Plastic Recycling Machine & Granulator Insulation Jacket
Plastic recycling lines run some of the longest hours in the industry — often 22+ hours a day — with heaters constantly working to melt heavily contaminated feedstock. IHEAT's IWRAP recycling insulation jacket wraps the pelletiser barrel, cutter compactor and die-face, cutting heater electricity consumption by 20–30% and paying back in 3–5 months on typical Indian recycling lines.
The recycling energy problem
Plastic recycling machinery — pelletisers, agglomerators, cutter-compactors, densifiers — is inherently energy-hungry. The feedstock is contaminated with moisture, labels, dirt and mixed polymers, which means longer residence time, higher barrel temperatures, and often multiple melt zones. A typical Indian recycling line consumes 0.35–0.45 kWh per kg of output, with heaters alone accounting for 25–35% of total electricity.
Because these machines run 20–24 hours a day, even small percentage savings translate into meaningful bottom-line impact. A 300 kg/hr pelletiser saving 25% heater energy at ₹8/kWh saves ~₹1.8 lakh per year.
IWRAP for recycling: what gets covered
We insulate the pelletiser barrel (all heater zones), the die-face plate cover, the cutter-compactor (agglomerator) barrel and cone, and the die adapter. Jackets are designed with generous cut-outs around thermocouples, dosing screws, degassing ports and knife assemblies so routine maintenance is unaffected.
Materials are selected specifically for recycling environments: our fibreglass outer skin is treated for oil/plasticiser resistance, and the velcro fasteners are silicone-coated for humid, dusty conditions typical of a recycling shed.
Compatibility
IWRAP fits every major recycling OEM including Erema, Starlinger, Amut, Gamma Meccanica, NGR, Rajoo, Windsor, Aceretech, Polystar, Boston, and every Indian-built recycling extruder. We custom-manufacture from your machine drawing or from a site visit measurement.
For customers running mixed feedstock (PE + PP + PET flakes) we can supply a slightly thicker jacket to handle the wider process-temperature swing without letting external surface temperature climb.
Additional benefits on recycling lines
Beyond electricity savings, IWRAP has three secondary benefits on recycling machines. First, the shed ambient temperature drops by 3–5°C, reducing operator fatigue and cooling load. Second, thermocouples read more accurately because they are shielded from external draughts, which improves melt quality control. Third, insulated barrels experience less thermal cycling stress, extending heater band life by an estimated 30–40%.
Frequently Asked Questions
Will IWRAP handle the moisture and contamination typical of recycling feedstock?+
Yes. Our fibreglass outer skin is treated for oil, moisture and plasticiser resistance. Silicone-coated velcro fasteners stay reliable in dusty, humid recycling sheds. Warranty covers full 24 months in recycling environments.
Can I remove the jacket to clean the die face or change screens?+
Yes. The die-face and screen-changer cover pieces are separate jackets with independent velcro closures. Removal takes 2 minutes and refit is under 5 minutes — no downtime lost.
What kind of energy savings should I expect on a 300 kg/hr pelletiser?+
Typical savings are 22–28% on heater electricity, which works out to roughly ₹1.6–2.0 lakh per year at ₹8/kWh on a 20 hr/day operation. Exact savings depend on ambient conditions, feedstock and operating hours — use iheat.in/roi-calculator for a machine-specific number.
Does the jacket work on agglomerators and densifiers as well?+
Yes. We custom-make jackets for cutter-compactor barrels, agglomerator cones and densifier bodies. Insulation is even more valuable on agglomerators because they cycle between high and low speeds, which normally causes rapid heat loss.
Related insulation solutions
Ready to cut heater electricity bills by 20–35%?
Send us your barrel dimensions and heater load — our engineers respond with a custom IWRAP quotation within 24 hours.