Double Stage Cutter Compactor Pelletizing Line
The Double Stage Cutter Compactor Pelletizing Line is a high-performance recycling system designed to process challenging plastic waste materials that are difficult to handle with standard pelletizing equipment. It integrates crushing, compacting, plasticizing, filtration, and pelletizing into a single, continuous production flow. This streamlined design improves efficiency while delivering stable and consistent pellet quality.
Engineered with a two-stage extrusion process, the system provides an extended processing path that significantly enhances melt quality. The dual-stage configuration allows impurities, moisture, and gases to be removed more effectively during processing. As a result, heavily printed, contaminated, or moist plastic waste can be converted into clean, production-ready recycled pellets suitable for downstream manufacturing.
The two-stage design also enables gentler material handling, helping protect temperature-sensitive polymers from thermal degradation. Built for industrial use, the Double Stage Cutter Compactor Pelletizing Line is designed for continuous 24/7 operation, making it a reliable solution for high-capacity recycling plants that demand consistent output, high filtration performance, and long-term operational stability.
Key Highlights
- All-in-one system for crushing, compacting, extrusion, and pelletizing
- Two-stage extrusion for improved melt quality and process control
- Double filtration for more effective impurity removal
- Enhanced degassing to remove moisture and ink residues
- Gentle processing for heat-sensitive plastic materials
- Produces high-quality recycled pellets ready for reuse
- Designed for continuous, industrial-scale operation
This line is the professional choice for re-pelletizing a wide variety of polymers, including PE, PP, PS, ABS, XPS, EPS, and PVB.
1. Film & Flexible Packaging
Printed Materials: Easily process HDPE, LDPE, BOPP, and CPP films with heavy ink coverage.
Stretch & Shrink Films: Efficiently recycle thin, high-stretch materials into uniform granules.
Bags & Raffia: Ideal for woven bags, shopping bags, and raffia strings.
2. Foamed Plastics (EPS/XPS)
Volume Reduction: Convert bulky foamed materials like EPS and XPS into dense, high-quality pellets suitable for secondary manufacturing.
3. Industrial & Post-Consumer Waste
High-Moisture Scraps: The multiple exhaust systems handle materials with high water content.
Manufacturing Offcuts: Turn defective products, sheets, and factory scraps back into usable raw materials.
Rigid Plastics: Process ABS, PS, and PC scraps into durable pellets for injection molding.
Optimized for Downstream Production
The pellets produced by our Double Stage system are of such high quality that they can be used directly in:
Blown Film Lines
Pipe & Tube Extrusion
Injection Molding Systems
FEEDING
Films, filaments, and raffia are fed to the compactor via a belt conveyor as standard, while roll stock is handled by an optional roll haul-off unit.
Both drives are controlled by ABB inverters, automatically tuning feed speed to the compactor’s fill level for steady, jam-free throughput.
A conveyor-mounted metal detector ties into the control system to alarm and stop the line if metal is detected—protecting equipment and operators.
CRUSHING AND COMPACTING
The compactor integrates size reduction, pre-heating, and pre-drying in one step.
Rotor and stator knives generate frictional heat that drives off surface moisture and dust; the air-exhaust system removes these volatiles without extra energy demand.
Result: faster, more consistent feeding and reduced load on downstream degassing.
INTELLIGENT CONTROL
One-Touch Start: Launches the entire line and synchronizes all interlocked modules.
One-Touch Stop: Brings each module to a safe halt, quickly and cleanly.
Emergency Stop: Dedicated E-stop circuits protect the Double Stage Cutter Compactor Pelletizing Line from unexpected events.
REMOTE MONITORING AND INFORMATION TRANSMISSION
The system supports program-based remote monitoring and Bluetooth data transmission, enabling real-time status checks, parameter updates, and production analytics from a distance.
THE ROTATORY BLADES OF COMPACTOR
High-speed rotary blades work against fixed blades to cut material into uniform flakes.
Frictional heat simultaneously pre-shrinks and pre-heats the feed, stabilizing bulk density and improving downstream extrusion.
SINGLE SCREW EXTRUDER
Our precision single-screw extruder gently plasticizes and homogenizes the melt.
Bi-metal construction delivers exceptional wear and corrosion resistance, extending service life and process stability.
BARREL
The extended L/D ratio achieves double-stage performance in a single-stage layout.
After a mid-line double-piston screen, an optional final filter boosts cleanliness—elevating pellet quality and repeatability.
