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Maker - Product Challenge

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Plastic Granulation Equipment

Plastic pollution is one of the biggest climate-related problems mankind has. So what are your options? A bioplastic machine can help create an alternative to traditional plastics. Bioplastics, differently from regular plastics, don’t cause environmental contamination. Also, they don’t contain harmful ingredients and additives. Even with these benefits, the annual production of bioplastics is still less than one percent of all plastic making. However, the market is witnessing steady growth due to a rise in demand.

Bioplastics

When he was in Haiti in 1493, Christopher Columbus noticed that the natives were bouncing on rubber balls made from the milky sap of Hevea brasiliensis, also known as a rubber tree native to South America. The milky sap was nothing but latex, the source material for natural rubber. Latex processing technology includes equipment for coagulation techniques and rollers for natural latex and a sequence of mixers, pumps, and sieves for synthetic latex.

Latex

Also known as color concentrates for plastics, masterbatches are plastic granules that contain additives for coloring plastics. Their major purpose is to bring vibrance and improve the final product's appearance. In the process of making them, masterbatch production equipment is used to combine two major constituents—colorants and polymer-specific carriers.

Masterbatches

All plastics are polymers, but not all polymers are plastics. Polymer production is a multi-step process that transforms raw materials into products that we use in our day-to-day life with the help of polymer process equipment such as extruders, calenders and injection molding machines.

Polymers

The ubiquitous plastic shopping bag was first designed as a reusable carrier. Its inventor, Sten Gustaf Thulin, will have been appalled to see his creation turn into a single-use object. But this disposable tendency is common to all plastic materials, from screw taps to milk carton lining. With plastic recycling equipment, however, plastic waste can be reprocessed and given a second lease of life.

Recycled plastic

Despite only one letter difference, silicon and silicone are two different things. While silicon is the 14th chemical element on the periodic table, silicone is a synthetic material that, among other chemical elements, contains silicon. Although commonly observed as plastic, technically silicone is rubber. Among others, silicone processing equipment mainly involves several high-temperature machines, mixers and molds.

Silicone

As traced back to the first half of the 19th century, attempts at synthetic rubber production were simply to reproduce the original material due to the rubber shortage following World War II. Synthetic rubber production processes differentiate between producing the rubber, which can be done via solution polymerization and emulsion polymerization and creating the final product with the help of techniques such as molding and vulcanization.

Synthetic rubber

When it comes to aquafeed, you can find three types of pellets: floating pellets, sinking pellets, and slow-sinking pellets. Not all aquatic species eat at the same height of the water column. For example, tilapia and carp eat at the surface (floating pellets) while shrimp and sea bass eat at the bottom (sinking pellets). Slow-sinking pellets are ideal for species that eat along the water column such as salmon and cod.  To get the pellets to sink at the right rate, slow sinking pellets production must control water stability in the products.

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Slow sinking pellets

Cross-scissor-cut rotor guarantees optimum material intake and distribution

Cost-effective comminution of all kinds of plastics

User-oriented machine

Reduced energy consumption

Optimal accessibility for quick and easy cleaning

Continuous milling is a flow production method used to grind materials without interruption. It is often used in the production of foods, cosmetics, pharmaceuticals, chemicals, and minerals. The material to be processed flows in at one end and the milled output flows out at the other in a continuous process. By choosing the right combination of milling technology and processing power you can obtain the desired particle size distribution in an uninterrupted stream.

Continuous milling solutions

A granulator is a high-speed knife mill designed to cut down large components of feedstock and reduce them to smaller particle sizes. Selecting the right scissor geometry and configuration allows granulators to process plastic bottles, organic fibers, films, wires, cables, and other difficult materials. Agglomeration granulators combine fine particles into larger granules by creating bonds between them. Bonds are formed by compressing fine particles or through the use of a binding agent.

Granulators

Biomass

Chemical

Feed

Granulation

Connect directly with world leading manufacturers of Granulation equipment and find technology to build or improve your production line.

Granulation &ndash; Making.com

Aquaculture feed is used when rearing marine livestock such as fish, shellfish, and algae. Quality nutrition is needed for healthy growth and reproduction and feed usually consists of fats, carbohydrates, protein, vitamins, and minerals. Extruded aquaculture feed floats on the water surface and pressure-pelleted feed will sink to the bottom.

Aquafeed

Due to their potential hazardous nature, chemicals are classified for proper identification and safety during production. Chemical classification depends on their properties, structures and functions. In the chemical industry, you can regard them as basic chemicals such as acids, chemical products to produce plastic materials and finished chemicals for use in cosmetology. As a manufacturer or engineer, you want to know their reactivity when using chemical processing equipment.

