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Recycled plastic drying Equipment

Industrial drying machines are designed to remove moisture from your product. But the drying process must cater to variations in the state of matter and molecular structure of the input material. Industrial dryer technology exploits the modes of heat transfer (convection, conduction, radiation, evaporative cooling) to control the moisture content.

Drying

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

Pusher centrifuges are continuously operating filter centrifuges and can have several basket stages depending on the application. Widely used for processing salts, fertilizers, but also plastics, soda and cellulose.


<h2>Continuous solids throughput under the toughest conditions</h2>
Pusher centrifuges from Ferrum are continuously operating filter centrifuges that are based on the very successful Sulzer Escher Wyss design. The slurry is fed continuously to the product acceleration disc via the filling pipe. The solids are transported out of the centrifuge basket into the discharge channel, from where they leave the pusher centrifuge. The cake is cleaned in the centrifuge by adding washing liquid on to the solid cake.

Various models have been developed with basket sizes ranging from 230mm to 1200mm. The most common applications are developed in agricultural and petrochemical industries, such as filtration for obtaining zinc sulphate, lysine, nitrocellulose, sea salt, sodium carbonate, urea, Glauber’s salt, potassium chlorate, potassium nitrate, linters and so on.

Pusher centrifuge

<span style="font-weight: 400;">Heating, cooling and tempering are important processes in the production of many products across all industrial sectors. For non-sterile manufacturing, heat exchangers need to be robust, reliable and efficient. For sterile products and pharmaceuticals production, heat exchange solutions must meet the stringent hygienic GMP requirements. </span>
<h2>Tailor-made shell and tube heat exchangers</h2>
<span style="font-weight: 400;">Ipros produce a range of bespoke and standard design heat exchangers suitable for use in a wide range of processes in the pharmaceutical, chemical, food and beverage, and power sectors. They are well known for their high quality construction to the EN 13445 standard and the PED/2014/68/EU </span><span style="font-weight: 400;">pressure equipment directive, and offer a range of designs for different use-cases.</span>

<span style="font-weight: 400;">For pharmaceutical and sterile production environments, the shell and tube heat exchangers are available which meet all GMP/FDA requirements. Additional features on the pharma range include full drainability on product side, aseptic connections DIN 11864, and a product-side surface finish electropolished to Ra &lt; 0.4µm.</span>

<span style="font-weight: 400;">Working ranges for all versions include pressures up to 10 bar, temperatures up to 180°C, and flow rates up to 30,000 litres per hour.</span>

<span style="font-weight: 400;">Available in horizontal or vertical mounting styles to suit your needs, the standard shell and tube heat exchangers range in size from 750mm to 3000mm.</span>

<span style="font-weight: 400;">Standard versions are available with a short lead time and excellent performance to price ratio where a “best fit” solution is optimal. A wide range of special designs are available on request for a completely bespoke solution. Options include floating heads, higher pressures and temperatures, different connection standards, different materials, passivation, and many more.</span>

Shell and tube heat exchanger

The production of high-quality biltong and similar dried meat products can pose problems with maintaining product quality, as well as the high energy cost associated with traditional drying solutions. A cutting-edge closed-loop system can not only deliver significant savings in energy costs but can also deliver superior product quality thanks to more efficient, lower temperature operation.


<h2>Standalone cabinet dryer for biltong and dried meat products</h2>
The WRH100G cabinet dryer from IKE is suitable for drying batches of 15 to 100kg of product using heat pump technology.

Warm, dry air enters at the bottom of the cabinet, and warm moist air exits at the top, where it is passed to the heat exchange unit. There is no cross-contamination between products, so different items can be dried at the same time. The closed-loop heat exchange system means there is no moisture in the cabinet to condense and drip, another problem with traditional solutions.

Featuring 15 shelves, the operation of the unit is simple thanks to touchscreen control. Set target temperature and humidity level and the machine will operate until the targets are met. There is no risk of over-drying the product, and quality is maintained from batch to batch. No other external connections are required - simply plug into a standard 220v supply.

By avoiding the use of traditional electric drying methods, the WRH100G provides energy savings of up to 80%.

All stainless-steel exterior construction means the WRH100G is easy to clean, and sturdy wheels enable to easy move it around, maximising your use of space. 15 open-mesh shelves mean there is no requirement for the manual turning of the product during the drying cycle. Alternatively, the product can be suspended in the cabinet.

