Convert eligible blown-film, cast-film, and selected sheet edge trim or off-spec rolls into reusable pellets that can be conveyed, stored, and accurately blended back into an approved production recipe.
Meet the Sasquatch by Advanced Blending Solutions. Sasquatch is a direct-extrusion film repelletizer family with Alpha and Omega models covering published estimated rates from 110 to 551 lb/h.
Direct film-scrap extrusion
Designed around lightweight process scrap such as eligible edge trim and identified rolls.
Converts compatible scrap into a conventional pellet form for the connected resin system.
Published Alpha and Omega estimates span 110 to 551 lb/h, depending on material.
Recovered pellets can return through conveying, storage, blending, and recipe controls.
Representative normal and worst-approved scrap can be evaluated in the manufacturer’s lab.
Sasquatch is most compelling when a plant has clean, known post-industrial film scrap and a defined place to reuse the pellet. Polymer compatibility, heat history, print, coating, contamination, moisture, feed form, and final product requirements still govern the result.
Continuous edge trim or identified film rolls from a controlled blown-film, cast-film, converting, or selected sheet process.
These materials may still be candidates, but they demand representative testing and a written review of filtration, volatiles, compatibility, degradation, pellet condition, and downstream quality.
Scrap that needs washing, sorting, aggressive size reduction, densification, separation, or broad contaminant removal belongs in a different recycling-system review.
Qualification boundary: pelletizing changes the scrap into a feedable form; it does not make incompatible material compatible or automatically make the pellet equivalent to virgin resin. Approve the reclaim percentage through material and finished-product testing.
The repelletizer is the conversion step. With controlled scrap capture, pellet cooling and collection, conveying or buffer storage, accurate reclaim dosing, line permissives, and a quality plan, Sasquatch can be engineered into a fully closed material-recovery loop.
A practical line identifies where scrap originates, how it enters the repelletizer, where the pellets collect, which destinations are permitted, how the reclaim ratio is controlled, and what happens during a stop, roll change, contamination event, or material change.
Important: for eligible clean and controlled film scrap, direct extrusion may remove a separate grinder as the first step. It is not a universal no-preparation claim for every roll, trim geometry, or material.
Continuous edge trim creates a repeatable base load. Rolls and startup scrap create intermittent peaks. A combined project must be sized around the real operating sequence—not only the plant’s annual scrap total.
Continuous trim from a known recipe can be collected and fed inline while the production line runs, subject to feed stability and rate confirmation.
Edge or web scrap from cast film and selected thin-sheet processes can be reviewed around construction, thickness, trim geometry, speed, and feeding.
Identified rolls create scheduled recovery batches. Record roll width, diameter, weight, core, tension, construction, and expected feed rate.
One project may serve a continuous trim load plus planned roll reclaim. Verify whether those demands overlap and how the controls prioritize them.
The current Sasquatch literature describes advanced melt-temperature control, an enlarged feed entry that reduces bridging risk, a large collector chamber for improved pellet transport, compact and efficient design, and easy cleaning access.
Choose the rate range only after the plant separates eligible scrap from total scrap and records normal, peak, and simultaneous demand. The attached August 2026 cut sheet is the controlling source for this table.
| Series | Model | Published estimate | Approximate metric |
|---|---|---|---|
| Alpha Series | |||
| Alpha | Alpha XS | 110 lb/h | 50 kg/h |
| Alpha | Alpha S+ | 198 lb/h | 90 kg/h |
| Alpha | Alpha M | 265 lb/h | 120 kg/h |
| Alpha | Alpha L | 375 lb/h | 170 kg/h |
| Omega Series | |||
| Omega | Omega Compact | 220 lb/h | 100 kg/h |
| Omega | Omega S | 331 lb/h | 150 kg/h |
| Omega | Omega M | 441 lb/h | 200 kg/h |
| Omega | Omega L | 551 lb/h | 250 kg/h |
Published-rate note: every rate is a manufacturer estimate and varies by material type. Metric values are rounded conversions of the published lb/h estimates. Final performance, model, cooling, pelletizing, utilities, controls, footprint, and integration require representative material testing and written quotation. The current cut sheet does not publish universal family-wide horsepower, energy, footprint, heater-zone, or screen-changer specifications.
Minimum, normal, peak, duration, and whether trim and roll recovery overlap.
