Foam pelletizing machine production line

The foam pelletizing machine production line is a recycling and reuse system specifically designed for waste foam plastics (such as EPS, EPE, XPS, etc.). Through processes such as physical crushing, melt extrusion, and cooling pelletization, it converts waste foam into plastic pellets that can be reprocessed and reused. This production line is widely used in fields such as packaging materials, building insulation, and daily necessities manufacturing. It is a key piece of equipment for achieving a closed-loop circular economy for foam plastics and has significant advantages such as high efficiency, energy saving, and environmental protection.

Core Process Flow of Foam Pelletizing Machine Production Line

Pre-processing stage

• Crushing and cleaning: Waste foam is fed into a crusher via a conveyor belt, where it is cut into small pieces (usually 10-30 mm). The pieces are then cleaned in a washing machine to remove surface dust, oil stains, and other impurities.
• Dehydration and drying: The washed foam pieces are then dehydrated in a centrifugal dehydrator or hot air dryer to remove moisture and ensure the quality of the subsequent melting process.

Melt extrusion stage

• Feeding system: The dried foam blocks are uniformly fed into the extruder hopper via a screw conveyor.
• Melting and Plasticization: The extruder screw rotates to push the material forward while heating the foam to a molten state (temperature approximately 180-220°C) via electric heating or electromagnetic induction heating, ensuring complete plasticization.
• Vapor Removal and Filtration: Volatile substances (such as blowing agents) in the molten material are removed through a vacuum vapor removal system, while impurities are intercepted by a filter screen to ensure particle purity.

Granulation and molding stage

• Water ring pelletizing: After the molten material is extruded from the extruder die head, it immediately enters the water ring pelletizer, where high-speed rotating blades cut the material into uniform pellets (diameter 2-5 mm).
• Cooling and drying: The pellets are rapidly cooled in a cooling water tank, then passed through a centrifugal dehydrator or vibrating screen to remove surface moisture and prevent clumping.

Finished product packaging and storage

• The dried particles are transported to the storage tank via a pneumatic conveying system and finally packaged in specified quantities by an automatic packaging machine for easy transportation and storage.

How the production line works

The foam pelletizing machine production line processes waste foam (such as polystyrene EPS) by first crushing it into small pieces using a shredder. The crushed foam is then conveyed via a conveyor belt into the main machine’s heated barrel. Under high temperatures and the rotational shearing action of the screw, the foam material is uniformly melted and plasticized. Simultaneously, the screw’s advancing and compressing action thoroughly mixes the melt and removes air bubbles. The melt is then extruded through a die head into a strip, rapidly cooled and solidified in a cooling water tank, cut into uniform particles by a pelletizer, and finally separated into qualified particles by a vibrating screen. This completes the closed-loop production process from waste foam to reusable plastic pellets, achieving efficient energy savings, environmental protection, and pollution-free conversion of recycled resources throughout the entire process.

Technical Advantages and Innovation

high efficiency and energy saving

• Optimized screw design reduces energy consumption by 20%-30%;
• Equipped with a waste heat recovery device to utilize waste heat from the melting process to preheat raw materials.

environmental performance

• Fully enclosed production process to reduce dust and volatile organic compound (VOC) emissions;
• Wastewater recycling system to reduce water consumption.

Intelligent control

• The PLC control system monitors parameters such as temperature, pressure, and speed in real time and automatically adjusts process conditions.
• The fault warning function reduces downtime and improves production stability.

product diversification

• By replacing the die head and pelletizing knife, pellets of different specifications can be produced to meet the needs of different industries.

Application scope of foam pelletizing machine production line

Foam pelletizing machine production lines have a wide range of applications, primarily targeting the recycling and reuse of waste foam plastics such as polystyrene (EPS), polyethylene (PE), polypropylene (PP), and other foam products. The machine processes foam waste through crushing, heating and melting, and extrusion granulation, converting it into granular raw material that can be reused in the production of plastic products. It is widely used in the production of insulation panels, building decoration materials, packaging products (such as pallets and cushioning materials), household items (such as stationery and toy casings), as well as plastic pipes and profiles. This effectively achieves resource recycling, reduces production costs, and minimizes environmental pollution, making it a critical piece of equipment in the foam recycling industry and plastic regeneration manufacturing sector.

• Construction: Insulation boards, lightweight concrete additives.
• Packaging: Cushioning materials, void fillers.
• Consumer goods: Stationery, toys, flower pots.
• Automotive: Soundproofing components, interior trim.
• Textiles: Synthetic fibers for carpets and interior decoration.

The foam pelletizing machine production line is not only the core equipment for the recycling of waste foam resources, but also an important force driving the green transformation of the plastics industry. Through technological innovation and intelligent upgrades, this production line is providing strong technical support for the global circular economy and sustainable development.