Single Stage Cutter Compactor Pelletizing Line
High-Efficiency Plastic Regeneration
The Single Stage Cutter Compactor Pelletizing Line is an integrated 4-in-1 solution that combines crushing, compacting, plasticizing, and pelletizing into a single, seamless process.
By integrating the cutter-compactor directly with the extruder, the system pre-heats and densifies the material using frictional heat.
Why Choose the Single Stage System?
This line is engineered for versatility and cost-effectiveness. It is particularly effective for "light" materials that typically occupy a large volume but have low weight, such as films and foams.
Unified Processing: Eliminate the need for separate shredding or densifying steps.
Superior Homogenization: The specially engineered granulator ensures uniform flakes, leading to consistent pellet quality.
Energy Savings: By utilizing the thermal energy generated during compaction, the extruder requires less power to reach melting temperature.
Turnkey Ready: The output pellets are ready for immediate reuse in blown film, pipe extrusion, and injection molding applications.
This system handles a wide array of polymers, including PE, PP, PS, ABS, XPS, EPS, and PVB.
1. Film & Flexible Recycling
Transform HDPE, LDPE, BOPP, and stretch films into high-density pellets. The high-speed friction in the compactor helps "flash off" surface moisture for a cleaner melt.
2. Woven Materials & Fibers
Efficiently process raffia strings, woven sacks (PP bags), and filaments that often tangle in standard feeding systems.
3. Foamed Plastic Recovery
Ideal for densifying bulky EPS and XPS foam into uniform granules, significantly reducing storage and transport costs for recycled materials.
4. Rigid Scrap & Bottles
The durable granulator blades are capable of grinding plastic bottles and small rigid injection scraps, making this a true multi-purpose recycling line.
FEEDING
Plastic scraps such as films, filaments, and raffia are conveyed into the compactor chamber by a belt system.
For rolls, an optional roll-hauling device ensures smooth transfer. Both systems operate with ABB inverters, automatically adjusting feeding speed to match chamber capacity.
Integrated metal detectors connected to the control system trigger warnings and shutdowns if contaminants are detected, preventing damage and ensuring operator safety.
SLIDING GATE WITH SERVO MOTOR
The servo-driven sliding gate manages residence time inside the compactor.
This ensures only clean, pre-dried material moves into the barrel, while substandard feed is withheld.
Controlled by PLC, the gate precisely regulates forced feed quantities, optimizing efficiency and production consistency.
INTELLIGENT CONTROL
Intelligent Start: Launches the entire line with a single button, synchronizing all modules.
Intelligent Stop: Shuts down all components instantly, ensuring fast and safe halts.
Emergency Stop: Integrated emergency protocols protect the system and operators from unexpected risks.
REMOTE MONITORING AND INFORMATION TRANSMISSION
The system is equipped with Bluetooth-based remote monitoring and data transmission.
Operators can track performance in real time, adjust parameters, and access production data for streamlined management and quick decision-making.
CRUSHING AND COMPACTING
The compactor integrates cutting, friction heating, and air exhaust in one process.
As the rotor and stator knives cut and compress material, heat builds naturally, removing surface moisture and dust.
This eliminates the need for additional drying equipment, combining pre-heating, pre-drying, and size reduction into one efficient step.
ROTATORY BLADES OF COMPACTOR
High-speed rotating blades work with fixed blades to slice material into uniform flakes.
Frictional heat shrinks and preheats the flakes, preparing them for efficient extrusion while improving density and consistency.
SINGLE SCREW EXTRUDER
The precision single-screw extruder ensures uniform plasticizing and blending.
Built with bi-metal material, it offers outstanding resistance to wear and corrosion, ensuring a long and reliable operating life.
BARREL
The extruder barrel, designed with a super L/D ratio, can perform like a double-stage extruder.
With the addition of double-piston screen filters, final product quality is further improved, ensuring higher purity and consistency.
DOUBLE VACUUM DEGASSING ZONES
Dual vacuum zones effectively remove micro-molecules, volatile compounds, and moisture.
This process is ideal for printed or contaminated materials, resulting in higher-quality granules with improved stability.
