Custom Plastic Waste Recycling Plant

XTG, a U.S.-based company, required an efficient recycling system for relatively clean post-industrial plastics such as turnover boxes, trash bins, and pallets. The priority was to recover material while preserving its mechanical properties and keeping operating costs under control. At the same time, they needed to process PP wood-plastic composite (WPC) flooring scrap. This material presented additional challenges of irregular shapes, large volume, dust generation during shredding, and the risk of heat-induced sticking caused by friction.

In 2020, after on-site evaluation in Georgia, HS Machinery customized two recycling systems for XTG. The first system focused on crushing and screening relatively clean rigid plastics such as crates, bins, and pallets. The line included a double-shaft plastic shredder for primary size reduction, a crusher for secondary crushing and a vibrating screen for physical separation. The final output consisted of 8 to11 mm regrind. As the material was processed through crushing and screening only without remelting, the polymer molecular structure remained largely unchanged. Melt flow rate (MFR) stayed stable, and the original material properties were retained.

In 2022, XTG purchased an additional system for PP wood-plastic composite flooring waste. Due to the material’s irregular strips and dust-prone behavior, HS designed a dedicated solution:

• A low-speed, high-torque single-shaft shredder for initial size reduction. The low-shear cutting principle minimizes dust and prevents frictional overheating or sticking.
• A crusher to further process the shredded material into uniform flakes.
• A counter-rotating twin-screw three-stage pelletizing line to complete melting, filtration, pressure stabilization, and pellet formation. The three-stage design supports the more complex formulation requirements of WPC materials.

After 180 days covering manufacturing, shipment, and commissioning, the system was successfully installed and reached a stable output of 500 kg per hour. The production capacity aligned with the operational targets and scheduling needs of XTG. The project enabled efficient recycling while maintaining mechanical performance, and it provided a scalable reference model for rigid plastic and WPC recycling applications.

• Material collection
• Primary shredding
• Secondary crushing
• Melt extrusion
• Two-stage high-precision filtration
• Cooling and pelletizing
• Pellet packaging