DOUBLE VACUUM DEGASSING ZONES
Two independent vacuum ports remove moisture, volatiles, and micro-molecules—especially effective for heavily printed or contaminated inputs—ensuring cleaner melt and higher-grade granules.
TWO SETS OF SINGLE-SCREW EXTRUDERS
A dual extruder configuration is ideal for high-ink, high-moisture, temperature-sensitive, or impurity-rich materials.
It enables double filtration, multiple exhaust stages, and longer residence time to meet demanding specifications.
LIQUID OUTLET
For higher output and cleaner melt, multiple single-screw extruders can feed a second-stage extruder.
This arrangement elevates filtration efficiency and scales production capacity.
NON-STOP PISTON TYPE FILTER
Fit single/double-station or continuous four-station piston screen changers for high filtration throughput.
Large filter areas extend screen life; quick, on-the-fly changes keep production continuous and operating costs low.
PLATE TYPE FILTER
A continuous dual-plate design ensures at least one filter remains online during screen changes.
Ring-style heating maintains stable temperature for consistent filtration performance.
SELF CLEAN FILTER
The SCF self-cleaning system sustains continuous extrusion even with heavily contaminated streams—removing up to ~5% impurities such as paper, wood, aluminum, rubber, and unmelted plastics.
WATER RING PELLETIZING SYSTEM
A self-adjusting head maintains ideal blade pressure for consistent granulate quality and longer uptime.
Blade RPM auto-adapts to melt pressure, and tool-less blade swaps require no readjustment—saving maintenance time.
UNDER-WATER PELLETIZING SYSTEM
For high-MFI resins and large throughputs, this automated system includes pelletizer, valve, piping, dewatering vibration screen, and silo—delivering uniform pellets at scale.
VIBRATION DRY
A dewatering vibration sieve paired with horizontal centrifugal drying achieves low-energy, high-efficiency pellet drying.
Screw-assembled sieves (no welds) make future changeovers fast and simple.
PLASTIC PARTICLES
The finished product is high-quality recycled pellets, ready to re-enter production as consistent, reliable raw material.
PACKING SYSTEM
A drying shaker and horizontal centrifuge ensure well-dried pellets before storage.
Online capacity monitoring and quantitative weighing deliver accurate inventory and shipment control.
ADVANTAGES
– Single system integrates crushing, compacting, and pelletizing to reduce labor and footprint
– Optimized feeding for films, filaments, raffia, and foamed materials
– Lower upfront costs with durable, long-life components
– Higher output per kWh for superior energy efficiency
– Global installation & training support
– Robust warranty with stocked spare parts for fast service
Target Recycled Material | HDPE, LDPE, PP, BOPP, CPP, OPP, PA, PC, PS, PU, ABS,PET | |||||
System composition | Belt Conveyor, Cutting Compactor, Single Screw Extruder, Filtration, Pelletizer, Water Cooling Device, Dehydration Section,Conveyor Fan, Product Silo. | |||||
Feeding Device | Belt Conveyor (Standard), Roll Hauling off device (Optional) | |||||
Material of screw | 38CrMoAlA (SACM-645), Bimetal (Optional) | |||||
Heater of barrel | Ceramic heater or Far-infrared heater | |||||
Cooling of Barrel | Air cooling of fans through blowers | |||||
Vacuum deashing exhaust | Two Double-zone vacuum degassing system (Standard) | |||||
Pelletizing type | Water-ring pelletizing/ water-strands pelletizing/ Under-water pelletizing | |||||
Technical services | project design, factory construction, installation and recommendations, commissioning | |||||
TT-ACSS-HTM series single-stage compactor-granulator machine | ||||||
Model | Compactor Volume (L) | Compactor motor | Screw diameter(mm) | L/D ratio | Power(kw) | Productivity(kg/h) |
TT-ACSS-H80/120 | 300 | 37 | 80 | 42 | 45/55 | 160-220 |
120 | 10 | 22 | ||||
TT-ACSS-H100/120 | 500 | 55 | 100 | 42 | 90/110 | 300-380 |
120 | 10 | 30 | ||||
TT-ACS-H120/150 | 800 | 90 | 120 | 42 | 132 | 450-500 |
150 | 10 | 37 | ||||
TT-ACS-H140/150 | 1000 | 110 | 140 | 42 | 160/185 | 500-650 |
150 | 10 | 45 | ||||
TT-ACS-H160/180 | 1200 | 132 | 160 | 42 | 220/250 | 800-1000 |
180 | 10 | 55 | ||||
TT-ACS-H180/200 | 1600 | 160 | 180 | 42 | 315 | 1000-1200 |
200 | 10 | 75 | ||||