Single-Screw Plastic Pelletizing System

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Website: http://plasticrecyclinglines.com/1-4-1-single-screw-plastic-pelletizing-system.html

The plastic recycling pelletizing system is used in recycling plants for processing both soft and rigid plastic wastes. It handles crushed flakes and shredded materials smoothly, bringing plastic through melting and pelletizing in one continuous process. This plastic recycling line is commonly used for PE, PP, ABS, PS, PA, and PC, including regrind and plastic flakes. The finished output is uniform plastic pellets, which can be reused as raw material for film blowing, injection molding, and pipe extrusion in downstream plastic manufacturing processes.

Recyclable Materials

PP rigid waste plastic
PE rigid waste plastic
PS rigid waste plastic
ABS scraps
PA rigid waste plastic
PC rigid waste plastic
PP woven bag
LDPE film
PE greenhouse film
PP bulk bag
PP woven bag (mixed color)
PE agricultural mulch film

Video

Single-Stage Plastic Pelletizing System

High-cost efficiency as one extruder completes the full extrusion and pelletizing process. The system has a compact footprint and is suitable for plants with limited space.
Moisture and trapped air are released during extrusion through a single vent on the screw. The pellets come out solid and compact without visible pores.

Model	Screw Diameter (mm)	Screw Length (mm)	Power (kW)	Output Capacity (kg/h)
HS 110	Ø110	2600	37	150-200
HS 120	Ø120	3000	45	200-250
HS 130	Ø130	3200	55	250-300
HS 140	Ø140	4000	75	300-350
HS 150	Ø150	4200	90	350-400
HS 160	Ø160	4500	110	400-500
HS 180	Ø180	5200	160	500-700
HS 200	Ø200	6000	250	700-800

Double-Stage Plastic Pelletizing System

Improved melting and plasticizing.
The screw design includes two venting sections, which results in higher efficiency for larger-throughput production.
The system can handle a broad range of plastics, including PE, PP, PA, PS, PC, and ABS.

Model	Screw Diameter (mm)	Screw Length (mm)	Power (kW)	Output Capacity (kg/h)
HS 110/110	Ø110	2600	37	200-250
HS 110/110	Ø110	1100	11	200-250
HS 120/120	Ø120	3000	45	250-300
HS 120/120	Ø120	1200	15	250-300
HS 130/130	Ø130	3200	55	300-350
HS 130/130	Ø130	1300	18.5	300-350
HS 140/140	Ø140	4000	75	350-400
HS 140/140	Ø140	1400	30	350-400
HS 150/150	Ø150	4200	90	400-500
HS 150/150	Ø150	1500	37	400-500
HS 160/160	Ø160	4500	110	500-600
HS 160/160	Ø160	1600	37	500-600
HS 180/180	Ø180	5200	160	700-900
HS 180/180	Ø180	2000	45	700-900
HS 200/200	Ø200	6000	250	900-1000
HS 200/200	Ø200	2600	75	900-1000

Video

Triple-Stage Plastic Pelletizing System

In addition to the advantages of single-stage and double-stage systems, the triple stage palletizer is used for tighter control over pellet quality. It is mainly used in plastic film and other soft-material processing.

Model	Screw Diameter (mm)	Screw Length (mm)	Power (kW)	Output Capacity (kg/h)
HS 110/110/110	Ø110	2600	37	200-250
	Ø110	1100	11
	Ø110	1100	11
HS 120/120/120	Ø120	3000	45	300-350
	Ø120	1200	15
	Ø120	1200	15
HS 130/130/130	Ø130	3200	55	350-400
	Ø130	1300	18.5
	Ø130	1300	18.5
HS 140/140/140	Ø140	4000	75	400-450
	Ø140	1400	30
	Ø140	1400	30
HS 150/150/150	Ø150	4200	90	450-500
	Ø150	1500	37
	Ø150	1500	37
HS 160/160/160	Ø160	4500	110	500-600
	Ø160	1600	37
	Ø160	1600	37
HS180/180/180	Ø180	5200	160	700-900
	Ø180	2000	45
	Ø180	2000	45
HS 200/200/200	Ø200	6000	250	900-1000
	Ø200	2600	75
	Ø200	2600	75

System Composition and Operating Process

Step 1

Material Feeding & Conveying
After crushing and washing, the material is transferred to the extruder by a conveyor belt. Once it enters the screw, compression and melting begin. Moisture and trapped gases are released along the way. The melt is passed through the filtration system before pelletizing. Feeding speed is adjusted based on how the line is actually running, rather than fixed settings. Depending on line size, conveyor motor power usually falls between 0.4 kW and 3 kW. The conveyor belt is made from PVC or rubber, chosen for wear resistance and long service life. A magnetic roller at the top section catches metal fragments before they reach the extruder.

Rigid plastic conveying
Flexible plastic conveying

Step 2

Volumetric Feeding

Rigid material feeder
Flexible material feeder

Step 3

Single-Screw Extrusion

Variable-frequency control is used so feeding speed adjusts with extrusion load, allowing a stable feeding speed that follow the actual output requirement.
A photoelectric sensor monitors material flow and manages automatic feeding control.
The barrel uses a longer L/D ratio. A single-stage extruder can be configured to run as a double-stage setup.
The screw is made from high-strength 38CrMoAl alloy steel, heat-treated for long-term stability.

Step 4

Filtration System

Self-Cleaning Melt Filter (Optional for double-stage plastic palletizing line)

The self-cleaning melt filter operates while the extruder is running. Contaminants are removed automatically from the filter surface without interrupting the production. It reduces manual cleaning and maintenance work, and is suitable for recycling materials with higher levels of contamination.

Double Plate Screen Changer (Screen change without stopping the line)

This filter uses two screen plates that work alternately. When one screen is being changed, the other remains in operation, allowing filtration to continue without interruption. Heating elements are built into the unit to keep temperature consistent during screen changes. In double-stage single-screw lines, a piston-type screen changer can also be used as an alternative option.

Step 5

Cooling & Pelletizing
After extrusion, the molten plastic strands pass through a cooling water trough, where they are solidified quickly. The cooled strands are then pulled forward and fed into the pelletizer. The rotating cutter in the pelletizer slices them into pellets of consistent length.

Strand Pelletizer
Strand Pelletizer

Step 6

Screening
The vibrating screen is made from stainless steel to resist corrosion during long-term operation. As pellets pass through, screening, conveying, and cooling take place at the same time. Qualified pellets move forward, while oversized pieces and fine powder are separated out for consistent pellet sizes.

Vibrating Screen
Vibrating Screen

Step 7

Packaging & Storage
Qualified pellets are collected, packaged, and moved into storage.

How does a double-stage pelletizing line help recyclers processing ABS and PS from electronic housings?

Melting and pressure-building are handled separately in double-stage pelletizing line. The second stage of pelletizing performs melt stabilization, degassing, and filtration. This improves material consistency and removes impurities commonly found in ABS and PS regrind.

What is the functional difference between single-stage, double-stage, and triple-stage pelletizing lines?

The main difference between the pelletizing lines depends on how the screw units are arranged and divided. A single-stage line completes the entire process with one screw, while double-stage and triple-stage lines separate melting, degassing, and pressure control into different sections. These configurations are selected based on material behavior and process needs, rather than performance ranking.

What type of recycled pellets are suitable for blueberry pot production?

Using a double-stage pelletizing line combined with efficient filtration, recyclers can produce clean, stable pellets that meet the forming requirements for agricultural planting pots.