Mechanical Recycling of Plastic Materials

Processes and technical criteria for re-pelletizing

Extrusion and Mechanical Recycling: The Role of Bausano Technologies

Plastic recycling is an increasingly strategic process for the manufacturing industry, driven by regulatory, environmental, and economic requirements. In this context, Bausano offers plant solutions dedicated to mechanical recycling, a method that recovers plastic waste and transforms it into ready-to-use material through grinding, extrusion, and pelletizing. Unlike chemical recycling, which involves depolymerizing the material, mechanical recycling leaves the polymer's molecular structure unchanged, making it more energy-efficient and more sustainable.
The main benefits of extrusion for mechanical recycling include:

Reduced environmental impact through the recovery of waste
Recovery of material with still-valid technical properties
The ability to reintroduce material into the production cycle
Lower disposal costs

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Post-Consumer, Post-Industrial: Which Materials Can Be Recycled?

Bausano technologies for mechanical recycling are designed to process both post-consumer waste (such as bottles, packaging, containers) and post-industrial waste (trimmings, processing scraps, production powders). Among the most commonly re-pelletized materials are HDPE, LDPE, PP, PVC, and other polyolefins. Each material has different physical characteristics, particularly in terms of density, viscosity, and moisture content. For example:

Post-consumer LDPE film is lightweight, contaminated, and often has high moisture content
HDPE bottles have higher density but often contain residues
PVC requires careful temperature control to avoid thermal degradation
Industrial PP scrap is usually clean but may contain inks, glass fibers, and impurities

Bausano solutions integrate degassing systems, self-cleaning filtration, and advanced thermal control to ensure maximum pellet quality, even from heterogeneous and complex raw materials.

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Re-Pelletizing Process in Mechanical Recycling

In the mechanical recycling of plastic materials, re-pelletizing is a key stage that transforms waste into a reusable secondary raw material for new production cycles. The process involves a sequence of technical operations, including controlled material feeding, homogeneous melting, removal of moisture and volatile substances, filtration of impurities, and solidification into pellets. The effectiveness of this stage depends on the correct management of parameters such as melt viscosity, thermal stability, contamination level, and material throughput. With heterogeneous waste or high residual moisture, it becomes essential to adopt suitable degassing and filtration solutions, along with thermal profiles designed to preserve the polymer's properties.
Bausano's experience in mechanical recycling makes it possible to address these complexities with an engineering approach based on real-world testing and process analysis, ensuring consistent pellet quality even from complex recovered materials.

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Innovation and Sustainability: Bausano Solutions for Plastic Recycling

Unlike other players in the market, Bausano stands out for integrating engineering know-how, an application laboratory, and formulation support, offering the customer a true industrial platform for recycling. Every solution is calibrated based on practical tests conducted on real material in the company's Test Room, ensuring repeatable results and maximum compatibility with production requirements. In a context where demand for regenerated pellets is constantly growing, Bausano provides high-productivity, low-energy-consumption solutions featuring proprietary technologies such as the Multidrive System, which reduces mechanical wear. The result is a plant capable of combining sustainability, efficiency, and competitiveness, contributing concretely to a new circular economy for plastics.

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A starting point to define the right solution together

By filling in the form below, it is possible to describe specific technical or production requirements. The technical team will carefully evaluate the request in order to propose the most suitable extrusion line or extruder.