From Aging European Equipment to High-Value Recycling: How KITECH Plastic Film Pelletizing Machine Helped a Russian Packaging Company Achieve 500 kg/h Output

Introduction

In the Moscow region of Russia, a packaging manufacturer with nearly 30 years of experience in blown film production faced a major challenge: its aging European recycling systems were no longer able to support growing production demands and increasingly strict quality requirements.

For many years, the company had relied on European-brand recycling equipment to process internal film waste generated during its blown film and packaging production. However, as production capacity expanded, two existing recycling lines—a system purchased from an Italian manufacturer in 2008 and an Austrian brand installed in 2012—began to experience limitations in processing capacity, maintenance efficiency, and operational flexibility.

The company was producing more than 300 tons of internal film scrap every month. However, the existing recycling lines, with a maximum output of approximately 250 kg/h, struggled to keep pace with waste generation. Frequent maintenance requirements, high spare parts costs, and long service cycles created increasing pressure on production stability.

After 18 months of technical discussions, factory visits, solution optimization, and supplier comparisons, the customer finally selected KITECH Machinery’s KCP120 single-stage compacting pelletizing system over several well-known domestic and international suppliers.

This project was not simply an equipment replacement. It represented a strategic upgrade from maintaining aging machinery to investing in a high-performance plastic film pelletizing machine solution designed for higher efficiency, improved pellet quality, and long-term production reliability.

With KITECH’s customized recycling technology, the customer achieved a stable output of 400–500 kg/h, transforming internal waste film into high-quality recycled pellets through a complete recycling process. The project demonstrates how advanced plastic film pelletizing machine technology can help packaging manufacturers reduce waste, improve resource utilization, and establish a sustainable closed-loop recycling model.

I. Client Background: A Russian Packaging Company with Nearly 30 Years of Blown Film Experience

Founded in 1997, the customer is a large-scale packaging manufacturer located in the Moscow region of Russia, specializing in blown film production, printed packaging materials, and bag manufacturing.

After nearly three decades of development, the company has established a complete production system covering film blowing, printing, and bag conversion. Its main production equipment includes Macchi blown film machines, Chinese blown film equipment, Contec bag making machines, and Soma printing systems.

With its stable production scale, the company generates significant quantities of internal plastic film scrap every year. Instead of treating these materials as waste, the company has continuously invested in recycling technology to create an internal circular production model:

Production → Waste Generation → Recycling → Reprocessing → Production

The company’s recycling goal is to convert clean production waste into reusable recycled pellets that can be returned directly into blown film manufacturing.

Because the materials mainly come from clean LDPE and LLDPE film production waste, the customer required a reliable pe film recycling machine capable of processing flexible plastic materials while maintaining stable output and consistent recycled pellet quality.

Unlike ordinary waste processing systems, the customer was looking for a complete recycling solution that could combine efficient plasticizing, precise filtration, automated operation, and long-term production stability.

II. Customer Pain Points: How Aging European Equipment Limited Recycling Development

Before cooperating with KITECH, the customer mainly depended on two European recycling systems:

• The first recycling line was purchased from an Italian manufacturer in 2008, with an output capacity of approximately 150–200 kg/h.
• The second recycling system was acquired from Austrian brand  in 2012, with an output capacity of approximately 250 kg/h.

Although these machines had provided reliable service during their early operating years, increasing production requirements exposed several limitations.

Pain Point 1: Insufficient Recycling Capacity

The customer was generating more than 300 tons of internal film scrap every month. However, the existing equipment could no longer efficiently handle the increasing recycling volume.

A capacity of around 250 kg/h meant the customer needed extended operating hours to process monthly waste generation. Any unexpected downtime immediately created material accumulation and production pressure.

The customer needed an upgraded plastic film pelletizing machine that could significantly increase throughput while maintaining high-quality recycled pellets for reuse in blown film production.

Pain Point 2: Aging Equipment and Rising Maintenance Costs

After more than ten years of continuous operation, the existing European recycling equipment entered a stage where key components required increasingly frequent maintenance.

Spare parts were expensive and often required long international transportation periods, creating uncertainty in daily production planning.

For the customer, the challenge was no longer simply improving recycling output—it was reducing production risks caused by equipment aging.

A modern plastic pelletizing equipment solution needed to provide higher reliability, easier maintenance, and better long-term operating efficiency.

Pain Point 3: Factory Space Limitations and Installation Challenges

The customer’s new production project had strict limitations regarding available installation space and factory height.

Traditional recycling equipment layouts often require long linear installation areas, which were difficult to implement within the customer’s facility.

