Mexico Case | KiTech PE Film Compactor Pelletizing Machine
How RAC in Mexico Improved PE Film Recycling with KiTech
For manufacturers that rely on recycled polyethylene, rising recycled resin prices can directly affect production costs. One practical solution is to recover suitable plastic waste in-house and convert it into reusable pellets.
This was the challenge faced by RAC, a Mexican manufacturer of agricultural irrigation products. The company uses recycled LDPE to produce drip tape, but increasing recycled LDPE prices encouraged RAC to develop a more efficient internal recycling process.
To meet this need, RAC partnered with KiTech Machinery to install an integrated recycling system featuring an AGF Series grinding machine and KCP Series PE film compactor pelletizing machine.
The new system is designed to process post-industrial LDPE and HDPE film at approximately 300–350 kg/h, helping RAC improve recycling efficiency while reducing manual labor.
1. RAC's PE Film Recycling Challenge
RAC is a family-owned Mexican company specializing in irrigation products such as sprinklers, micro-sprinklers, and drip irrigation systems. With 13 distribution centers across central and southern Mexico, the company has a consistent demand for recycled LDPE in drip tape production.
Previously, RAC used a second-hand single-screw pelletizer to process PE film. However, the system required several manual preparation steps, including pre-shredding and densification.
Because loose PE film has a low bulk density, feeding it efficiently into a conventional pelletizer can be difficult. RAC's previous process achieved only around 1,000 kg/day, which was not sufficient to support its growing recycling requirements.
The company therefore needed more than a conventional pelletizer. It needed a plastic pelletizing line that could efficiently prepare lightweight film, stabilize feeding, and produce consistent recycled pellets.
2. KiTech's Customized Recycling Solution
KiTech Machinery and RAC had maintained technical discussions for several years, including communication at PLASTIMAGEN Mexico.
In March 2025, RAC confirmed a complete recycling system designed specifically for its post-industrial LDPE film and HDPE rigid flakes.
The process includes:
PE Film → Crushing → Cutter Compaction → Extrusion → Filtration → Water-Ring Pelletizing → Recycled Pellets
The complete system combines an AGF Series grinding machine with a KCP Series PE film compactor pelletizing machine.
This configuration allows RAC to prepare the film and pelletize it through a more integrated production process, reducing the manual preparation required by its previous equipment.
3. How the PE Film Compactor Pelletizing Machine Works
3.1:Crushing for Better Material Preparation
The AGF Series crushing machine reduces large PE film pieces into smaller pieces before pelletizing.
This creates a more manageable feedstock and improves feeding stability for the downstream recycling process.
3.2:Compaction for Stable Extrusion
The KCP Series cutter compactor is the core of the PE film compactor pelletizing machine.
Loose PE film takes up considerable space because of its low bulk density. The cutter compactor cuts and densifies the material before extrusion, making it easier to feed continuously.
This process is particularly suitable for flexible materials such as LDPE film and HDPE rigid flakes.
3.3:Extrusion, Filtration and Pelletizing
After compaction, the material enters the extruder for melting and homogenization. The molten plastic then passes through the filtration system before being processed by the water-ring pelletizing unit.
The final output is recycled PE pellets that can be collected and returned to RAC's manufacturing process.
This makes the system more than a conventional plastic film pelletizing machine. It connects waste preparation, extrusion, filtration, and pellet production into one recycling workflow.
4. Automation Reduces Manual Work
Another important part of the KiTech system is automated operation.
The equipment includes features such as:
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One-touch operation
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Real-time alarm monitoring
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Parameter memory
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Automated process control
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Reduced manual intervention
These functions simplify daily operation and reduce the amount of routine manual handling required.
For RAC, this was particularly valuable because manual preparation had been one of the main limitations of its previous recycling process.
5. Results: Higher Efficiency and Lower Labor Costs
After adopting the KiTech recycling system, RAC established an internal recycling loop for suitable PE film waste.
The company reported several improvements:
5.1:3× Higher Recycling Efficiency
RAC achieved approximately 3× higher recycling efficiency compared with its previous recycling approach.
The improvement was supported by the integrated grinding, compaction, extrusion, and pelletizing process.
5.2:40% Lower Labor Costs
The new system also contributed to an approximately 40% reduction in labor costs by reducing manual material preparation and handling.
5.3:Consistent Recycled Pellet Quality
The integrated process provides RAC with more consistent recycled pellets for its drip tape production.
For manufacturers using recycled material internally, consistent pellet quality is important for maintaining stable downstream processing.
5.4:A More Efficient Internal Recycling Loop
RAC can now convert suitable PE film waste into recycled LDPE pellets and return the material to its manufacturing process.
This reduces dependence on externally purchased recycled LDPE and creates a more direct material recovery route.
6. Why This Project Matters for PE Film Recycling
RAC's experience shows that successful PE film recycling is not simply about choosing a higher-capacity extruder.
Flexible film presents specific challenges because of its low density and feeding characteristics.
A suitable PE film compactor pelletizing machine should therefore be evaluated according to the complete process, including:
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Feedstock type
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Film bulk density
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Contamination level
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Required capacity
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Feeding stability
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Filtration requirements
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Final pellet application
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Labor requirements
For manufacturers that both generate PE film waste and consume recycled polyethylene, an integrated plastic pelletizing line can provide a practical route to recover material and improve production economics.
7. KiTech's Approach to Customer-Specific Recycling
The RAC project was developed through long-term technical communication rather than a standard equipment transaction.
KiTech evaluated RAC's material characteristics, production requirements, and final application before configuring the recycling system.
KiTech also provided flexible payment support and technical guidance during the project, supporting the company's long-term cooperation with customers in the Latin American market.
This customer-specific approach is important because PE recycling requirements vary significantly between manufacturers.
The right plastic film pelletizing machine depends on the actual feedstock and the quality requirements of the recycled pellets.
8.Conclusion
RAC's project in Mexico demonstrates how an integrated recycling process can turn PE film waste into a usable manufacturing resource.
By replacing a labor-intensive recycling workflow with a KiTech PE film compactor pelletizing machine system, RAC achieved approximately 3× higher recycling efficiency and 40% lower labor costs, while establishing an internal route for recovering PE film into reusable recycled pellets.
For manufacturers looking to reduce dependence on purchased recycled resin and improve the value of their plastic waste, a properly configured plastic pelletizing line can become an important part of their production strategy.
KiTech Machinery provides customized plastic recycling and pelletizing solutions for PE film, HDPE, PP, and other recyclable plastics.
If you are planning a PE film recycling project, contact KiTech with your material type, capacity requirement, and final application to discuss a suitable plastic film pelletizing machine configuration.