LIQUID OUTLET
The liquid outlet design improves melt filtration and supports higher production output.
In advanced configurations, multiple single-screw extruders feed into a second-stage extruder, further boosting quality and efficiency.
NON-STOP PISTON TYPE FILTER
This system uses either a single/double station piston screen changer or a continuous four-station option.
Large filter areas extend screen life, while quick-change functionality allows seamless operation without halting production.
Lower downtime means higher productivity and reduced operational costs.
PLATE TYPE FILTER
Continuous dual filter plates ensure uninterrupted operation during screen changes.
Equipped with a ring-shaped heater, the system maintains stable and uniform temperature for consistent filtration.
SELF-CLEAN FILTER
The SCF (Self-Cleaning Filtration) system enables continuous extrusion even with highly contaminated materials.
Capable of filtering out up to 5% impurities such as paper, wood, aluminum, and rubber, it ensures uninterrupted recycling and improved product purity.
WATER RING PELLETIZING SYSTEM
The self-adjusting pelletizing head maintains blade pressure for consistent granule size.
Blade RPM adapts automatically to extrusion pressure, while quick-change pelletizer blades simplify maintenance and reduce downtime.
UNDERWATER PELLETIZING SYSTEM
A highly automated pelletizing system designed for high-MFI materials and demanding capacity requirements.
The setup includes pelletizer, valve, pipelines, vibrating dewatering screen, and silo for efficient large-scale pellet production.
VIBRATION DRY
Advanced dewatering combines vibrating sieve technology with horizontal centrifugal drying.
Screw-assembled sieves simplify future replacements, reducing downtime and lowering maintenance costs.
PLASTIC PARTICLES
The end result is high-quality plastic granules, ready to be reused in manufacturing.
This recycling loop reduces waste and provides reliable raw material for producing new plastic products.
PACKING SYSTEM
The final qualified granules are dried using a shaker and horizontal centrifuge, then packed with precision.
Continuous capacity monitoring and quantitative weighing systems guarantee accurate storage and shipment readiness.
ADVANTAGES
– Integrated crushing, compacting, and pelletizing in one system reduces labor costs
– Higher feeding efficiency for film, filament, raffia, and foaming materials
– Lower investment with a durable, long-lasting design
– Energy-efficient operation with increased production output
– Overseas installation and training services available
– Warranty support with stocked spare parts for fast delivery
Target Recycled Material | HDPE, LDPE, PP, BOPP, CPP, OPP, PA, PC, PS, PU, ABS | |||||
System Composition | Belt Conveyor, Cutting Compactor, Single Screw Extruder, Filtration, Pelletizer, Water Cooling Device, Dehydration Section, Conveyor Fan, Product Silo. | |||||
Material of Screw | 38CrMoAlA (SACM-645), Bimetal (Optional) | |||||
L/D of Screw | 31/1, 32/1, 34/1, 36/1 (According to the characteristics of recycling) | |||||
Heater of Barrel | Ceramic heater or Far-infrared heater | |||||
Cooling of Barrel | Air cooling of fans through blowers | |||||
Pelletizing Type | Water-ring pelletizing/ water-strands pelletizing/ Under-water pelletizing | |||||
Technical Services | project design, factory construction, installation and recommendations, commissioning | |||||
Machine Model | Compactor | Single Screw Extruder | ||||
Volume | Motor Power | Screw Diameter | L/D | Extruder motor | Output capacity | |
(Liter) | (kw) | (mm) | (kw) | (kg/h) | ||
TT-ACS-H300/80 | 300 | 37 | 80 | 36 | AC 55 | 160-220 |
TT-ACS-H500/100 | 500 | 75 | 100 | 36 | AC 110 | 300-380 |
TT-ACS-H800/120 | 800 | 110 | 120 | 36 | AC 160 | 450-550 |
TT-ACS-H1000/140 | 1000 | 132 | 140 | 36 | AC 200 | 600-700 |
TT-ACS-H1200/160 | 1200 | 160 | 160 | 36 | AC 250 | 800-1000 |
TT-ACS-H1600/180 | 1600 | 200 | 180 | 36 | AC 315 | 1000-1200 |