Home›Products›Plastic Recycling and Re-pelletizing Systems

Recycling & Re-pelletizing

Plastic Recycling and Re-pelletizing Systems

Green Extrusion Technology offers two main solutions: the compact all-in-one Lab-REC for testing, teaching and material development, and the Green REC in-house recycling extruder, supplied as a stand-alone repelletizer or as a complete line for clean production waste.

Request information See the two solutions How it works

Compact laboratory recyclingStand-alone or complete in-house lineFilm flakes and pre-granulated rigidsAir-cooled die-face pelletizingMade in Denmark

Green REC in-house recycling extruder with press feeder and air-cooled die-face pelletizing system

Two recycling solutions, one practical approach All-in-one laboratory testing or modular in-house production recycling

Up to 15 kg/hLab-REC laboratory line

Up to 120 kg/hGreen REC in-house line

2 solutionsAll-in-one or modular

DenmarkDesign, assembly and testing

Two main recycling solutions

Choose the solution that fits your work

Green Extrusion Technology supplies a compact laboratory line for small controlled trials and a production recycling extruder that can work alone or as part of a complete in-house line.

01Testing · teaching · development

Lab-REC laboratory recycling line

A compact all-in-one line that integrates size reduction, extrusion, filtration, pelletizing, cooling and pellet handling in one system.

Main uses

Testing recycled materials and new formulations
Teaching, training and research work
Producing small batches and sample pellets before scale-up

Integrated process

Output: Up to 15 kg/h, material dependent
Size reduction: Integrated screw-shredder combination
Extrusion: Universal recycling screw with degassing and melt filtration
Pellet handling: Air-cooled die-face cutting, cyclone and bag filling

Discuss a Lab-REC system

02In-house production recycling

Green REC in-house recycling extruder

A production repelletizing system for clean in-house waste, available as a stand-alone extruder or as a complete shredder-to-pellet line.

Stand-alone repelletizerFor customers who already have a granulator or shredder. The machine is fed with plastic film flakes or pre-granulated rigid plastics.

Complete in-house lineConfigured with the GET-45 shredder, conveyor, optional metal detector, reel-feeder, flakes blower and PF 200 press feeder.

Key data

Output: Up to 120 kg/h, material dependent
Extrusion: Degassing, screen changer and optimised pelletizing screw
Pelletizing: Air-cooled die-face system, cooling serpentine and cyclone
Control: Schneider Electric touchscreen HMI and automatic load-controlled feeding

Discuss an in-house system

Key facts & benefits

Practical, compact and easy to run

The same qualities apply to both the production and the laboratory system.

All-around re-pelletizing system for a wide range of plastics
Easy to install and run
Compact. Limited space needed
Quick to learn and use
Operator-friendly touch screen HMI
Easy to programme

Easy access to all parts
Fast and easy removal of the screw and knives
Low sound level
Top-brand electrical components, drive and motors
Strong build for long service life
2-year guarantee

How it works

From plastic waste to clean pellets

Both solutions follow the same main process. In the Lab-REC, the stages are integrated into one compact unit. In the in-house line, the stages are modular and selected to match the waste form, output and available equipment.

1Size reduction

2Controlled feeding

3Extrusion & degassing

4Melt filtration

5Die-face pelletizing

6Air cooling

7Cyclone & bag filling

Integrated in the laboratory, modular in production

The Lab-REC combines the complete process in one compact machine. The Green REC in-house system can start with the repelletizing extruder and later be extended with Green Extrusion size-reduction and feeding equipment.

In-house recycling line

The building blocks of the in-house line

The in-house system is modular. It can be supplied as a stand-alone Green REC repelletizer or as a complete line with Green Extrusion size-reduction, conveying and feeding equipment.

The Lab-REC is different

The laboratory version is an all-in-one unit. The separate modules shown below apply to the Green REC in-house production line.

1Size reduction

GET-45 single-shaft shredder

The GET-45 prepares flexible and rigid in-house waste for controlled feeding to the recycling extruder. It can work as a stand-alone shredder or as part of the complete in-line system.

Robust construction with protected rotor bearings
Clean-cut knives that can be rotated and reused before replacement
Flexible loading by conveyor, reel-feeder or direct input
Easy cleaning for quick material changes

GET-45 single-shaft shredder for flexible and rigid plastic production waste — GET-45 single-shaft shredder for the Green REC in-house recycling line.

2Material loading

Inclined conveyor with optional metal detector

The conveyor feeds production waste into the GET-45 shredder. It can be prepared with a pass-through all-metal detector that stops the belt when metal contamination is detected.

GET-45 shredder with inclined conveyor belt for loading plastic production waste — GET-45 shredder with adjustable inclined conveyor belt.

3Film from rolls

GET-RF 45 reel-feeder

The reel-feeder introduces film directly from rolls at a controlled speed. It is suitable for edge trims, rejected rolls and other continuous film waste.

450 mm intake width
Adjustable feed speed up to 50 m/min
Safety guards and emergency-stop connection

GET-RF 45 reel-feeder for feeding plastic film rolls into the shredder — GET-RF 45 for controlled feeding of film directly from rolls.

