H.R. PLASTIC MACHINERY PVT. LTD.

Plastic Dana Plant

September 10, 2025

Plastic Dana Plant

Plastic Dana Plant in India | Granule Making Line, Extruder & Pelletizer

Plastic Dana Plant

Introduction

A Plastic Dana Plant converts post-consumer or industrial plastic scrap into uniform granules (dana) suitable for reprocessing. Typical lines include conveyor feeding, shredder/crusher, agglomerator (for films), twin/single-screw extruder with degassing, melt filtration, and strand or die-face pelletizing followed by drying and screening. When sized correctly and paired with efficient washing, plants deliver consistent MFI and colour, lower production cost, and support EPR/circular economy goals across India.

Working Principle and Process Flow

Scrap is inspected and pre-sorted, then reduced in size and washed to remove labels, dirt, oil, and moisture. A controlled feeder loads material to the extruder where it is plasticized; vacuum/vent ports remove volatiles and moisture. Multi-stage screen packs filter contaminants before the melt exits through a die. Depending on product needs, strands are water-cooled and cut (strand pelletizing) or cut at the die (die-face/hot-cut). Granules are dried, screened, and bagged. SCADA/PLC recipes maintain temperature profiles, screw speed, and kWh/kg for traceability.

Types of Plastic Dana Plants

Single-Screw Extrusion Lines (100â€“500 kg/hr) for PP/PE films, raffia, liners; economical and easy to maintain.
Twin-Screw Compounding Lines (300â€“1500 kg/hr) for filled/reinforced grades, colour/masterbatch, and better mixing.
Direct Film/Raffia Reprocessing with agglomerator or force-feeder for light, fluffy inputs and stable throughput.
PET Bottle Flake to rPET Pellet Systems with hot caustic wash, IV retention, and food-contact compliant design.
Rigid HDPE/PP Regrind Lines integrating label/metal removal, friction washers, and intensive drying for drum/crate scrap.

Key Features and Specifications

High-efficiency motors with VFDs; benchmarkable energy index (kWh/kg) for cost control.
Automatic screen changer, multi-zone heating, and vacuum degassing for cleaner melt and fewer black specks.
Die options: strand, water-ring, or hot-face cutter; online pellet classifier and dryer for uniform pellet size.
Stainless-steel wetted parts for PET and wash sections; robust bearings and sealed gearboxes for long life.
PLC-SCADA with recipe management, alarms, preventive maintenance prompts, and remote diagnostics.

Applications of Plastic Dana

Film & Packaging: LDPE/LLDPE/HDPE films, liners, pouches, carry bags (as per local compliance), shrink/stretch wraps.
Injection Moulding: Crates, caps/closures, houseware, automotive trims using rPP/rHDPE with controlled MFI.
Extrusion Profiles & Pipes: HDPE pipes, corrugated pipes, cable ducts, and PP/PE profiles for infrastructure.
Textiles & Strapping: rPET chips/pellets used for fibres, non-wovens, monofilaments, and PET strapping tapes.

Benefits of Installing a Dana Plant

Material cost reduction by converting in-house scrap and sourced waste into saleable granules.
Quality stability via controlled washing, filtration, and degassingâ€”fewer rejections downstream.
Higher productivity with automated feeding, quick screen changes, and reliable conveying/cooling.
Compliance & ESG impact through traceability, EPR alignment, and reduced landfill burden.

Manufacturers & Suppliers in India

India hosts specialized manufacturers offering turnkey Plastic Dana Plants from 100 to 1500+ kg/hr with layout design, installation, commissioning, and operator training. Customers typically compare screw/barrel metallurgy, filtration area, vacuum efficiency, cutter type, energy index, and service network strength. Options include stainless contact parts, water-recycling modules, odour control, dosing feeders, auto-bagging, and inline quality monitoring for MFI, moisture, and colour consistency.

Maintenance and Safety Tips

Inspect blades, screens, heaters, thermocouples, and seals daily; track vibration/temperature anomalies.
Maintain wash chemistry and replace contaminated water; keep moisture below target for stable pellets.
Calibrate load cells, temperature sensors, and pressure transmitters as per schedule.
Implement lockout-tagout and guarding checks; train operators on hot surfaces and emergency stops.
Stock critical spares (heaters, screen packs, gear oils) with traceable part numbers.

FAQs â€“ Plastic Dana Plant

1. What capacity should I choose for my dana plant? +

Match capacity to consistent scrap availability, planned shifts, polymer mix, and customer demand. Modular designs allow scaling without compromising filtration or mixing efficiency.

2. Which pelletizing method is betterâ€”strand or die-face? +

Strand pelletizing offers excellent pellet shape for many PP/PE grades; die-face/hot-cut is preferred for high outputs and sticky materials. Choose based on polymer, throughput, and downstream needs.

3. Can one line handle mixed municipal plastics? +

With proper pre-sorting, density separation, and staged filtration it can, but separate loops for different polymers deliver more predictable MFI/colour and better commercial value.

4. How do I ensure odour control and consistent MFI? +

Use hot wash where applicable, effective degassing, correct screen-pack sequence, and maintain stable temperature profiles and screw speed. Monitor MFI and moisture batch-wise.

5. What standard deliverables should be in the scope? +

Plant layout, foundation and utility list, installation & commissioning, operator training, spares kit, documentation (FAT, IQ/OQ), warranty terms, and guaranteed performance metrics (throughput, kWh/kg, pellet quality).