Therefore, the new recycling system required not only advanced processing performance but also customized engineering support.

The customer needed a compact pe film recycling machine configuration that could maximize available factory space while ensuring convenient operation and maintenance access.

Pain Point 4: Higher Standards for Recycled Pellet Quality

Because recycled pellets would be reused in blown film and packaging applications, the customer had increasingly strict requirements for:

• Pellet cleanliness
• Material consistency
• Filtration precision
• Automation level

The previous equipment had limitations in melt filtration performance and production automation, making it difficult to achieve the quality standards required for modern packaging production.

The upgraded recycling solution needed to deliver:

• Stable plasticization
• Efficient impurity removal
• Uniform pellet size
• Continuous automated operation

These requirements became the foundation for KITECH’s customized plastic film pelletizing machine solution.

III. Material Characteristics and Processing Requirements: Building a Closed-Loop Recycling System for 300 Tons/Month of Film Waste

The materials recycled by the customer mainly come from internal production waste generated during the blown film manufacturing process, including:

• LDPE film
• LLDPE film
• HDPE film
• Printed film materials

Compared with post-consumer plastic waste, these production scraps have significant advantages: stable sources, consistent material properties, and relatively high cleanliness. These characteristics make them ideal feedstock for producing high-quality recycled pellets.

The customer’s objective was straightforward: to convert production waste film into reusable plastic granules through a complete recycling process including feeding, densifying, plasticizing, filtration, pelletizing, and drying.

The recycled pellets would then be returned directly to the blown film production line, creating a complete internal recycling loop:

Waste Film → Recycling → High-Quality Recycled Pellets → New Film Production

To achieve this goal, the customer required a professional pe film recycling machine capable of handling different types of polyethylene film waste while maintaining stable production performance.

Unlike conventional recycling systems that focus only on waste reduction, this project required a complete plastic film pelletizing machine solution that could achieve:

• High processing efficiency
• Stable melt quality
• Precise impurity removal
• Consistent pellet performance

The final objective was not simply recycling plastic waste, but creating a reliable production resource through advanced plastic pelletizing equipment technology.

IV. KITECH Solution: Achieving 500 kg/h Performance Through KCP120 Technology and Advanced Filtration

Based on the customer’s key requirements—including processing more than 300 tons of waste film per month, limited factory space, and high automation expectations—KITECH did not recommend a standard recycling machine.

Instead, the engineering team conducted a detailed analysis of:

• Raw material characteristics
• Production volume
• Pellet application requirements
• Factory installation conditions

Based on this evaluation, KITECH developed a customized recycling solution centered around the KCP120 single-stage densifying pelletizing system.

The complete solution integrated:

• High-efficiency densifying and plasticizing technology
• Advanced self-cleaning laser filtration
• Customized compact layout design
• Intelligent automation control

This combination created a high-performance plastic film pelletizing machine system specifically designed for clean industrial film recycling applications.

1. High-Efficiency Agglomeration System: Improving Output and Pellet Quality

The KITECH KCP120 agglomeration system is designed for processing a wide range of flexible plastic materials, including:

• PE film
• PP woven bags
• Ton bags
• BOPP film

It is compatible with multiple material sources, including:

• Virgin materials
• Production scraps
• Recycled materials
• Crushed plastic waste

This flexibility allows customers to process different batches of film waste without major adjustments.

Through optimized screw and barrel design, the KCP120 improves material plasticization efficiency and ensures more stable melt quality.

Compared with traditional recycling systems, the optimized design provides:

• Higher output efficiency
• More complete melting performance
• Better impurity distribution control
• Improved pellet consistency

The final recycled pellets feature:

• Uniform particle size
• Smooth surface appearance
• High density
• Reduced internal bubbles
• Stable processing performance

For manufacturers seeking to upgrade their recycling capability, this advanced plastic film pelletizing machine provides a practical balance between productivity, pellet quality, and operating reliability.

The equipment is also designed for continuous 24-hour operation. Its improved sealing structure helps reduce dust, noise, and material leakage, while comprehensive safety protection systems support stable industrial production.

As a complete plastic pelletizing equipment solution, the KCP120 enables manufacturers to move from basic waste handling toward higher-value plastic recycling.

2. Self-Cleaning Laser Filtration System: Ensuring High Purity and Continuous Operation

For film recycling applications, filtration performance directly determines the quality and usability of recycled pellets.

Because the customer’s waste film included printed materials, potential ink contamination and fine impurities could affect final pellet quality. To address this challenge, KITECH configured a self-cleaning laser filtration system as the primary filtration solution, supported by a plate filtration system as backup.