Chemicals

We continuously talk to suppliers of feed processing technologies that have important know-how on how to create the smarter, better, and greener feed products we need to kickstart a better tomorrow. Are you into making animal feed or pet food and looking for ways to improve your production process? Let’s navigate the world of feed production technologies together!

Can it be said that we live in the Plastic age? Basically, yes. From pillows over toothbrushes, and packaging to utensils, plastic is a widely used material in our day-to-day lives. But what is it? Plastics are synthetic or semi-synthetic materials built of polymers that are easily shaped into various structures with the help of plastic processing equipment such as extruders and molders.

Plastics

Process

Continuous

Milling machines are used to reduce the size of material by cutting, crushing, or grinding it. The choice of industrial milling equipment depends on the industry and the materials to work with. Besides, there is a significant difference between those aimed to remove layers from metal or other materials workpieces and those designed to reduce particle size for materials that come in bulk.

Milling

solid

Compact granulator for cuttable products from Hosokawa Alpine offer all the technology necessary for the cost-effective comminution of all kinds of plastics

When working with plastics, film, and other cuttable products, you can benefit from a custom-designed granulator. Cost-effective granulation at an

Compact granulator for cuttable products &ndash; Making.com

We open production technology to everyone

Making.com

Landline telephones in the 1980s were minimalist gadgets that kept getting slimmer in the 1990s. In contrast, cell phones in the same period were bulky and cumbersome. And once they lost their charge, they turned into a giant paperweight. Then came a revolution in batteries and automation with lithium-ion battery manufacturing equipment. Mobile phones packed more power, recharged faster, and endured more recharge cycles. Above all, they were light and small, making cell phones the inseparable companions they are today. But Lithium-ion batteries power much more than phones. As a result, the world is seeing steady growth in battery manufacturing equipment and lithium-ion production lines.

Lithium-ion batteries

Laundry detergents are currently on the rise due to increasing urbanization and the need for automation. The global market will reach $98,139.7 million by 2030 from $61,711.0 in 2020, influencing the demand for laundry detergent equipment. Unlike in Western countries, powdered detergents are more popular in Asia and China because they’re cheaper.

Laundry detergent

Limestone

Open rotor with powerful parallel cut

Compact design

Easy to clean

Sizes from 15 – 500 kW

The exchangeable feed control bars ensure optimal product feeding characteristics

Food

Metal

Mineral

The battery revolution is as old as the industrial revolution. But batteries only emerged as a viable power source with lithium-ion solutions in the last quarter of the 20<sup>th</sup> century. Today, anything from power tools to automobiles runs on batteries, but advances in battery making equipment are eyeing more ambitious undertakings. Will we ever see battery-powered container ships? Will Battery Energy Storage Systems grow grid-scale successfully? Production technology is steadily moving towards this vision.

Batteries

We carry dozens of metals around every day. The ubiquitous smartphone is built with no less than 20 metals, each with specific behaviors and purposes. Metals are a pervasive class of materials that have defined entire eras of human development. It is no exaggeration to say that metal processing equipment is the core of our metallic world. But, paradoxically, this manufacturing technology itself is mainly made of metal.

The nearly 5,000 known minerals on earth share some characteristics to be classified as minerals – they are inorganic, solid, naturally occurring elements and have a particular chemical formula and an ordered internal geometric structure. However, minerals are not all the same. One way to divide them is based on their physical characteristics such as hardness, luster, color, and shape. For example, the diamonds we use to make jewelry are very hard minerals while talc is a soft mineral; gold is a shiny mineral while others are less so.

Minerals

Cutting

The Ro Rotoplex from Hosokawa Alpine is a large granulator that offers process technological superiority and improves material feeding characteristics.

When high cutting forces and high throughput are required, you need a granulator that has proven its reliability under the hardest of tasks. High

Large granulator &ndash; Making.com

The wave of liquid soaps and detergents in the 1950s revolutionized home and personal care. Cheap and convenient, these off-the-shelf products fit perfectly into the lifestyle of the time. A few decades later, though, plastic waste put the sustainability of hygiene products into question. Refill tablet production technology answers that by eliminating single-use plastic. Instead of picking up a new bottle every time, end-users complete the formulation process in a multi-use container and with a simple instruction: just add water.

Refill tablets

3 different product lines

Drive power 5.5 – 55 kW

Double scissor-cut rotor

Optimal product feed

Integrated noise insulation

Polymer line granulator from Hosokawa Alpine designed for size reduction of mouldings, blown containers, sprues, flashes and other polymers.