Polymer grades, layers, additives, print, coating, color, thickness, and heat history.
Trim count and width, web tension, roll dimensions, core, density, static, and consistency.
Pellet condition, filtration, melt flow, gels, reclaim percentage, and finished-film criteria.
Power, cooling water where required, compressed air, ventilation, space, access, and ambient conditions.
Receivers, pump, conveying route, storage, blender, line controls, reporting, and future capacity.
Advanced Blending Solutions can connect the Sasquatch conversion step to receivers, central conveying, intermediate storage, gravimetric blending, weigh hoppers, route controls, alarms, reporting, and remote support.
A qualified system identifies the recovered pellet by source and recipe, transfers it to a receiver or buffer, and meters a controlled percentage with virgin resin and additives. If several machines or products share reclaim, routing permissions and material identity become part of the controls scope.
Move cooled reclaim from collection to an approved receiver, buffer, blender, or production destination with the right velocity, filtration, line size, and controls.
Plan the return route → Recipe accuracyMeter recovered pellets at a controlled percentage with virgin resin and additives, then document the recipe and operating window.
Review reclaim dosing → Line coordinationCoordinate permissives, feed status, temperature, reclaim ratio, destination, alarms, trends, recipes, and optional remote troubleshooting.
Review controls engineering → Wrong-route preventionWhen several sources or destinations share hoses, route verification can help prevent reclaim from reaching the wrong silo, blender, or line.
See verified routing → Material-path protectionReview conveying fines, pump protection, and magnetic separation separately when the scrap, pellet-return route, or downstream equipment requires them.
Review contamination control → Finished-film validationConnect reclaim trials to actual thickness, profile, basis weight, startup scrap, and finished-product performance rather than judging pellet appearance alone.
Review film measurement →
Advanced Blending Solutions supports scalable PC- and PLC-based controls, including Allen-Bradley and Beckhoff architectures, custom software modules, recipe integration, process visibility, and optional remote support subject to plant network and cybersecurity approval. Final platform, I/O, historian, interfaces, alarm strategy, and support enrollment are quoted by project.
Total plant scrap is not the numerator. Separate eligible, captured, successfully pelletized, and approved reclaim from material that is mixed, contaminated, prohibited, unavailable, or assigned to another recovery route.
Choose the receiving, storage, conveying, routing, blending, drying, and controls tasks that surround the repelletizer. The selector will organize a practical starting architecture for the connected material system.
Scope boundary: the selector narrows connected equipment and quote inputs. It does not independently approve the film for reuse, choose a Sasquatch model, or replace representative material testing.
You do not need to choose Alpha or Omega first. A short operating history, representative scrap, photos, a marked-up layout, and the intended reclaim destination are enough to begin a technical review.
Provide what you know. Unknowns become explicit test or engineering items instead of hidden assumptions.
Include available melt-flow or rheology data, resin and film specifications, scrap samples from good and bad production periods, screen-change history, gel or contamination concerns, current salvage route and value, pellet and finished-film acceptance tests, power details, cooling-water conditions, compressed air, ventilation, line-control platform, I/O and network standards, cybersecurity requirements, alarm and historian expectations, installation responsibilities, and planned commissioning support.
Use these Gauge Advisor resources to validate the scrap route, material-return architecture, finished-film performance, and next engineering step.
Compare direct extrusion with other scrap-recovery architectures and review fit limits, trials, pellet quality, and business-case inputs.
Read the guide → Complete material pathConnect scrap recovery to receiving, storage, conveying, drying, routing, blending, controls, and plant support.
View the equipment pillar → Interactive planningOrganize the equipment families and application questions that surround the repelletizer and pellet-return path.
Open the selector → Blown-film performanceReview thickness profile, air-ring response, cooling, bubble stability, startup scrap, and process-control opportunities.
Review blown-film control → Melt qualityEvaluate stable melt pressure and downstream filtration separately where reclaim changes screen loading or melt quality.
Review melt filtration → Verify the outcomeMeasure thickness, basis weight, profile, and process response before and after the qualified reclaim recipe is introduced.
View film measurement →These answers establish a practical starting scope. Final material fit, model, rate, cooling, pelletizing, filtration, controls, utilities, installation, performance, reuse percentage, and support require representative testing and written Advanced Blending Solutions engineering.
