Issue 293 2025-09-11 Author : GENIUS MAQUINARIA CO., LTD. Suscríbete

Integrating Dewatering and Pelletizing Into One Innovation: The DWX Series-A Whole New Chapter in Film Recycling

The DWX Series Squeeze-Dry Integrated Pelletizing Line changes that equation. It is the first system to combine squeezing and extrusion into a single production line

Recycling post-consumer plastic films presents a unique challenge. Washed films and flakes often contain up to 50% moisture, which can overload conventional shredder–extruder lines. The result is steam flashes, wasted energy, and brittle pellets—issues that raise costs and reduce product quality.

Traditionally, recyclers have relied on two separate systems: a squeezer to remove water, and an extruder to melt and pelletize. This fragmented setup means higher energy demand, more operators, larger factory space, and added risk of material degradation between stages.

The DWX Series Squeeze-Dry Integrated Pelletizing Line changes that equation. It is the first system to combine squeezing and extrusion into a single production line, aligning both screws on one axis and powering them with a single motor. The result is a breakthrough in integration that redefines simplicity and efficiency in film recycling.

Integration That Delivers Measurable Results

Energy Savings with Proven Logic

Conventional configurations consume around 432 kW across three separate drives. By contrast, the DWX-3512 model, as an example, operates on a single 150 kW motor. Based on standard industrial power consumption formulas, this translates into monthly savings of about 107,000 kWh—equivalent to more than €22,500 in electricity costs at average European industrial rates.

Compact Footprint and Lower Handling Costs

By consolidating equipment, line length is reduced from roughly 23 meters to 14 meters, freeing nearly 40% of factory space. At the same time, eliminating additional conveyors between machines cuts down on material handling costs and simplifies overall operations.

Reduced Staffing

Traditional setups require at least three operators: one for the squeezer and two for the extruder. The integrated DWX system runs with only two operators, lowering labor costs while making the process easier to manage.

Superior Pellet Quality and Higher Throughput

Moisture is reduced to below 3%—sometimes under 1%—before melting, preventing steam flashes and multi-cycle thermal stress. This ensures higher-grade, more stable pellets and enables throughput increases of at least 20%.

A Payback Timeline That Speaks to Business Value

For a typical 600 kg/h line running two shifts per day, energy savings alone can exceed €26,000 annually. When combined with reduced labor and floor space costs, this efficiency translates into a payback period of less than 18 months, even against an estimated capital expenditure of around €770,000.

Integration as the Future of Recycling

The DWX Series proves that integration is innovation. By merging two processes into one seamless line, recyclers achieve significant cost savings, operational efficiency, and improved output quality. More importantly, the system addresses one of the industry’s biggest challenges—high-moisture washed films—turning a persistent problem into a profitable opportunity.