G3 PlastiCycler


General Description

The G3 PlastiCycler is a unique, patented system designed to upgrade virtually any rigid post-consumer or post-industrial plastic. This is the 3rd generation of a proven design initially developed over 15 years ago for recycling polystyrene products. The system is simple to install, operate and maintain – and it’s cost effective.

The finished product from the PlastiCycler recycling system is a clean dry flake suitable for extruding or molding into new products.
G3 PlastiCycler


This continuous-flow system offers many advantages over other plastic recycling systems on the market.

  • Low operating cost
  • Minimal labor requirements
  • Easy to operate and service
  • Readily available replacement parts
  • Compatible with virtually any rigid plastic
  • Modular design allows a system to be configured for specific customer needs and materials
  • Designed for easy maintenance and serviceability
  • Lift open, gas strut supported drum/sump access doors
  • Heavy duty, removable end panels to support custom in-feed and out-feed mechanism
  • Continuous sump clean out system
  • PLC controlled solid-state safety interlock system
  • Motors and heating elements can be optionally PLC controlled
  • Quick release drum screens for easy access for cleaning, maintenance and change-out
  • The stressed skin drum is supported at each section by an adjustable large wheel spring suspension to assure full support and reduced mechanical stresses
  • Uses 2-8 GPM of fresh water
  • Externally adjustable material transfer chutes between each drum section to control material residence time
  • Laser fabricated components for precision fit and function


The PlasctiCycler can process at rates of up to 2,000 pounds per hour depending on bulk density of the material.

G3 Plasticycler-Process


The heart of the PlastiCycler system is the G3 Washer/Dryer. The washer/dryer has a horizontal, multi-sectioned, rotating drum enclosed in perforated or solid stainless steel skins. As the drum rotates, material is introduced at the in-feed end and flows through a series of processes including some or all of the following:

  • wash
  • rinse
  • de-water
  • drying stages


In the wash stage, material is continually submerged, sprayed, and flushed with a heated closed loop wash solution. The combination of the heated water and attrition scrubbing from particle to particle contact while tumbling in the drum provides exceptional cleaning. The wash drum sections can be fitted with optional internal turbine scrubbers and a wash detergent pump for additional cleaning power. Small particles and dissolved contaminants pass through the perforated drum skin, collect in the sump, and are removed by a vibratory screener and sump auger conveyor system.

G3 PlastiCycler


The rinse stage uses a spray of clean preheated 180F water to rinse away remaining wash solution and prepare the cleaned material for tumble de-watering and drying.


The tumble de-watering stage allows free moisture to be jolted off the material as it impacts the lower inside surface of the drum skin. The water is collected in the common wash/rinse sump and re-circulated. The rinsing and de-watering stages provide the wash re-circulation loop with clean preheated make-up water. Some of the system water is lost in the drying process and the remainder is collected and discharged at the wash water re-heat tank to allow the wash solution to be continually revitalized.


Drying is performed by one of two methods:
Rotary Drying: Rotary drying is accomplished by forcing 60 mile per hour hot air through the falling material in a designated number of drum sections. The rotary dryer can be made and integral part of the washing/rinsing unit or can be a separate “stand-alone” unit. It can be configured in either an electric or gas version. The residence time of the material in the drum is controlled by drum rotational speed and by adjustment of a transfer chute located between each drum section.
Centrifugal Drying: The second method of drying is centrifugal drying. This method involves a separate unit that uses high rotational velocities to remove moisture. Optional counter-flow heated air can be used to provide additional drying capacity.

Ancillary Machines

Polymer Recovery Systems has other ancillary machines that can be configured and combined into a custom system for your specific plastic recovery needs.

  • air classifiers
  • float/sink tanks
  • bale breakers
  • granulators
  • shredders

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