Washed film scrap that contains 50% moisture usually spells trouble for conventional “shredder-extruder” recycling lines—think steam spikes, wasted energy, and brittle pellets. Genius Machinery’s new squeeze-dry pelletizing line turns that headache into a single, ultra-compact, energy-saving step. Users report up to 30% lower energy per kilogram and a 40% shorter line length, all while producing high-grade pellets. (Squeeze-dry technology patented in Taiwan.)
To see precisely how Genius eliminates those headaches, we first need to understand why wet film is so challenging.
Key takeaway: Removing water before melting is the fastest route to lower OPEX and better pellet properties.
With the challenge now clear, let’s examine how Genius tackles moisture and low bulk density in a single stroke.
| Core Module | What It Does | Benefit to You |
|---|---|---|
| Mechanical Squeeze Dryer | Compresses wet flakes & film, forcing out free water to ≤3 % before melting. | ≈ 30 % energy savings |
| Inline Pelletizer & Centrifugal Dryer | Cuts and surface-dries pellets without extra conveyors. | Ultra-compact footprint |
| Smart PLC & Cloud Dashboard |
Tracks OEE and energy consumption (kWh/kg); predictive alarms flag drift. CO₂e tracking and ESG reporting available as an optional upgrade. |
Data-driven maintenance & ESG reporting |
Understanding the principles is useful, but dimensions and hard numbers turn theory into a purchasing decision.
| Parameter | Value | Notes |
|---|---|---|
| Throughput | 300 – 1000 kg/h | LDPE/LLDPE film, ≤ 50 % incoming moisture |
| Specific Energy | ≈ 0.27 kWh/kg | Internal test, washed LDPE |
| Line Length | ≈ 14 m | Fits most brownfield bays |
| Power Supply | 220 – 480 V, 50/60 Hz | Global-ready electrical package |
| Control System | Siemens PLC + cloud gateway with programming, data logging, and error tracking | Live OEE and torque dashboard; CO₂e tracking available as an optional upgrade |
| Optional Upgrades | Upgradable to Self-Cleaning Filter, Metal Detector, inline bagger | Ideal for ink-heavy or highly contaminated streams. (Explore: Self-Cleaning Filter by Genius Machinery) |
Read more : 6 Factors to Consider When Choosing Melt Filters for Plastic Recycling Extrusion Machines
Specs look promising, but how does the line stack up against mainstream alternatives?
(PLC)
| Key Metric | Genius | Shredder-Extruder (Friction-Dry) System | Cutter-Compactor Extrusion Line |
|---|---|---|---|
| Dedicated mechanical dryer | Yes | No | No |
| Energy (kWh/kg, washed LDPE) | ≈ 0.27 | 0.35 – 0.40* | 0.34 – 0.38* |
| Line footprint (12 t/month) | ≈ 14 m | ≈ 23 m | ≈ 22 m |
| Ideal feedstock focus | High-moisture post-consumer film | Dry production scrap | Mixed scrap / rigid |
*Published ranges; no dedicated mechanical dewatering unit.
(Dryer)
All that value begs the next question: how quickly does the investment pay for itself?
| Variable | Example Value |
|---|---|
| Line throughput | 600 kg/h |
| Operating shifts | 2 × 8 h, 300 days/year |
| Energy cost | US$ 0.15/kWh |
| Energy saved vs. compactor line | 0.08 kWh/kg |
| Annual energy savings | US$ 34,560 |
| Estimated CAPEX | US$ 900,000 |
| Payback period | < 18 months |
(Assumes washed LDPE film; excludes resin margin uplift.)
If those numbers resonate, the logical next step is to validate them with your own material.
Turn wet film into dry profit—contact our experts to discuss your scrap mix, energy targets, and layout constraints. We’ll craft a customised payback plan around the squeeze-dry pelletizing line. Prefer to explore the specs first? Download the full product catalog for complete data and layout drawings.
Meet us live at K 2025 – Hall 15 / Stand H12 A15, or book a virtual demo today.
