KIMURA Selects GREENMAX LDPE/LLDPE Film Washing Line in Japan
As KIMURA expanded its LDPE/LLDPE film recycling operation, variation in incoming feedstock became a growing processing challenge.
Some batches contained sand and dirt, while others included different plastics or surface contamination. When these impurities remained in the material, it became more difficult to maintain consistent feedstock conditions before pelletizing.
To improve material preparation, KIMURA selected a GREENMAX LDPE/LLDPE film washing line to remove more contamination and moisture before the film enters downstream pelletizing.
Long-Term Recycling Experience Expands into Film Processing
KIMURA is a Japanese plastic recycling company with a history of around 60 years. It operates recycling facilities in Hokkaido, Chiba, Hyogo, Kyushu and Yamaguchi, handling materials including PET bottle bales, waste paper, plastic film and compacted foam.
KIMURA's involvement with EPS blocks dates back to around 2000, with monthly supply volumes of approximately 100–150 tons. Over time, the company also extended its recycling activities into further processing of waste plastic film.
From around 2020, KIMURA began processing recovered LDPE/LLDPE film into recycled pellets. Part of the output is sold in Japan, while the remainder enters further recycling and reuse channels.
As film processing increased, the condition of the incoming material became increasingly important to downstream production.
Feedstock Variation Became the Main Processing Challenge
Recovered LDPE/LLDPE film can vary significantly from one batch to another.
Some material handled by KIMURA contained sand and dirt, while other batches included different plastics or surface contamination. These variations affected the consistency of the feedstock entering the pelletizing process.
The project therefore shifted more attention to pre-treatment.
Rather than relying on pelletizing alone to deal with variable feedstock, KIMURA decided to improve the condition of the film before it reached the pelletizer. The objective was to remove more contamination and moisture earlier in the process and provide more consistent material for downstream recycling.
Improving Material Preparation Before Pelletizing
The GREENMAX LDPE/LLDPE film washing line was configured to carry out more material preparation before pelletizing.
Recovered film is first shredded to make it easier to handle continuously through the system. It then passes through washing stages designed to remove sand, dirt and surface contamination. Drying and squeezing/dewatering are used afterwards to reduce the moisture remaining in the cleaned material before it moves to downstream pelletizing.
For KIMURA, the purpose of the washing line is not simply to clean the film. The more important goal is to prepare cleaner, lower-moisture LDPE/LLDPE material for the next recycling stage.
By moving more contamination removal and moisture reduction upstream, the company can reduce the influence of variable incoming film on subsequent pellet production.
Washing Line Configuration Based on KIMURA's Material
KIMURA reviewed the process flow and equipment configuration of the GREENMAX LDPE/LLDPE film washing line in detail and provided its own production requirements based on years of plastic recycling experience.
The project went through several months of discussion and adjustment before the final configuration was confirmed. Film condition, contamination problems and downstream pelletizing requirements were all considered during this process.
The system was therefore configured around the LDPE/LLDPE film KIMURA actually processes rather than applying a fixed washing-line layout.
The main focus is to reduce sand, surface contamination and moisture before pelletizing so that the next production stage receives material in a more controlled condition.
Factory Testing Completed and Equipment Shipped to Japan
The GREENMAX LDPE/LLDPE film washing line has completed factory testing and inspection and has been packed and shipped to Japan.
For KIMURA, the new line adds a more controlled pre-treatment stage to its existing film recycling process. By removing more contamination and moisture before pelletizing, the company aims to improve the consistency of the material entering its downstream recycling operation.
