LR pelletising lines

Linia do regranulacji plastuku odpadów przemysłowych SMART EKOCHEM

Optimised for the processing of plastics

LDPE

LLDPE

HDPE

EPS

The LR Line enables efficient processing of clean, homogeneous production waste and film without the need for pre-agglomeration. This solution allows for quick return of raw material to the technological process, increased control over regranulate quality and optimisation of operating costs. The LR Line supports rational plastic management, reduces material losses and is a practical tool for implementing a sustainable production strategy in processing plants.

Specific Energy Consumption

0,38

kWh/kg

Lower unit production cost

25-30%

PLN/kg

VOC reduction via a specially designed degassing zone

by 40%

Consistency of process parameters

>95-99

Improved geometry of the plasticising system guarantees increased efficiency

>30

Energy efficiency

Production efficiency

Granulate quality

Automation

Economic and environmental aspects

PE waste products

Agglomerates

PP filament

Wires and cables

PP injection-moulded parts

Foils

Agglomerates

PVC Recycling

Bulk Bags

EPS

LR line key data

70–90% high automation level

The high automation level of the LR line (up to 90%) significantly reduces manual labour, thereby minimising the human error factor and providing stability to the entire pelletising process. Automatic control over the key stages of the production process ensures consistent quality parameters of the granulated product, reduces response time to process changes, and lowers the unit production cost (PLN/kg). This results in higher predictability, lower need for manpower, and increased operational efficiency.

100% dedicated support

Each instance of LR line installation comes with tailored and comprehensive support from Ekochem. Each customer is appointed a dedicated account manager who becomes responsible for the order from its acceptance until each problem is fully solved. This cooperation model reduces the response time, facilitates communication, and ensures continuity of production. This is no mere technical support, but a real partnership whose goal is to ensure a stable and efficient operation of a pelletising line.

Each 1 kg closed-loop material cycle

Our LR line fully supports the implementation of a closed-loop material cycle at a production facility. Each kilogram of post-production waste may be efficiently recycled and reused with zero material loss and no additional waste generation. The results include lower costs of virgin material and disposal, as well as meeting the requirements of sustainable development and the ‘Zero Waste’ policy.

Twice the service life of the components

Components that are prone to fast wear and tear feature an improved design enabling operation in demanding industrial conditions. Their service life is up to twice as long as the standard ones, substantially reducing the replacement intervals and minimising unplanned downtime. Longer service life of components translates into lower running costs, higher line availability, and a stable, uninterrupted production process.

The numeric and financial data presented above have been calculated based on average industry values for the LR machine option.

Parts/additional components

HEADS

They come in two variants – water-ring die head and air-ring die head.

CONVEYOR BELT

Suitable for conveying agglomerates of cut film, agglomerated film sheets, or waste to the shredder hopper.

GRANULATE TRANSPORTING SYSTEM

Featuring an automatic material feeding, a material quantity sensor, and a dust removal system.

METAL DETECTOR

Prevents unwanted metal parts from entering the crusher or extruder.

🔧 LR Line modules and configurations

LR Pellet™ – the pelletising system is available in water or air versions, selected according to the type of material being processed and the expected pellet quality. It ensures uniform shape, high repeatability of parameters and stable operation under variable production loads. The result is a commercial-quality finished product without additional processing.

LR RollFeed™ – automatic dosing system for clean production waste and post-production film. It guarantees smooth, controlled feeding to the extruder, eliminating performance spikes and the risk of jams. Stable feed means stable process – and that translates into quality and energy savings.

LR CompactLift™ – A conveyor module designed for loose, lightweight film and regrind fractions. It minimises manual labour, improves ergonomics and increases workplace safety. The ideal solution for companies looking to increase productivity without expanding their team.

LR ScreenPro™ – A filtration system that ensures effective material cleaning even with variable feed quality. It stabilises granulate parameters, reduces the risk of defects and protects key extruder components. This guarantees consistent quality across production batches.

LR Degas™ – A degassing module that supports the processing of printed, moist or volatile materials. It reduces odours and improves the mechanical properties of granules, increasing their market value.

LR Monitor™ – A set of sensors that monitor key line operating parameters in real time. The system detects deviations early on and supports the operator in maintaining optimal settings. Less downtime, less material waste, greater production predictability.

LR Control+™ – An advanced line management system with an intuitive operator panel. It enables quick recipe changes, saving settings for different materials, and remote service diagnostics. This provides full control over the process and quick response without interrupting production.

Characteristic features of the LR line:

01

New generation compactor improving compaction efficiency by at least 30%

02

Sound insulation thanks to applying protective covers, ensuring a more hygienic and safer operation

03

Heat recovery and its use in the following stages

04

Automatic compactor gate valve

05

Efficient extraction of steam from the compactor

06

Dual temperature control system for the plasticising unit

07

Dual-stage vacuum degassing system

08

Automatic filtration of plastic material

09

Drives with the IE5 ultra-premium efficiency class

A complimentary and non-binding consultation is the first step in optimising your production process.
We answer each and every question and show the best course of action.

Frequently Asked Questions

What are your filtration systems and output, and how many kilograms of granulate per hour can be produced?

The LR lines are equipped with various types of filtration systems (single- and dual-piston, plate or self-cleaning) depending on the contamination level of the material. The output depends on the configuration and the type of processed material. Our standard lines achieve the output of approx. 60 to 2000 kg/h of granulate.

Are your lines compliant with the CE standards?

Yes, all our production lines meet the requirements of EU directives and have CE marking. Each machine is delivered with a declaration of conformity, full technical documentation, and an operation manual.

How about maintenance, availability of spare parts, and response time in Poland?

We offer both warranty and post-warranty maintenance throughout Poland. We have a spare parts depot in Poland, and a typical response time is 24-48 hours after receiving a notification. This is how we ensure our client’s production continuity.

What is the output capacity of your pelletising lines (e.g., stationary, cascade)?

Our pelletising lines, both stationary and cascade, offer the output capacity of approx. 60 kg/h in laboratory/pilot lines, and up to 2000 kg/h in industrial lines. Precise values depend on the type of material used, screw configuration, filtration system, and the method of pelletising.

Do you provide FAT/SAT testing and operator training?

Yes, each line undergoes FAT tests at our production facility and SAT tests at our customers’ facilities. We also provide full training for operators and the maintenance department, ensuring a machine is immediately ready for safe and efficient operation.

What is the delivery time?

Precise production and delivery dates are determined individually after the machine specifications have been approved. Please contact our technical and sales departments to estimate the lead time.

What are the installation requirements and turnkey layout options?

The line requires electric power, access to cooling water, and compressed air. We offer comprehensive turnkey solutions, from plant layout design, machine delivery and assembly, to staff training and handover of the CE documentation.

Is there any protection against foreign objects in the plasticising system, and if yes, what type is it?

Yes, our lines are equipped with mechanical and electronic protection against foreign objects. These include: metal separators, torque overload detectors, and mesh screen filters. They minimise the risk of damaging the screw and the cylinder.

What input material contamination and moisture levels can be handled by each configuration?

Standard lines handle clean regrind and dry foil. For moist materials or printed foil, we use vacuum degassing systems. For heavily contaminated and highly-moistened foils (e.g., agricultural or post-consumer foils), we use cascade lines with self-cleaning systems and multi-stage degassing.

Can you design a custom pelletising line?

Of course. We design turnkey lines which meet the specific needs of our clients. We analyse the type of material, efficiency, quality requirements, and plant conditions to design a dedicated layout and machine configuration.

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