Extrusion scrap recycling
Extrusion lines for pipes, profiles, and sheets generate heavy, rigid waste that requires robust processing. From massive start-up lumps to thick-walled off-spec pipes and edge trims, this scrap represents a significant volume of raw material. Plasmac offers heavy-duty recycling solutions designed to size-reduce and re-extrude bulky, rigid plastics, converting them back into uniform granules suitable for immediate re-introduction into your primary extruders.
Processing heavy and rigid scrap
Recycling extrusion waste presents specific mechanical challenges compared to flexible packaging.
Size and bulk handling
Start-up purgings (lumps) can weigh dozens of kilograms, and off-spec pipes are often long and unwieldy. Standard granulators cannot handle these dimensions without pre-cutting. Our systems are engineered with integrated shredding capabilities to accept large, bulky parts directly, eliminating the need for dangerous and labor-intensive manual saw-cutting.
High thickness reduction
Thick-walled pipes and solid profiles require high-torque shredding to break down effectively. Our low-speed, high-torque rotor technology “shaves” and crushes these rigid materials efficiently, minimizing noise and dust generation compared to high-speed grinding.
Sector-specific solutions
We provide tailored configurations for the distinct needs of the pipe, profile, and sheet industries.
Pipes
Whether processing HDPE pressure pipes, PP corrugated tubes, or irrigation lines, the material quality is critical. Recycling start-up lumps and chamfering waste requires a system that preserves the polymer’s density and mechanical properties. Our extruders ensure that the recycled pellet maintains the necessary specifications to be blended back into the pipe production without compromising pressure ratings or surface finish.
Profiles
From window profiles to technical trunking, this scrap is often rigid and may contain impact modifiers or mineral fillers. Our recycling systems are built with wear-protection options to handle filled materials and offer gentle plasticization to prevent thermal degradation, which is particularly important for heat-sensitive technical profiles.
Sheets
Sheet extrusion generates edge trims (inline) and off-spec slabs (offline). For thermoforming sheet lines, we also process the skeletal waste. Our systems can be configured to take inline trims directly or shred rigid skeletal waste, returning a clean pellet that mixes perfectly with virgin resin for optical-grade sheet production.
Membranes
Waterproofing and geomembranes (often HDPE, LDPE, or TPO) are heavy, wide, and tough. Recycling edge trims or defective rolls requires a system capable of handling high throughputs. Our technology ensures consistent melting and homogenization, preventing unmelted gels that could compromise the impermeability of the final membrane.
One-step size reduction and extrusion
For the extrusion sector, efficiency means minimizing handling steps.
Integrated shredding
Our technology combines size reduction and extrusion in a single footprint. The integrated shredder allows for the feeding of whole pipes (cut to length), heavy lumps, and stacks of sheets directly into the machine. This ensures a constant, surge-free feed to the extruder screw, which is difficult to achieve when feeding irregular regrind from a separate granulator.
Dust-free environment
Grinding rigid plastics traditionally creates significant dust. By using slow-speed shredding technology, we drastically reduce the creation of fines. This keeps your production environment clean and prevents dust-related feed issues in the recycling extruder.
Pellets vs. regrind
Many extruders try to re-feed ground scrap (regrind) directly, but pelletizing offers superior control.
Gravimetric dosing accuracy
Extrusion lines rely on precise gravimetric blenders. Regrind has a variable bulk density and irregular shape, which can throw off dosing accuracy. Plasmac pellets match the bulk density and geometry of virgin granules, allowing for precise, high-percentage dosing without process instability.
Eliminating moisture
Scrap stored in the yard or on the factory floor can absorb moisture. Our extrusion systems with vacuum degassing remove this moisture, ensuring the recycled material is dry and does not cause porosity or surface defects in your final product.
Recover your heavy scrap
Turn your lumps, pipes, and trims back into valuable production material. Contact us to discuss your specific extrusion waste.