Abstract: Conventional water-washing and melt granulation equipment for residual agricultural film recycling has long been plagued by three major challenges: high energy consumption, substantial water requirements, and a significant tendency to generate microplastic pollution. These inherent limitations have severely restricted its application in the arid and semi-arid agricultural regions of Northwest China, where water resources are particularly scarce and environmental sustainability is of paramount importance. To address these critical challenges, this research developed an innovative dry granulation device specifically engineered for processing residual film after dry cleaning operations. The design incorporates the technical advantages of existing water-based systems while effectively adapting to the unique material characteristics and handling requirements of dry-cleaned residual film.The development process employed a comprehensive methodology that integrated theoretical analysis with experimental validation. Key components including the granulation barrel, rotating moving blade assembly, and stationary fixed blade system were systematically designed with optimized structural parameters through rigorous engineering calculations and design iterations. Through detailed kinematic and mechanical analysis of the granulation process, the critical factors influencing equipment performance were identified and their operational ranges were precisely determined using advanced analytical methods and experimental data. To verify the structural design rationality and functional performance, sophisticated numerical simulations were conducted using state-of-the-art simulation software to analyze both the film feeding process dynamics and the particle mixing behavior under various operational conditions. Experimental verification was performed using three key operational parameters as test factors: rotational speed of the moving blade, wedge angle of the fixed blade, and the length of the upper end of the stirring blade. The residual film feeding rate and granulation efficiency were selected as the primary evaluation indicators to comprehensively assess the system performance.The experimental program began with systematic single-factor tests to establish preliminary parameter ranges and optimize testing efficiency while reducing overall experimental costs. Subsequently, response surface methodology was implemented to develop accurate regression models that precisely describe the relationships between the operational parameters and performance indicators. Through multivariate regression analysis and optimization algorithms, the optimal parameter combination was determined to be: rotating blade speed of 754.5 r/min, fixed blade wedge angle of 39.57°, and upper stirring blade length of 97.2 mm. This configuration achieved remarkable performance with a film feeding rate of 92.77% and a granulation rate of 95.56%, demonstrating excellent processing capability. Prototype validation tests were conducted under practically adjusted parameters of 755 r/min blade speed, 40° wedge angle, and 97 mm stirring blade length to accommodate manufacturing tolerances and operational practicality. The results demonstrated outstanding operational performance with average feeding and granulation rate of 91.71% and 94.16% respectively. These values showed minimal deviations of only 1.06 and 1.40 from the theoretical predictions, conclusively confirming the accuracy and reliability of the optimization models and design approach.This research provides a practical and efficient technical solution for addressing the persistent problem of residual film accumulation in Northwestern regions such as Xinjiang. The developed dry granulation technology effectively eliminates water consumption, significantly reduces energy requirements, and prevents secondary microplastic pollution that typically occurs in conventional water-based systems. The successful implementation of this technology offers a sustainable and environmentally responsible approach for managing agricultural plastic waste in water-sensitive environments while promoting advanced agricultural practices in dryland farming regions. The innovation represents a significant step forward in sustainable agricultural waste management and contributes to the development of circular economy principles in agricultural production systems.