4Material transfer

Flakes blower and conveying connection

After size reduction, a flakes blower transfers the shredded material to the PF 200 press-feeder. The feeding path is arranged to provide a stable flow and a practical buffer between the shredder and the extruder.

Internal graphic view of the GET-45 shredder with integrated material discharge blower — Graphic view of the GET-45 cutting system and material discharge blower.

5Controlled extruder feeding

PF 200 press-feeder and densifier

The PF 200 compacts film flakes, punching ribbon, powder, agglomerates and other poorly free-flowing materials. A densifying screw feeds the extruder at controlled pressure for stable loading.

210 dm³ hopper volume
Capacity up to 250 kg/h for film flakes
Level monitoring, speed control and lifting system

PF 200 press-feeder hopper and densifier for stable feeding of plastic flakes — PF 200 press-feeder and densifier for constant extruder loading.

6Repelletizing

Green REC in-house recycling extruder

The main recycling extruder processes clean film flakes and pre-granulated rigid plastics. It includes a bimetal cylinder, an optimised pelletizing screw, controlled heating, degassing and melt-pressure monitoring.

Output up to 120 kg/h, material dependent
Ø60 mm pelletizing screw
Single degassing system with water-ring vacuum pump and tank
Seven heating zones and four cooling blowers

Green REC in-house recycling extruder with press feeder and die-face pelletizing unit — Green REC production recycling extruder for clean in-house plastic waste.

7Melt filtration

SCM 80 screen changer

The manually operated SCM 80 filter provides safety filtration of clean production waste before pelletizing. Screen replacement requires only a short interruption of the working cycle.

85 mm screen diameter
Low maintenance and safe operation
Hydraulic versions available for other requirements

SCM 80 manual melt screen changer for the Green REC recycling extruder — SCM 80 manual screen changer for controlled melt filtration.

8Pelletizing and cooling

Air Cooling Die Face Pelletizing System

Rotating knives cut the polymer at the heated die face. The pellets are cooled and transported through an air-cooling serpentine to the cyclone and bag filling unit.

Adjustable pellet size
Dry pellets without water contact
Suitable for compostable and water-soluble polymers
Compact and maintenance-friendly construction

Air-cooled die-face pelletizing system with cooling serpentine and cyclone — Air-cooled die-face pelletizing, cooling, conveying and cyclone separation.

9Line control

Schneider Electric touchscreen HMI

The touchscreen provides clear control of the recycling line, with a graphic process overview and settings for the connected equipment.

Recipe management and alarm monitoring
Language options
Automatic load-controlled feeding
Remote access for service and assistance

Schneider Electric touchscreen HMI for the Green REC recycling line — Touchscreen HMI for process control, recipes, alarms and service access.

Technical data

Technical specifications

The values below describe the two main solutions. Final specifications depend on the material, waste form and selected configuration.

Two main recycling solutions

Item	Lab-REC laboratory line	Green REC in-house system
Main purpose	Testing, teaching, research and trials with new recycled materials	Continuous recycling of clean in-house production waste
Output	Up to 15 kg/h, material dependent	Up to 120 kg/h, material dependent
Configuration	Compact all-in-one machine	Stand-alone repelletizer or complete modular line
Material input	Film and semi-rigid plastic scrap, flakes and small controlled batches	Film flakes or pre-granulated rigid plastics; clean production waste
Size reduction	Integrated screw-shredder combination	Customer’s existing granulator or shredder, or optional GET-45
Feeding	Integrated feeding from the shredder to the extruder	PF 200 press-feeder; optional conveyor, metal detector, reel-feeder and flakes blower
Degassing and filtration	Included	Single degassing system and SCM 80 screen changer
Pelletizing	Air-cooled die-face system with two knives	Air-cooled die-face system with four knives
Pellet handling	Cooling serpentine, pneumatic conveying, cyclone and bag filling	4 kW air blower, 10 m cooling serpentine, cyclone and bag filling
Control	Operator-friendly touchscreen HMI	12-inch Schneider Electric touchscreen HMI

Lab-REC laboratory line

Extruder motor	AC 8 kW with extrusion gearbox and thrust bearings
Cylinder	Bimetal extruder cylinder
Screw	Universal recycling screw
Temperature control	Ceramic heater bands, 5 heating zones and 4 cooling blowers
Degassing	Single degassing system with water-ring vacuum pump and tank
Filtration	Manual melt screen changer
Die-face cutter	Adjustable direct drive with 2 pelletizing knives
Nominal line power	Up to 25 kW, according to configuration

Green REC in-house extruder

Main extruder motor	AC 30 kW with extrusion gearbox and thrust bearings
Cylinder	Bimetal extruder cylinder
Screw	Ø60 mm, optimised for pelletizing applications
Temperature control	Ceramic heater bands, 7 heating zones and 4 cooling blowers
Degassing	Single degassing with water-ring vacuum pump and tank
Filtration	SCM 80 manual screen changer, 85 mm screen diameter
Die-face cutter	Adjustable direct drive with 4 pelletizing knives
Nominal main line power	Up to 55 kW, according to configuration