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Industrial drying cabinet

Drying can be the most energy and time-consuming process in the food industry. This can have an effect on the quality of the produce. The batch flow technique can efficiently remove the maximum amount of moisture using the minimum amount of air, also saving on your energy costs.


<h2>A clean drying solution for high capacity and fast changeovers, maximizing energy efficiency</h2>
The Geelen Counterflow Batch dryer is a sustainable solution that monitors energy performance using an online energy efficiency indicator. It increases energy efficiency by 15-25% ensuring the maximum amount of moisture is removed using the minimum amount of air. Its drying process starts at the lowest deck and sequentially moves through the upper decks to ensure no product cross-contamination. Every product batch is treated individually in separated drying zones.

The batch dryer provides excellent moisture uniformity. The amount of evaporation can be controlled on each deck by variations of the drying air volume and temperature. Unlike crossflow dryers, it incorporates an online microwave moisture sensor that provides a solution of controlled and uniform moisture discharge during the process.

The recirculating batch dryer also comes in a large number of deck perforation designs suitable for drying in the pet food, aqua feed, or any granular food product industry that requires the highest standards of sanitation. This includes breakfast cereals, snack foods, coffee beans, cocoa, chocolate, breadcrumbs, couscous, fruits, vegetables, and nuts. It is designed to achieve the lowest need for cleaning and fastest cleaning times using the power of gravity flow to keep a dryer clean.

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Recirculating batch dryer

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

Salmatec is a manufacturer of pelleting presses, assembly components, and complete units. Based in Germany, the supplier offers solutions for feed, renewable raw materials, and recycling industries.

Plastic recycling has a dynamic duo: mechanical and chemical.

Chemical recycling is still in the research stage, aiming to convert plastic into its original building blocks. But our interest lies in mechanical recycling, which involves first sorting, cleaning, and shredding the plastic material and then transforming it into small, uniform pellets.

With no standardized global sorting system in place and a wide range of plastic types, plastic recycling results in a shockingly low recycling rate of only 9%. Fortunately, countries are joining forces to raise this percentage together by establishing uniform recycling guidelines and investing in the development of sorting facilities.


<h2>Give plastics a second chance.</h2>
We spoke with Timo Muller, from <a href="https://www.salmatec.de/de/" target="_blank" rel="noopener">Salmatec</a>, an expert in pelleting technology, about how pelletizing plastics reduces emissions, conserves energy and gives plastics a new life.

But what potential products can be made from recycled pellets?

“<em>Well… you might have even sat on one of them,</em>” replies Timo. “<em>When park benches are not made of wood, there’s a good chance they’re actually made from recycled plastic pellets.</em>”

They typically have a grayish color, but if you look closer, you’ll spot red and yellow colors, which are a testament to the plastic waste that has been reborn.

“<em>Another popular use for pellets involves the production of plastic pillars and various construction materials. The only restriction is that they cannot be used for food packaging due to hygiene concerns,</em>” says Timo.
<h2>Why do pelletizing plastics play a crucial role?</h2>
“<em>Plastic bottles are typically larger and have a more complex shape compared to pelletized plastic. If you have to melt a plastic bottle, you need more energy to reach the necessary melting point. Pellets just melt faster,</em>” explains Timo.

Pelletizing allows for maintaining the same weight of plastic while significantly reducing its volume saving valuable energy resources.

“<em>Salmatec pellet mill stands out for its energy efficiency in terms of energy consumption per ton of pellet output. This is achieved due to two motors that work in tandem evenly distributing power, minimizing energy waste, and maximizing utilization</em>,” continues Timo.

Before entering the pellet mill, plastic waste needs to be reduced to a particle size of 4 cm. Larger sizes pose a risk of machine plugging and breakdown. The second important factor is moisture.

“<em>Pellet moisture should not exceed 15%, preferably below 10%. It is imperative to check all parameters before entering the pelleting line</em>,” adds Timo.

Recycled plastic pellets are easy to handle, making transportation and storage more efficient while minimizing fuel consumption and our carbon footprint. Moreover, these compact pellets require significantly less space on-site. And who doesn't always need a little extra space?

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

Chemical

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

Find production technology for Recycled plastic drying, and connect directly with leading machine manufacturers worldwide

Recycled plastic drying Equipment

Which recycled plastic drying equipment do you need?

Pusher centrifuge

Shell and tube heat exchanger

Industrial drying cabinet

Recirculating batch dryer

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