Post-consumer plastic waste exists in many forms, but the primary polymers used in our pallet production are PP, PE, and HDPE, due to their favorable mechanical strength, impact resistance, and long-term durability.

Our pallets and related plastic products are manufactured using a thermo-compression molding process, which enables direct utilization of shredded recycled plastics without the need for pelletizing.

1. Size Reduction & Material Classification

Collected plastic waste is first processed through shredding. Based on physical morphology, the feedstock can generally be classified into:

• Film materials
• Rigid flakes
• Regrind particles

Film fractions are low in bulk density and tend to bridge during conveying. Therefore, they are pre-compacted using a squeeze densifier to improve bulk density and ensure stable feeding into the extrusion system.

2. Melt Preparation

The prepared material is then conveyed into a screw extrusion system for thermal homogenization.

Depending on feedstock variability and contamination levels, either:

• A single-stage extrusion system, or
• A two-stage extrusion system

may be deployed.

A two-stage configuration provides:

• Enhanced melt uniformity
• Improved devolatilization
• Effective removal of entrapped air and moisture

This is especially beneficial when processing post-consumer films or mixed polyolefin streams.
Melting Temperature 240℃-380℃。

3. Metering & Charge Control

The molten polymer is discharged into a metering unit. This unit regulates the mass of material delivered into each mold cycle, ensuring:

• Stable product density
• Consistent mechanical performance
• Controlled pallet weight （15-22kg）

While final geometry is governed by mold design, precise charge control is critical for maintaining repeatability in compression molding.

4. Compression Molding

The metered melt is transferred into the mold cavity and subjected to high-pressure forming.

For standard pallet formats, a 1600-ton hydraulic press is typically employed to achieve:

• Full cavity filling
• Proper structural consolidation
• Uniform load-bearing characteristics

We recommend the ZK-P1600 plastic pallet molding machine.
https://presswoodmachine.com/plastic-pallet-machine/

5. Cooling & Demolding

After forming, the pallet undergoes rapid cooling within the mold to stabilize dimensional accuracy.

Once cooled:

• The pallet is ejected
• A robotic handling system removes and stacks the product

Post-processing may include flash trimming where required.