Revolutionizing Film Recycling for a Global Plastic Recycler

Challenge:
A leading plastic recycling enterprise faced critical bottlenecks in its film pelletizing line: inconsistent plasticizing and subpar production capacity. These issues resulted in unstable quality of recycled pellets, preventing access to premium markets and undermining profitability. The thin, variable nature of recycled film further complicated uniform melting—a common industry pain point.

Innovative Solution:
Avian Solutions engineered a bespoke single-screw extruder, integrating two groundbreaking modifications:

1. Patented Flight Geometry: Asymmetric screw flights enhanced shear distribution, eliminating localized overheating and achieving homogeneous melt.

2. Optimized L/D Ratio: Extended to 32:1 (from industry-standard 28:1), this design prolonged material residence time, ensuring complete polymer fusion while boosting throughput.

Transformational Results:

• ↑ 30% Production Surge: Output scaled from 800 kg/h to 1,040 kg/h, slashing energy-per-unit costs by 18%.

• Quality Leap: Melt Flow Index (MFI) variance tightened by 60%, enabling the production of ISO 9001-certified pellets.

• Market Expansion: Entry into high-end sectors (automotive, medical packaging) with 40% premium pricing, elevating annual revenue by €2.3M.

• Sustainability Win: Annual film waste diversion increased by 12,000 tonnes—equivalent to 480 million single-use bags.

Technical Edge:
The screw’s micro-grooved feed zone prevented film slippage—a notorious challenge with low-bulk-density materials. Concurrently, its multi-stage compression profile expelled entrapped volatiles, reducing gel formation by 75% and enhancing pellet clarity. Post-installation spectral analysis confirmed contaminant dispersion within 0.5% tolerance, surpassing EU REACH standards.

Legacy Impact:
This project cemented the recycler’s position as a circular economy pioneer, attracting ESG investments and setting new benchmarks for closed-loop film recovery. Avian’s solution exemplifies how precision engineering can convert recycling hurdles into competitive advantages.