PP Plastic Container Recycling Project | Customized Washing Line with 99% Silicone Separation

Helping a Customer Produce Higher-Purity PP Flakes Through Customized Recycling Technology

Every recycling project begins with a different challenge.

For one of our recent international customers, the objective was not simply to recycle PP plastic containers—it was to produce recycled PP flakes clean enough for higher-value applications while keeping long-term operating costs under control.

The raw materials consisted of various post-consumer PP containers, many of which contained silicone stoppers and sealing components. These contaminants are difficult to remove using conventional washing systems and can significantly reduce the quality and market value of recycled PP flakes.

After evaluating the customer's raw materials, production targets, factory layout, and investment plan, RAYFON developed a customized PP plastic container recycling solution designed specifically for this application.

Understanding the Customer's Recycling Challenge

Unlike standard PP bottles or rigid packaging, these plastic containers included silicone accessories that remained mixed with the crushed plastic after shredding.

If silicone particles enter the final product, they may cause processing defects during pelletizing or injection molding, reducing product consistency and customer acceptance.

At the same time, the customer also wanted to reduce electricity consumption without sacrificing production efficiency.

Instead of simply recommending a larger production line, our engineering team focused on solving two key issues:

· Achieving exceptionally high material purity.

· Lowering long-term operating costs through energy-efficient equipment.

These objectives became the foundation of the entire process design.

A Process Designed Around Material Quality

The complete recycling line includes:

· Trommel Screen

· PP Plastic Crusher

· High-Speed Friction Washer

· Two Washing Tanks

· Two High-Speed Dewatering Machines

· Silicone Separator

Rather than increasing equipment quantity unnecessarily, every machine was selected to solve a specific problem during the recycling process.

The result is a stable production line capable of producing cleaner recycled PP flakes with higher processing efficiency.

Better Recycling Starts with Better Pre-Treatment

Before crushing, incoming materials pass through a Trommel Screen for pre-treatment.

Loose dirt, small stones, dust, and oversized impurities are removed before entering the crusher.

Although this is only the first step, effective pre-treatment reduces unnecessary wear on downstream equipment and creates better conditions for the washing process.

A cleaner input always leads to a cleaner output.

Efficient Washing Is About More Than Water

After size reduction, the PP flakes enter the High-Speed Friction Washer, where mechanical friction continuously removes surface contamination that cannot be eliminated through soaking alone.

The material then passes through two washing tanks, allowing contaminants to be separated progressively rather than in a single stage.

This process improves cleaning efficiency while maintaining stable material flow throughout the production line.

99% Silicone Separation Makes the Difference

The most important part of this project is the Silicone Separator, one of RAYFON's core technologies.

Many PP recycling plants can successfully wash plastic flakes but still struggle to remove silicone components completely.

For applications involving medical packaging, cosmetic containers, laboratory bottles, or specialty packaging, even a small amount of silicone contamination can affect the quality of the recycled material.

To solve this challenge, our independently developed silicone separation system achieves up to 99% separation efficiency, allowing silicone stoppers to be removed with exceptional accuracy.

For the customer, this means:

· Higher-purity PP flakes

· Better consistency during pelletizing

· Improved finished product quality

· Greater market competitiveness

· Higher value for recycled materials

The customer was highly satisfied with the final separation performance, which exceeded expectations for material cleanliness and product consistency.

High-Speed Dewatering That Reduces Energy Costs

Another highlight of this project is the use of two High-Speed Dewatering Machines, one of RAYFON's flagship products.

Operating at speeds of up to 2400 RPM, the system achieves up to 99.5% dewatering efficiency, rapidly removing moisture from the washed PP flakes while maintaining smooth and stable operation.

High dewatering efficiency delivers more than dry material.

It also reduces the energy required during downstream conveying, storage, and pelletizing.

For recycling plants operating continuously, lower moisture translates into:

· Reduced electricity consumption

· Lower operating costs

· Improved production efficiency

· More stable processing

· Faster return on investment

Our goal is not only to maximize production performance but also to help customers reduce the total cost of ownership throughout the life of the recycling plant.

Every Recycling Project Is Designed Around the Customer

No two recycling facilities process exactly the same materials.

Raw material conditions, contamination levels, available factory space, production capacity, and investment budgets all influence the final equipment configuration.

Instead of supplying standardized production lines, RAYFON works closely with every customer to develop a recycling solution that matches their actual operating requirements.

Whether the project involves PP containers, PET bottles, HDPE drums, or mixed rigid plastics, our engineering team designs every recycling line with one objective:

Helping customers produce cleaner recycled plastics with greater efficiency and lower operating costs.

From Engineering Design to Global Delivery

With successful recycling projects delivered across Asia, South America, the Middle East, Africa, and Europe, RAYFON continues to support recyclers worldwide with customized plastic recycling solutions.

Our services cover every stage of the project, including:

· Process engineering

· Plant layout design

· Equipment manufacturing

· Quality inspection

· Container loading

· Installation guidance

· Commissioning

· Operator training

· Long-term after-sales support

Every completed project reflects our commitment to combining practical engineering with reliable equipment performance.

Looking for a Customized PP Plastic Recycling Solution?

If your recycling project involves PP containers, cosmetic packaging, medical plastic containers, industrial packaging, or other rigid plastic waste, our engineering team can help you develop a solution tailored to your materials and production goals.

At RAYFON, we believe the best recycling line is not the one with the most equipment—it's the one engineered to deliver the highest material quality, the lowest operating cost, and the greatest long-term value for your business.