The laser filtration system provides several key advantages:

 >High-Precision Melt Filtration

With filtration accuracy of up to 200 mesh, the system effectively removes fine contaminants from molten plastic, improving the purity of recycled material.

This is especially important for a pe film recycling machine processing clean production scraps where pellet consistency is critical.

>Lower Material Loss

The system maintains a material loss rate of only 1%–3%, helping customers maximize raw material utilization and reduce unnecessary waste.

>High Processing Capability

With a maximum capacity of 2.5 tons/hour, the filtration system provides sufficient performance for large-scale recycling operations.

>Reduced Downtime

The filter screen lifespan can reach approximately 2–6 months depending on material conditions, while replacement requires only 30–40 minutes.

>Automated Operation

The self-cleaning function reduces manual intervention, lowers labor requirements, and improves overall production efficiency.

As a backup solution, KITECH also equipped a plate filtration system featuring:

• Ceramic heating belt for precise temperature control
• GEFRAN® pressure sensor for automatic filter replacement reminders

The combined filtration configuration:

Self-cleaning laser filtration + backup plate filtration

provides continuous production security and ensures stable recycled pellet quality.

Together with the KCP120 system, this advanced plastic pelletizing equipment configuration allows the customer to achieve cleaner, more consistent recycled pellets for blown film applications.

3. Customized Compact Layout: Solving Factory Space Restrictions with an L-Shaped Design

One of the biggest challenges of this project was the customer’s limited installation space.

Traditional recycling systems usually require large linear layouts, which were unsuitable for the customer’s factory environment.

To solve this problem, KITECH’s engineering team performed multiple rounds of layout optimization, completing 5–6 design revisions before finalizing the customized L-shaped configuration.

The optimized design achieved:

• Reduced installation height
• Better utilization of factory space
• Convenient operator access
• Easier maintenance procedures

Compared with the customer’s previous European recycling lines, the customized layout provided greater flexibility and improved space efficiency.

This project demonstrates that modern plastic film pelletizing machine solutions are not only about processing capacity—they also require professional engineering design that adapts to real production environments.

Core Value of the Solution: More Than Equipment Replacement

Through the combination of:

High-efficiency densifying and pelletizing + high-purity filtration + customized engineering design

KITECH provided the customer with a complete recycling upgrade rather than a simple machine replacement.

The new recycling system improved production performance in three major areas:

1. Higher Pellet Quality

The customer achieved cleaner, denser, and more consistent recycled pellets suitable for reuse in blown film manufacturing.

2. Lower Operating Costs

Reduced manual intervention, lower maintenance requirements, and improved material utilization helped decrease long-term production costs.

3. Stronger Production Continuity

The upgraded system supports stable 24/7 operation, reducing production interruptions caused by equipment limitations.

Most importantly, the KITECH KCP120 increased recycling capacity from approximately 250 kg/h to 400–500 kg/h, allowing the customer to efficiently process more than 300 tons of internal film waste every month.

This successful upgrade proves how a properly engineered plastic film pelletizing machine and complete plastic pelletizing equipment solution can help manufacturers achieve higher recycling value while improving operational efficiency.

V. From Initial Contact to Final Deal: 18 Months of Building Technical Trust

The successful cooperation between KITECH and the Russian packaging company was not achieved overnight. Instead, it was the result of 18 months of technical communication, solution optimization, and trust building.

The cooperation began at the 2024 Chinaplas exhibition, where both sides established initial contact and discussed the customer’s existing recycling challenges.

Later, during a 2025 industry exhibition in Russia, the customer shared detailed information about its current European recycling equipment, production requirements, and automation expectations.

In March 2025, a four-person delegation from the customer visited KITECH’s factory to inspect equipment operation and evaluate KITECH’s recycling technologies. During the visit, the customer observed the KCP120 system in operation and experienced demonstrations of the self-cleaning laser filtration technology.

After the factory visit, the customer continued comparing solutions from several suppliers.

Throughout this evaluation process, KITECH maintained close technical communication and provided:

• Equipment configuration recommendations
• Customized layout drawings
• Technical documentation
• Operation and maintenance guidance
• Application-based recycling suggestions

Although KITECH’s quotation was not the lowest among all suppliers, the customer ultimately selected KITECH because of the comprehensive advantages of:

• Equipment reliability
• Engineering customization capability
• Recycling technology experience
• Long-term technical support

The decision demonstrated that customers purchasing a plastic pelletizing equipment solution are not only choosing a machine—they are selecting a technology partner capable of supporting their long-term production development.

