SUMMARY PRODUCTION PROCESS OF HDPE RECYCLED PLASTIC PELLETS?

HDPE recycled plastic pellets are manufactured from clean plastic scrap. This scrap includes blue, red, green, yellow and black colors. This source of scrap has undergone a process of careful ion, classification, cleaning and drying before being put into granulation.

The production process follows a modern and closed model. Environmental issues and product quality are given top priority. The technical team and workers have many years of experience in this field. Meet all requirements in terms of technical, quantity, quality and price of customers. Recycled HDPE plastic is produced from used recycled HDPE virgin plastic products. For example, some types of pipes, plastic packaging or household plastic products. After being collected, plastic waste is sorted, chopped, washed and dried and then put into the granulator.

1. Overview of the production process of HDPE recycled plastic granules
The process of recycling plastic waste to produce finished products, which are recycled HDPE pellets, consists of four main stages.

➝ Stage 1: Sorting the collected plastic waste
This stage will usually be carried out manually to be able to separate and clean each type of plastic waste separately such as: HDPE, PP, PVC, PS, etc. However, the level of plastic waste classification is at each level. The place will be different. Depending on the requirements of the manufacturer, the factory will distribute. Plastic scrap will be sorted at any stage in the recycling process. They will be classified according to the criteria of color, origin, type, etc. The salary is low but requires a lot of workers, so the workers performing this stage are still mainly women and children.

➝ Stage 2: Chop and dry plastic waste
HDPE virgin plastic waste, after being classified and cleaned, will be put into a blender for grinding. They are then transferred to the water tank to soak and clean the dirt on the surface. After that, the plastic samples will be dried on the open ground. This is followed by bagging and transporting them to granulation facilities to continue the process.

➝ Stage 3: Conduct granulation and glue
At this stage, the HDPE scrap plastic samples will be ground and mixed according to production requirements. The plastic samples are then heated to molten in a long tube and pushed through the mesh by the extruder. They form thin plastic fibers with a diameter of about 0.3 - 0.4 cm. Next, these plastic fibers are led directly through a cold water bath to harden the plastic fibers. Finally, these plastic fibers will be cut into small plastic particles. From there, the transportation process becomes easier and more convenient. Depending on the needs and purposes of use, HDPE recycled plastic beads will be mixed with appropriate colors.

➝ Stage 4: New product production
Recycled HDPE plastic pellets after being formed will be transported to production facilities to create products. Depending on the type of product being manufactured, there will be different types of machinery and equipment.

2. Production process of HDPE recycled plastic pellets from plastic bags
The recycling technology of recycled HDPE plastic granulating bags includes the following steps.
➝ Step 1: Sorting plastic bags collected from household waste
Similar to the above method, this is mainly done manually. Inorganic and organic wastes will be sorted by hand by workers. In inorganic waste, there are recyclable wastes, including plastic bags.
➝ Step 2: Carry out natural incubation
At this stage, people will reduce the oil content on the plastic bags or residual organic matter. This process is mainly based on the microorganisms available in the dirt that adheres to the bag during use. The incubation period in this phase can last about 10 to 15 days. When the oil and organic matter content on the plastic bags is reduced to 65-70%, it can be put into production. This stage will generate a stench due to the decomposition of organic matter on the plastic bag.
➝ Step 3: Carry out the chopping and washing process
Plastic bags that have gone through the natural composting process will continue to be chopped and washed. This step is carried out to clean the dirt remaining on the bag. Before mincing, the plastic bags will be put into the washing machine to shake off the residual organic matter. Aim to minimize the amount of chemicals and waste water in the washing phase. After that, they will be put into the mincing machine and minced into small pieces to facilitate the next stage of washing.

At the washing stage, the mixture will be added to cleaning chemicals to increase the ability to remove dirt adhering to plastic bags. This stage will consume a large amount of wastewater with mainly organics and detergents. However, to limit the amount of wastewater generated, many factories have conduct preliminary treatment and recycle this water.
➝ Step 4: Carry out the drying process
After being washed, the plastic bags will be dried in the drying yard. With the current method, this period is almost entirely dependent on weather conditions. Therefore, once the weather changes, it will affect the next production stages if there is no reasonable reserve plan.
➝ Step 5: Carry out the rinsing process
This stage is for the purpose of removing dirt or sand from the plastic bags during the drying process. This step can be eliminated directly if the drying step is replaced by the drying method
➝ Step 6: Carry out the grinding process
Samples of plastic bags, after shaking off all kinds of dirt, will be crushed again before being put into the extruder.
➝ Step 7: Extrusion process
Plastic bags after being crushed for the last time will be put into a two-stage extruder. Here, the plastic bags will be melted, extruded into fibers and cooled. This is the heating stage that melts the plastic bag thus producing a small amount of smoke and odor. In particular, the water used for cooling in this process does not need to be treated again, but can be cooled and put into circulation for reuse.
➝ Step 8: Carry out the seed cutting process
After finishing the plastic extrusion stage into filaments, these plastic fibers will be passed through the granulator. Finally proceed to cut the plastic fiber into even small particles.
➝ Step 9: Carry out product packaging
The finished HDPE recycled plastic pellets, after being cut, will be weighed, bagged and distributed to the market. With current production technology to get 3 tons of recycled HDPE plastic finished products, it takes 10 tons of scrap plastic bags. That means the loss rate in the production process falls in the range of 65 - 67%. Currently, HDPE recycled plastic granules from plastic bags are used to produce recycled HDPE plastic packaging, black water pipes. Or in the production process of other types of plastic pipes or some low quality plastic products they will be mixed in.