From 432 kW to 150 kW: The Machine Behind a Western European Film Recycling Plant

Why a Western European Investor Built Its PE Film Line Around One Machine

A recycling investment group in Western Europe had the site, the feedstock contracts, and the funding for a new PE film recycling line. What it didn’t have yet was a process design that could survive European operating costs.

Three numbers were working against the plan:

• Electricity. A conventional washed-film line runs several machines, each with its own main motor, around the clock. In the group’s financial model, power was one of the largest operating costs of the entire project.
• Labor. Every manual step between machines, from dewatering and bagging to transferring and re-feeding, meant another operator to hire, train, and keep on shift in a high-wage market.
• Moisture. Film leaves the washing line holding more than 50% water. When that water reaches the extruder, pressure becomes unstable and pellets come out with voids and darker color. In a market that expects compliance-grade resin, those pellets don’t sell at full price.

The group’s engineers did their homework before contacting any supplier. They read technical articles and watched equipment videos on high-moisture film recycling. That research led them to Genius Machinery and the DWX Series.

How the DWX changes the line

The DWX Series Squeeze Dryer Integrated Recycling Machine handles squeeze drying and pelletizing with one screw driven by one motor. Washed film enters at over 50% moisture and leaves the squeezing section at 1–3%. It then moves straight into extrusion, with no cooling, bagging, or reheating in between, and the final pellets come out completely dry.

The numbers the investors checked

• Installed main-motor power: about 432 kW across three machines on a conventional line, versus a single 150 kW motor in a DWX-3512 class setup
• Electricity: an estimated 107,000 kWh saved per month (24 hours a day, 22 days a month, 80% load), with energy cost savings of up to 65%
• Staffing: 1–2 operators for the whole plant
• Floor space: no intermediate storage needed between machines

Genius printed the assumptions next to every figure, and the investors’ engineers recalculated each one against the motor ratings. Their verdict: “This is the first supplier whose numbers we could recalculate ourselves.”

After a few video calls and one round of engineering questions, the group signed the order.

Is the DWX a fit for your plant?

The DWX was built for recyclers processing washed PE or PP film, especially where electricity and labor are expensive. It addressed the buyer's most important concerns at the same time: energy cost, labor cost, moisture control, and overall investment efficiency.

Request a DWX energy comparison for your line. Contact Genius Machinery directly today to find out how you can save yourself from the bills.