When it comes to the low-dust and cost-effective comminution of mouldings, blow mouldings and sprues and flashes, polymer line granulators are your best

Polymer line granulator &ndash; Making.com

<h2>Making plastics - from crude oil to plastic pellets</h2>

Although originally a natural product, nowadays plastic is mostly synthetic and widely produced. The production starts with <a href="https://www.youtube.com/watch?v=ggh0Ptk3VGE" target="_blank" rel="noopener">extracting oil</a> from the underground with the help of pumps that produce between 5 and 40 liters of oil per stroke, which is then transported to an oil refiner through pipelines. The crud oil is poured into preheater, where it is boiled and sent to a furnace. There, according to its molecular weight, oil is separated into several groups of <a href="https://making.com/products/chemicals">chemicals</a> — petroleum, gasoline, paraffin, etc.

For plastic manufacturing, <a href="https://www.livescience.com/how-oil-is-turned-into-plastic.html" target="_blank" rel="noopener">what's essential is naphtha</a>. Naphta has to be broken down into smaller units in a cracking process to get ethene. There are two types of <a href="https://www.bpf.co.uk/plastipedia/how-is-plastic-made.aspx#[3%20NEW" target="_blank" rel="noopener">cracking processes</a>. Stem cracking is done at high temperatures and pressure, which is not required for catalytic cracking, which uses catalyst instead. Ethene is forwarded into a reaction chamber where the process of polymerization links the hydrocarbon monomers together into thick, viscous substances used to make plastics. The resulting product, polythene, is processed into strings in an extruder before being ground into pellets dispatched to factories to be molded into end products using various plastic machinery.

<h2>Plastic processing equipment and transformation of pellets into usable products</h2>
Forming usable plastic products, for instance, bottles, hoses, or toys, is executed using <a href="https://www.britannica.com/science/plastic/The-processing-and-fabrication-of-plastics" target="_blank" rel="noopener">various processes</a>: compounding, <a href="https://making.com/technologies/forming">forming</a>, thermoforming, <a href="https://making.com/technologies/extrusion">extrusion</a> and molding. Compounding is the first step - mixing liquids with other ingredients according to the desired recipe in conventional stirred tanks. Other essential plastic processing equipment includes two types of mixers; the workhorse mixer, which applies heat and pressure simultaneously, and the Banbury mixer which reminds of a robust dough mixer with two interrupted spiral rotors.

The next step is forming plastics into various shapes by melting, shaping, and solidifying. Extrusion and <a href="https://making.com/technologies/moulding">molding processes</a> create finished or semi-finished products. During extrusion, the melted <a href="https://making.com/polymers" target="_blank" rel="noopener">polymer</a> is continuously forced through an orifice in an extruder for products such as sheets, tubing, and grocery bags. Various types of molding rely on molds to create the desired shape.

To illustrate, <a href="https://www.activeplastics.co.nz/types-of-plastic-moulding" target="_blank" rel="noopener">rotational molding</a> produces large, hollow products such as kayaks. On the contrary, blow molding is used for small hollow pieces - bottles or fuel tanks. With compression molding, plastic parts can replace metal in the automotive industry. Finally, the most common type, injection molding, has virtually limitless uses with a large production capacity.

Plastics are classified according to their unique properties acquired during production processes. The main classification is based on how plastic responds to heat - it is differentiated between <a href="https://plasticseurope.org/plastics-explained/how-plastics-are-made/" target="_blank" rel="noopener">thermoplastics and thermosets</a>. Thermoplastics are more common than thermosets. They can be heated without burning, melted, cooled and reheated without losing their properties. On the other hand, thermosets can be heated only, typically during injection molding, once due to irreversible chemical changes.

Classification of plastics 

Any further heating would result in burning. For this reason, thermosets are not recycling-friendly. Further categorization is between amorphous, also known as shapeless, material and semi-crystalline material. While the former gradually softens when exposed to heat, the latter maintains its shape until a certain temperature point, when it rapidly becomes liquid. Finally, according to their monomer composition, plastics can be classified as homopolymers, made of a single type of monomer, or, on the contrary, copolymers.

<h2>Bioplastics, biodegradable plastics and recycled plastics - ecological alternatives?</h2>

The environmental effects of plastic are a widely known topic. It takes up to 450 years for a plastic bottle and <a href="https://australian.museum/blog-archive/science/interesting-plastic-facts/" target="_blank" rel="noopener">50 to 80 years</a> for a plastic cup to decompose. Alternatives to traditional plastics are <a href="https://www.explainthatstuff.com/bioplastics.html" target="_blank" rel="noopener">biodegradable, bio-based and recycled plastics.</a> Biodegradable plastics are made of petrochemicals but degraded by microorganisms. However, it can be safely done under warm conditions; otherwise, it degrades into harmful microplastic.

