How One Recycler Boosted Throughput By Rethinking Their Washing Line
Question:
Is your plastic recycling line running at full potential, or could you be leaving efficiency on the table?
Many recyclers hit a point where throughput stalls. The line still works, but blockages, downtime, or energy costs start creeping in. The good news? A few smart upgrades can turn a struggling line into a smooth, high-output system.
This story is an illustrative example, drawn from common situations we see in recycling facilities across Australia. It’s not about one single customer, but it reflects the proven improvements our customers have achieved after upgrading their washing lines.
The Challenge
A mid-sized recycler in Victoria was running a mixed plastics line that processed post-consumer film, PET, and HDPE. On paper, the line was rated for 1,000 kg/hr. In practice, they were struggling to reach 700 kg/hr.
Issues included:
- High moisture levels after washing, slowing drying and pelletising
- Frequent contamination that reduced flake quality
- Rising energy use from worn equipment
- More labour hours spent on cleaning and maintenance
Sound familiar? Many recyclers face the same bottlenecks.
The Solution
Instead of a complete replacement, the recycler focused on key upgrades that made the biggest difference:
- Pre-Cleaner Installed Upstream
- Removed up to 80% of dirt and labels before hitting the wash line
- Reduced wear on the friction washer and hot wash tanks
- Friction Washer Upgrade
- Improved separation of fines and residual contamination
- Lowered water carryover, cutting drying times by 25%
- Optimised Dewatering System
- Achieved flake moisture levels under 2% consistently
- Reduced pelletiser stoppages and improved energy efficiency
The Results
Within three months, the recycler saw measurable improvements:
- Throughput increased 30% (from 700 kg/hr to 910 kg/hr)
- Energy consumption per tonne reduced 15%
- Labour hours cut by 10% thanks to fewer stoppages
- Higher flake purity meant more material sold into food-grade applications, lifting margins
In other words, a modest rethink of the washing line turned into a high-value win—without the need for a full replacement.
Why This Matters for Your Business
Every recycler knows downtime and inefficiency are costly. But not every business realises that small, targeted upgrades can unlock big performance gains.
Ask yourself:
- Could a pre-cleaner reduce your contamination headaches?
- Is your friction washer pulling its weight?
- Are moisture levels holding back your pelletiser?
The answers could point to untapped capacity in your existing line.
Takeaway
Improving your plastics recycling efficiency doesn’t always require new infrastructure. With the right upgrades, you can:
- Boost throughput
- Cut energy use
- Improve product quality
- Increase profitability
What’s Next
If you’re rethinking your washing line, Telford Smith can help assess where the biggest gains can be made - whether that’s a new friction washer, a pre-cleaner, or a smarter drying system.
📞 Contact us today to discuss how we can help your recycling line run faster, cleaner, and more profitably.
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