As with other industrial plastics, the recycling process begins with proper collection. Recyclers require that the material be compacted into bales for easy collection and optimal market value. FIBCs are collected in large quantities, so recycling is usually feasible only for businesses with a sizeable output, or ones that can store the bags over time.
After collecting them, recyclers take the mill-sized bales to a reprocessing center, where they are sorted and cleaned. As they are commonly used to transport a variety of materials, including fertilizers and chemicals, bulk bags must be thoroughly decontaminated before being recycled. All zips and buttons are also removed.
Next, the bags are resized into small flakes, making them easier to handle for further processing. The plastic is fed through shredders and granulators with industrial blades that cut rotationally to chop it down.
After cutting, the plastic regrinds go through a separation process to differentiate contaminants from the plastic polymers. With today's advanced technology, machines can separate plastic by size, shape, color, melting point, and even the ability to absorb light.
The final phase is compounding, which involves putting the regrinds through an extruder, where they are melted down at 240 degrees Celsius into uniform beads, also referred to as pellets or granules. The mixture is strengthened through the addition of virgin polypropylene.
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