Technology — Resin Reclaim Tech

Core Systems

Processing Equipment Overview

Our facility is equipped with a sequential multi-stage processing line, each element selected for material compatibility, throughput consistency, and output quality.

Industrial Shredding

Dual-rotor industrial shredders reduce incoming plastic scrap to uniform particle sizes for downstream processing. Knife geometry is selected based on material hardness and target output size.

Throughput: up to 2,000 kg/hr per line

Density Separation

Water float-sink tanks and air classification equipment separate mixed polymer streams by density, enabling identification and isolation of individual polymer types without manual sorting at scale.

Separation accuracy: >97% by polymer type

Hot Wash Systems

Heated wash tanks with caustic solution remove surface contamination, adhesive residues, and processing aids from shredded material prior to extrusion. Multiple rinse stages ensure residue removal.

Wash temperature: 70–90°C, variable pH

Centrifugal & Thermal Drying

Two-stage drying using mechanical centrifugal dryers followed by heated air drying tunnels reduces surface and absorbed moisture to levels compatible with extrusion processing (<0.1% moisture content).

Output moisture: <0.1% (material-dependent)

Twin-Screw Extrusion

Co-rotating twin-screw extruders process dried polymer material through melt filtration and controlled re-extrusion, producing uniform pellets with consistent melt flow index and colour profile.

Output: 3–5mm uniform pellets, colour-sorted

Inline Quality Monitoring

Optical sensors and automated sampling systems at each processing stage capture material data including colour, particle size distribution, and contaminant presence, feeding into the digital batch record.

Sampling frequency: every 15 minutes per stage

Industrial material processing facility interior

Facility Design

Structured for Continuous Industrial Operation

The Sendai processing facility operates on a continuous-shift schedule with equipment layouts designed for sequential material flow, minimising handling steps between processing stages.

Facility zoning separates incoming unsorted material from clean processing areas, reducing cross-contamination risk and supporting material traceability through each stage.

Segregated intake, processing, and output zones
Enclosed material conveyancing between stages
Dedicated storage bays by polymer type and grade
CCTV monitoring across all operational areas
Fire suppression and dust extraction systems
Staff PPE stations at each processing zone entry

Materials We Process

Polymer Compatibility Reference

The table below summarises the resin types and material forms currently accepted within our standard processing programme. Pre-assessment is required for materials marked as conditional.

Polymer Type	Common Abbreviation	Accepted Forms	Processing Route	Status
Polyethylene (High Density)	HDPE	Film, regrind, lumps, pipe	Shred → Wash → Extrude	Standard
Polyethylene (Low Density)	LDPE/LLDPE	Film, bags, regrind	Shred → Wash → Extrude	Standard
Polypropylene	PP	Mouldings, film, fibres, woven	Shred → Wash → Extrude	Standard
Polyethylene Terephthalate	PET	Bottles, sheet, fibre	Shred → Hot Wash → Dry → Extrude	Standard
Acrylonitrile Butadiene Styrene	ABS	Mouldings, sheet	Shred → Wash → Extrude	Standard
Polystyrene	PS/HIPS	Sheet, mouldings, film	Shred → Wash → Extrude	Standard
Nylon (Polyamide)	PA 6/66	Film, mouldings, fibre	Dry → Shred → Extrude	Standard
Polycarbonate	PC	Sheet, mouldings	Dry → Shred → Extrude	Standard
Polyvinyl Chloride	PVC	Rigid profiles, sheet	Shred → Specialised processing	Conditional
Mixed / Unknown Polymers	Mixed	Various	Assessment required	Pre-Assessment

Operational Performance

Key Performance Indicators

Operational metrics tracked across our processing facility, based on rolling 12-month average data from the Sendai primary facility.

Material Recovery Rate95%

On-Schedule Collection Rate98%

Batch Certification Pass Rate99%

Polymer Sort Accuracy97%

Water Recirculation Efficiency88%

Equipment Uptime92%

Digital Batch Records

All material processing events are logged digitally with timestamps and operator records for full traceability.

Automated Sampling

Material samples collected and logged at each processing stage without manual intervention using in-line sampling units.

Client Portal Reporting

Partner facilities access real-time batch status, material volumes, and compliance documentation through a dedicated online portal.

Closed-Loop Water Use

Process water is treated and recirculated within the washing system, reducing net water consumption per tonne of material processed.

Quality Assurance

In-House Testing Laboratory

The Resin Reclaim Tech testing laboratory performs material characterisation and certification analysis on all processed batches prior to release.

Melt Flow Index Testing

MFI measured using standardised extrusion plastometer equipment per ISO 1133. Values documented per batch and included in Certificate of Analysis.

Differential Scanning Calorimetry

DSC analysis confirms polymer identity, melting point, crystallinity, and thermal history of processed material batches. Used for engineering resin verification.

Tensile & Impact Testing

Mechanical property assessment per relevant ISO standards, including tensile strength, elongation at break, and notched Izod/Charpy impact resistance.

Colour & Appearance Grading

Visual and spectrophotometric assessment of pellet colour consistency and surface appearance, with output categorised into defined colour grade groups.

Contamination Screening

XRF and wet chemistry methods used to screen for restricted substances, heavy metals, and process chemical residues in processed batches where specified by client requirements.

Moisture Content Analysis

Karl Fischer titration and gravimetric drying methods determine residual moisture levels in dried and extruded material, critical for hygroscopic engineering polymers.

Equipment & Technical Infrastructure