Plastic Color Sorter Case Study – Recycled Plastic Pellets Sorting

1. Project Basic Info

Country: Malaysia

Application: Recycled HDPE/PP Plastic Pellets Fine Sorting (Industrial & Food-Grade Raw Material)

Project Time: January 2026

Machine Model: WYCS5-320 AI Plastic Color Sorter

Project Type: Customized Fine Sorting Solution + Production Line Integration Production Capacity: 1.8T/H Continuous Sorting Output

2. Client Background

This client is a professional recycled plastic recycling and reprocessing enterprise in Johor, Malaysia, focusing on waste plastic bottle flake crushing, cleaning, and pelletizing. The factory mainly supplies high-purity recycled plastic pellets for local plastic injection molding and food packaging material factories. With a full-day continuous production mode, the client has extremely strict standards for pellet purity, requiring zero tiny black spots, discolored particles, and impurity particles to meet EU recycled material environmental certification and food-grade auxiliary material access standards.

3. Customer Pain Points

Before the transformation, the client adopted traditional roller screening + manual secondary selection mode, which could only remove large-area discolored plastic particles and could not identify tiny foreign impurities. First, manual sorting efficiency was extremely low, with only 20–30 defective particles screened per minute, failing to match the production line output. Second, traditional equipment could not capture micro defects of 0.1mm–0.5mm, resulting in high defective rate of finished pellets. Third, unqualified particles mixed in finished products led to unstable batch quality, frequent customer complaints, and difficulty in entering high-end European and American procurement supply chains. Meanwhile, long-term manual sorting brought high labor costs and unstable sorting quality.

4. Our Customized Solution

Combined with the client’s HDPE/PP mixed pellet characteristics, high-purity production requirements and 1.8T/H stable output demand, we deployed the WYCS5-320 AI intelligent plastic special color sorter. The equipment is equipped with upgraded NIR near-infrared spectral recognition + 4K ultra-high-definition imaging system, supporting intelligent identification of tiny black spots, yellow spots, burnt particles, heterochromatic particles and mixed material particles as small as 0.05mm. We customized independent high-precision jet valve parameter settings for plastic fine sorting, completed on-site production line docking, dynamic parameter debugging and operator professional training. In addition, we provided 24/7 remote intelligent monitoring and after-sales debugging service to ensure long-term stable operation of the equipment under continuous working conditions.

5. Project Sorting Effect & Authentic Visual Data Table

After the equipment was officially put into full-load production and stable operation for one month, we obtained accurate and verifiable production comparison data. The overall sorting accuracy, finished product purity and production efficiency reached the industry high standard, completely solving the client’s quality pain point of recycled plastic pellets.

Core Data Conclusion: The equipment realizes ultra-fine impurity identification and high-precision sorting for recycled plastic pellets. While ensuring extremely low material loss, it greatly improves product purity and production efficiency, helping clients successfully pass high-standard recycled material audits and expand high-end overseas markets.

6. On-site Display Description

1. Whole machine running scene in Malaysian plastic recycling workshop 2. Close-up shot of 0.05mm micro defect particle identification and removal

2. Before & After comparison: impure mixed pellets vs high-purity finished pellets
4. On-site equipment commissioning and staff operation training scene

7. Client Feedback

"The AI plastic color sorter has excellent ultra-fine sorting performance, which solves our long-standing problem of tiny black spot impurities. The finished pellet purity fully meets European customer standards. The equipment runs stably all day with very low loss rate, and the after-sales technical support is very professional. It is a cost-effective upgrade for our recycled plastic production line." —— Production Director, Malaysian Plastic Recycling Factory

8. Bottom Conversion Module

Recommended Similar Solutions: Plastic Bottle Flake Color Sorter, Mixed Plastic Material Sorting Machine, High-precision Pellet Fine Sorting Equipment