For this Russian packaging company, the final choice was based on the complete value of the solution, including processing performance, operational stability, and future expansion potential.

VI. Transaction Value: Beyond Equipment Replacement, Achieving Long-Term Production Upgrade

The value of this cooperation extended far beyond delivering a recycling machine.

Through the KITECH KCP120 system, the customer achieved a comprehensive upgrade in recycling efficiency, product quality, and production reliability.

1. Significant Capacity Improvement

The customer increased recycling capacity from the previous 250 kg/h level to a stable output of 400–500 kg/h.

This improvement fully meets the requirement of processing more than 300 tons of internal film waste every month.

Compared with the previous system, the upgraded plastic film pelletizing machine provides significantly higher productivity while maintaining stable recycled pellet quality.

2. Reduced Production Risks

By replacing aging European recycling equipment, the customer significantly reduced:

• Unexpected downtime
• Maintenance pressure
• Spare parts waiting time
• Production uncertainty

The new recycling system provides a more stable operating foundation and reduces the risks associated with outdated machinery.

For manufacturers operating PE film recycling projects, a reliable pe film recycling machine can directly influence production efficiency, cost control, and business continuity.

3. Establishing a Complete Internal Circular Production Model

The upgraded recycling process enables the company to achieve:

Film Waste → Recycling → High-Quality Recycled Pellets → Blown Film Production

This closed-loop recycling model allows the customer to reduce dependence on virgin raw materials while improving sustainability and resource utilization.

The project demonstrates the real value of advanced plastic pelletizing equipment: transforming waste materials into valuable production resources.

VII. KITECH Service Philosophy: Long-Term Partnership Beyond a Single Equipment Transaction

This project, which lasted more than one and a half years, involved multiple rounds of technical discussions, equipment configuration adjustments, factory layout optimization, and supplier comparisons.

Throughout the entire process, KITECH maintained one core principle:

Providing customized recycling solutions based on actual customer production needs, rather than simply selling standardized machines.

From the initial communication stage to final commissioning preparation, the KITECH team focused on understanding every detail of the customer’s operation, including:

• Raw material characteristics
• Monthly waste generation volume
• Production targets
• Factory space limitations
• Final recycled pellet application requirements

Instead of recommending a standard recycling line, KITECH developed a complete solution combining advanced technology, practical engineering, and long-term operational value.

The customer ultimately selected KITECH not only because of the KCP120 system itself, but because of the confidence built through professional communication and technical support.

For companies looking for reliable plastic pelletizing equipment, the ability to provide continuous engineering support and customized solutions is often just as important as machine performance itself.

KITECH believes that successful cooperation does not end when equipment is delivered. It begins with helping customers achieve stable production, lower operating costs, and sustainable business growth.

VIII. Conclusion: Transforming Waste Film into High-Value Recycled Resources

From aging European recycling equipment to the advanced KITECH KCP120 system;

From limited 250 kg/h production capacity to stable 400–500 kg/h output;

From frequent maintenance challenges to reliable continuous operation—

this Russian packaging company’s recycling upgrade represents much more than a simple equipment replacement project.

It demonstrates how the right recycling technology can help manufacturers transform internal plastic waste into valuable production resources.

Through the combination of:

• High-efficiency densifying and pelletizing technology
• Advanced laser filtration
• Customized equipment layout
• Intelligent automation control

KITECH helped the customer establish a more efficient and sustainable recycling model:

Production → Waste → Recycling → Production

The success of this project reflects KITECH’s commitment to its mission:

“Reborn Plastic with Key-Tech.”

For KITECH, plastic recycling is not only about manufacturing machines—it is about creating complete recycling solutions that help enterprises improve productivity, reduce costs, and participate in the global circular economy.

With more than 20 years of experience in plastic recycling technology, KITECH continues to provide customized recycling solutions for companies worldwide.

The KCP120 system installed in the Moscow region is now continuously converting production film waste into high-quality recycled pellets, proving the value of advanced plastic film pelletizing machine technology in real industrial applications.

Whether you need a pe film recycling machine for processing internal film production waste, a high-performance plastic film pelletizing machine for converting flexible plastic materials into reusable pellets, or a complete plastic pelletizing equipment system for large-scale industrial recycling and pelletizing operations, KITECH can provide solutions based on:

• Raw material characteristics
• Required capacity
• Factory conditions
• Final application requirements

If your company is facing challenges such as:

• Aging recycling equipment
• Insufficient processing capacity
• Difficulties improving recycled pellet quality