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Plastics

Answer in brief

Plastics processing moves polymer pellets, regrind, powders and additives from silos and bulk bags to dryers, blenders and processing machines. System selection balances gentle conveying that limits dust and streamers, moisture control for hygroscopic resins, accurate additive dosing and contamination-free material changes.

Reviewed August 13, 2026 · Updated October 30, 2026

Resin silos and pneumatic conveying lines feeding extruder hoppers in a plastics plant

Process challenges

Frequent material and color changes require lines and blenders that purge completely. Gravimetric dosing of minor additives determines product cost and quality. Long-distance pellet conveying must limit attrition, angel hair and streamer formation through velocity control and line design. Hygroscopic resins (PA, PET, PC) need managed drying capacity matched to throughput.

Material challenges

Regrind flows unpredictably and bridges; powders such as PVC dryblend or micronized additives flood, smear or coat pipe walls. Static charge builds strongly on polymer flows and causes adhesion and ignition risk. Abrasive glass-filled compounds wear elbows and rotary valves; low-bulk-density fluff and film scrap resist steady feeding.

Hygiene requirements

Contamination control is the plastics equivalent of hygiene: closed transfer, filtered air, dedicated or verifiably cleaned lines between incompatible materials and colors. Medical, optical and food-contact applications add documented material compliance and stricter changeover discipline; regrind streams require traceability to protect certified products.

Safety requirements

Fine polymer powders and many additives are combustible dusts; micronized resins, pigments and flame-retardant systems require dust hazard analysis, extraction and explosion protection consistent with NFPA 652 practice. Static-electricity management — bonding, grounding, conductive components — is critical in high-velocity pellet and powder transfer.

Regulatory context

Workplace duties for dust and static hazards follow OSHA enforcement in the US and ATEX in the EU, with NFPA 652 as the technical baseline for combustible dust. Food-contact and medical applications add FDA and EU food-contact material compliance for product-contact equipment and resins.

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