<a href="https://making.com/bio-plastics" target="_blank" rel="noopener">Bioplastic</a> is sourced from renewable natural materials (corn, sugarcane, cellulose), which are compostable. The downside is that using food sources, as well as that, owing to chemical and mechanical differences, can be challenging to recycle. Finally, <a href="https://making.com/recycled-plastic" target="_blank" rel="noopener">recycled plastic</a> does not exploit raw material, but it can be used only to produce lower-grade products. Furthermore, it uses energy, water and emits gases. However, it is important to <a href="https://www.fortum.com/products-and-services/recycling-waste/fortum-circo/news-and-articles/bioplastic-vs-recycled-plastics-terms-sustainability" target="_blank" rel="noopener">recycle already existing materials</a> as replacing them with mass production of non-reusable lower-quality products is not the ideal solution either.

Considering that bioplastics, biodegradable plastics and recycled plastics have downsides, <a href="https://dailytimes.com.pk/572643/the-hungry-gut-bacteria-that-enable-waxworms-to-live-on-plastic-waste/" target="_blank" rel="noopener">scientists from Canada’s Brandon University</a> have found a unique possible solution. Namely, they discovered that waxworms could live off polyethylene. Their guts contain bacteria that biodegrade plastics and turn them into glycol. In the lab-controlled environment, 60 waxworms can eat more than 30 square centimeters of a plastic bag in less than a week. While it is unrealistic to expect that waxworms can solve the plastic pollution issue, understanding the symbiosis of waxworms and gut bacteria could lead to the development of better plastic biodegradation systems.

Green innovations - plastic-eating waxworms 

Plastic Processing Equipment

Find production technology for processing plastics and connect directly with leading machine and equipment manufacturers worldwide.

Plastics &ndash; Making.com

Plastic Processing Equipment - Making.com

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At the industrial level, the application areas of pellets range widely in fields such as feeds, biomass, wood chips, sawdust, and other renewable raw materials. To adapt to the most diverse requirements, the pelleting presses must have a modular design while keeping maintenance costs low and providing a long service life.


<h2>Producing pellets using a modular pelleting press with an energy-efficient direct drive</h2>
The MAXIMA Pellet Mill from SALMATEC is an industrial-grade pelletizer capable of producing pellets for various applications like feeds, woodchips, recycled plastics, and many more renewable raw materials. The system has a vertical ring die with optional 2 or 3 rollers that can be equipped with a cooling system. The rollers press the product through the ring die at the highest possible pressure before cutting it down to the right size with its adjustable knife. The system has a lifting frame to support heavy parts such as rollers and dies removed during maintenance.

The unit has a central lubrication system that automatically lubricates the rollers and the main bearings. A maintenance drive is equipped inside a well-ventilated housing for larger units to ensure slow and safe die rotation for work on the press tools. The system is made from high-quality materials and complies with the latest safety standards and guidelines. The Maxima provides energy efficiency and equal power transmission thanks to a one-step operated v-belt drive. The system is available in various capacities of up to 50 tons per hour, depending on the type of machine and product application.

Industrial pellet mill

Large industries are shifting towards more environment-friendly technology, such as recycling wastes and utilizing them as an alternate energy source. For instance, sawdust and wood chips from wood mills are collected and processed into pellets which can be used in households or large industrial plants as a source of energy for heating systems. Plastic waste can also be recycled and made into pellets. Later these will be used in injection and molding machines to produce bottles, containers, or bags.


<h2>Turning wood and plastic byproducts into uniform pellets using a complete pelletizing system</h2>
The Complete Pellet Line from SALMATEC is a pelletizing system that includes multiple processes from conditioning raw materials and turning them into uniformly sized pellets. The entire system is specifically designed for the required product specifications. The conditioner helps the products achieve the optimum amount of moisture before feeding them to the pelletizer. The moisture content of raw materials can be controlled through a conditioning system in which the product moves inside a chamber while steam is also injected.

The pelletizer can be equipped with 2 or 3 rollers and multiple knives to cut the extruded products from the die into the necessary pellet size. The pellets then go to the cooler to prevent them from sticking to each other before storing them for at least one day in the silos. This process allows the structure of the pellets to stay intact and prevents them from breaking into tiny particles. Each complete system is designed according to the desired production capacity, raw material input, and high safety standards.

Complete pellet line

Plastic recycling has a dynamic duo: mechanical and chemical. Chemical recycling is still in the research stage, aiming to convert plastic into its

Every pellet counts! Let’s make the plastic recycling process greener &ndash; Making.com

Every pellet counts! Let’s make the plastic recycling process greener

Deborah

Find production technology for Plastic Granulation Equipment, and connect directly with leading machine manufacturers worldwide.

Plastic Granulation Equipment

Which plastic granulation equipment equipment do you need?

Compact granulator for cuttable products

Large granulator

Polymer line granulator

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