling. This is crucial for film producers who need to maintain the tensile strength and elongation properties of the recycled material when adding it back to the bubble.
Zero-waste manufacturing
By implementing a dedicated solution for defective reels, you close the final loop in your production facility. Start-up waste and changeover scrap become a resource rather than a disposal cost, significantly improving your plant’s overall sustainability profile.
Designed for industrial throughputs
Whether you generate a few rolls a week or have continuous waste from high-speed converting lines, our systems scale to your needs.
Variable reel sizes
Capable of handling various reel diameters and widths, from narrow slit rolls to full-width jumbo rolls.
Tension control
Automatic synchronization prevents web breaks during the feeding process.
Filtration options
Continuous screen changers remove paper labels, tape, or other contaminants often found on the outer layers of waste reels.
Recover your reel waste
Stop stockpiling defective reels. Contact us to determine the best configuration for your film type.