GET-45 shredder and optional in-house line modules

GET-45 inlet opening	995 × 400 mm
Rotor	495 mm length, 180 mm diameter
Knives	42 rotor knives and 3 × 2 stator knives
Drive and speed	10 kW, 160 rpm
Shredder output	Up to 150 kg/h, material dependent
Conveyor	3.500 mm long, adjustable inclination, 3 m/min

Metal detector	Pass-through all-metal detector; stops the belt after detection
GET-RF 45 reel-feeder	450 mm intake, adjustable up to 50 m/min
PF 200 volume	210 dm³
PF 200 capacity	Up to 250 kg/h for film flakes
PF 200 inlet	100 mm diameter from the flakes blower
PF 200 drive	1 kW geared motor with speed and torque control

Internal construction of the GET-45 shredder with cutting rotor and discharge blower — GET-45 internal construction with cutting rotor, screen and integrated material discharge.

Graphic side view of the Green REC in-house recycling extruder and air-cooling system — Green REC in-house recycling extruder with press feeder, filtration and air-cooling section.

GET-45 shredder rotor and clean-cut knives processing plastic film flakes — GET-45 clean-cut rotor and replaceable knives processing plastic film waste.

Electrical and general specifications

Mains voltage: 3 × 400 V AC, 50 Hz; other voltages available on request
Control voltage: 24 V DC
Standards: IEC / DIN
Electrical components and PLC: Schneider Electric
Documentation: Electrical drawings, operator manual, spare-parts manual and EC declaration of conformity

Specifications can be adapted to the material and application. We reserve the right to make technical changes without prior notice.

Materials

A wide range of plastics and bioplastics

The systems process a large variety of plastic polymers, as well as materials with additives or fillers. They are suitable for film and semi-rigid plastics, and for testing the effect of one or more recycling cycles.

PE LDPE LLDPE MLLDPE HDPE PP Bio-based Biodegradable

Materials must be free from PVC and from abrasive or corrosive contaminants. The recommended maximum moisture is approximately 3 % for the Lab-REC and 1 % for the Green REC in-house extruder, unless another configuration is agreed.

Green recycled PE pellets held in hands inside a bag — Recycled pellets produced on a Green Extrusion system.

Sustainability

Turn plastic waste into value

Recycle plastic materials into new products rather than sending residual products to waste.

Green Extrusion Technology recycling systems enable our customers to recycle plastic materials into new products rather than sending residual products to waste. This is a benefit on many levels: our customers extract greater value from their plastic raw materials, and the environment is not impacted with unnecessary plastic waste.

Green Extrusion Technology provides equipment that is both rugged and reliable, built to last and usable for many years. The machines are built with re-usable and long-lasting materials and components. The vast majority of the electrical components are supplied by Schneider Electric, Green Premium series, among the most sustainable and long-lasting components on the market.

Working with Green Extrusion

Built in Denmark, supported for the long term

Practical assurances that make the investment easier to plan.

✓

2-year guarantee

Confidence in the reliability and performance of the equipment.

€

Financing possible

Financing options can be arranged for the equipment.

⚑

Made in Denmark

Designed and manufactured in Denmark with reliable European components.

⚙

Test with your material

The machine can be tested with your own material before delivery, by agreement.

Customer-specific systems

Every recycling task is different. The line can be configured for your material, your waste form and your available space, from a single stand-alone shredder or extruder to a complete automatic line. Tell us the material and the product, and we will propose a suitable configuration.

Questions and answers

Frequently asked questions

Which of the two recycling solutions should I choose?

Choose the Lab-REC for testing, teaching, product development and small batches up to 15 kg/h. Choose the Green REC in-house extruder for production recycling up to 120 kg/h. The in-house machine can be supplied alone when size reduction already exists, or as a complete line with GET-45 shredder, conveyor, feeding and material-transfer equipment.

Which materials can be recycled?

The systems can process PE, LDPE, LLDPE, MLLDPE, HDPE, PP, many bio-based and biodegradable plastics, and materials with additives or fillers. Suitability depends on the formulation and configuration. Material must be clean, free from PVC and free from abrasive or corrosive contaminants.

Can the system run without a full-time operator?

Yes. The material feeding rate is controlled automatically by the load on the extruder screw, so overloading and underloading are avoided. The buffer capacity of the press feeder hopper means there is no need for a full-time operator.

Can I test my own material before deciding?

Yes. The machine can be tested with your own material before delivery, by agreement. This is especially useful for recycled and bio-based combinations.

Is there a guarantee and financing?

The machines carry a 2-year guarantee and are designed and manufactured in Denmark with reliable European components, mainly Schneider Electric. Financing can also be arranged.

Recycle your own plastic in-house

Tell us your material, waste form and required output. We will help you select the Lab-REC, a stand-alone Green REC in-house extruder or a complete recycling line with size reduction and feeding equipment.

Request information Contact us

Know How

Technical articles that may help

Background reading about materials and recycling from the Green Extrusion Know How section.

Plastic Recycling and Re-pelletizing Systems