What Machine Do You Need to Recycle Plastic?

Recycling plastic isn’t just about tossing bottles into a bin anymore. Behind the scenes, there’s an entire system of specialized machines working together to turn waste plastic into reusable material. But what machines are actually needed for this process?

In this guide, we'll walk you through all the essential machinery used in plastic recycling, breaking down what each one does and how they work together. Whether you're starting a small recycling business or just curious about the process, this article has got you covered!

Understanding the Plastic Recycling Process

Before we dive into the machines, let’s understand the basic steps involved in plastic recycling:

1. Collection and Sorting

2. Shredding

3. Washing

4. Separation

5. Drying

6. Extrusion and Pelletizing

Each of these stages requires specific types of machinery. Let’s take a look at them one by one.

1. Plastic Baler or Compactor

Purpose: Prepares plastic waste for easier handling.

Before plastics even reach the main recycling line, bulky items like bottles, containers, or film need to be compressed.

Machine Types:

• Horizontal Balers – Great for large-scale operations.

• Vertical Balers – Compact and ideal for small facilities.

• Plastic Compactors – Reduce volume for easy transport.

2. Plastic Sorting Machine

Purpose: Sorts plastic by type (e.g., PET, HDPE, PP) and sometimes by color.

Types of Sorting:

• Manual Sorting Tables – Budget-friendly but labor-intensive.

• Optical Sorters – Use infrared light to detect and sort plastics automatically.

• Density Separation Tanks – Float/sink method to separate plastics based on density.

Proper sorting is critical to ensure high-quality recycled plastic.

3. Plastic Shredder / Granulator

Purpose: Cuts plastic into smaller flakes or granules for further processing.

This is where the magic begins! After sorting, plastic items are fed into a shredder or granulator to break them down into uniform pieces.

Types:

• Single-Shaft Shredders – Ideal for large, bulky plastics.

• Double-Shaft Shredders – Used for tougher materials.

• Granulators – Finer cutting, often used after shredding.

4. Plastic Washing Machine

Purpose: Cleans the plastic of labels, dirt, glue, oil, and food residue.

Clean plastic = high-quality recycled product. A washing line typically includes:

Machine Components:

• Friction Washers – Spin the plastic flakes at high speed to clean them.

• Hot Wash Tanks – Use heated water and detergent to remove glue and oil.

• Floating Wash Tanks – Help separate contaminants.

5. Plastic Dewatering Machine

Purpose: Removes water from washed plastic flakes.

After washing, the plastic needs to be dried thoroughly to avoid issues during extrusion.

Machines Used:

• Centrifugal Dryers – Spin the flakes rapidly to shake off water.

• Thermal Dryers – Use hot air to dry the material.

6. Plastic Separator (Optional but Important)

Purpose: Removes unwanted materials like metals or different plastic types.

This is especially useful if you're dealing with mixed plastic waste.

Examples:

• Metal Separators – Remove nails, staples, etc.

• Electrostatic Separators – Separate plastic types with similar density.

7. Plastic Extruder Machine

Purpose: Melts and reshapes plastic into a consistent material for reuse.

This is the heart of the recycling process. Flakes are melted and pushed through a die to form new plastic shapes or strands.

Extruder Types:

• Single-Screw Extruder – Common for basic recycling lines.

• Twin-Screw Extruder – Offers better mixing and performance for complex plastic blends.

8. Pelletizing Machine

Purpose: Turns melted plastic into small, uniform pellets.

The extruded plastic is cut into small pellets, also known as granules, which are used as raw materials for manufacturing new plastic products.

Pelletizer Types:

• Strand Pelletizers – Cut solidified plastic strands.

• Underwater Pelletizers – Cut while plastic is still hot and underwater.

• Die-Face Pelletizers – Cut at the face of the die for softer plastics.

Optional: Agglomerator or Densifier

Purpose: Pre-treats soft plastic film (like LDPE or bags) before extrusion.

Film plastics are lightweight and hard to feed into extruders. An agglomerator compresses and densifies them, making them easier to process.

Optional: Storage Silos and Conveyors

To keep the line running smoothly, conveyors, storage silos, and screw feeders are often added to move material between machines.

Bonus: Fully Integrated Plastic Recycling Lines

Many manufacturers offer turnkey solutions—complete recycling lines with all components integrated. These lines automate the entire process, from feeding plastic waste to producing recycled pellets.

Choosing the Right Machines for Your Needs

Factors to Consider:

• Type of plastic (PET, HDPE, PP, etc.)

• Clean or contaminated feedstock

• Production capacity

• Budget and space

• Automation level

For example:

• A small PET bottle recycling plant might need a basic shredder, washer, dryer, extruder, and pelletizer.

• An LDPE film recycling line might require an agglomerator, hot washing system, and twin-screw extruder.

Conclusion: Building the Right Plastic Recycling Setup

Recycling plastic isn't a one-machine job. It’s a team effort of specialized machines, each playing a critical role in turning waste into something valuable again. Whether you’re starting a local recycling center or upgrading your existing line, choosing the right combination of machines can make or break your success.

Start small, learn the process, and scale up as needed!