All film converting operations result in trim and other waste. This is quite voluminous and difficult to dispose off.

If the waste is of a single type, e.g., LDPE or BOPP or simple mixtures such as LDPE + HDPE it can be easily reprocessed.

However, when it is a laminate waste such as PET/PE (Polyester film laminated with LDPE) recycling is not possible. In such cases incineration is the usual method but it leads to heavy smoke generation resulting in atmospheric pollution.

Panchal Plastics Machinery Pvt. Ltd. have developed fully automatic plastic recycling machine  that process to recycle such waste. The process is ideally suited to Indian conditions and no imports of any type are involved.


Currently the following extruded products are considered feasible: flooring, sheets for architectural uses, e.g., office partitions, roofing – corrugated and  therwise, slats for benches and chairs and generally any extruded sections needing mechanical load bearing capacity similar to aforesaid applications.

The resulting product has mechanical properties intermediate between General Purpose Polystyrene and HIPS.


Basically, the process involves

  • (1-stage) Compaction of the waste  by agglomeration / grinding / shredding followed by extrusion.
  • (2-stage) Dry the granules, mix with the bonding/compatibiliser and other additives.
  • (3-stage) Extrusion into final usable shapes.
  • (4-stage) Lamination for decorative finish.

Plastic Recycling Business Plan in Detail

Stage:1 Sorting the Plastic

Plastic waste needs to be collected by the recycling company, once the plastic arrives at the recycling plant the first stage begins to sort the plastic into the specific types.

In this methods sorting plastic waste into different categories before going to the next stage in the recycling process.

Stage:2 Grinding the Plastic

The shredding stage is when plastic waste is taken and loaded onto conveyor belts or directly into huge hoppers that funnel the clean scrap towards rotating metal teeth that rip the plastic into small pellets which are bagged up afterwards ready for testing.

Stage:3 Washing of Waste Plastic

Washing Waste Plastic Once plastic waste has been identified and separated into one of its many forms the cleaning process can begin, this usually starts with washing to remove paper labels, adhesives and other impurities.

All the labels on your plastic containers, bottles and even your wheelie bin need to be completely removed as these will lower the quality of the finished recycled plastic.

Stage:4 Drying the Plastic

Washed Plastic waste processing into dryer machine for drying the material.

Stage:5 Making Granules

This is the final stage in the recycling process of plastic. This process involves making granules from grinded material.

Granules are used in reprocessing or sell in the market for good price.

Depending upon the application and type of waste a filler or other additives may be added in stage (2-stage) along with bonding/compatibiliser.

Use of a compatibilizer and the control of process parameters is the key to the successful operation of the technology. The compatibilizer has also been developed indigenously and this has kept the cost of the whole process low.

Due to the presence of all kinds of inks in the PET/PE film laminate waste available from conversion industry, the final colour of the product from this reprocessed material islikely to be dark (e.g., dark green/grey/black). Some further colour variation may be brought about by the presence of metallised film in the waste.

Major pieces of machinery are listed below:

  • Shredder / Agglomerator / Grinder Machine
  • Dryer
  • Mixer/Blender
  • Extruder (profile/sheet)

By Hemant Kumar

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