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Recycled plastic extrusion Equipment

The extruder was first developed to make lead pipes in the late 18th century. But the extrusion process technique quickly spread to other manufacturing sectors, including food, feed, and biomass products. An extruder machine presses a fluid or solid material through a die. Depending on your use case, extruders adopt single- or twin-screw systems to push the premixed feed material through a barrel. Thermal pressure applied in this step can chemically modify the mixture, so the screw system must be precisely calibrated to achieve the desired result. Finally, a knife head cuts the extruded material into your designed dimensions. Extrusion machinery produces items of a uniform size, shape, and consistency.

Extrusion

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

Low pressure extrusion for the production of slightly dispersed dust-free granulates. For shingled, highly porous granulates with good dispersal properties. With the basket extruder the material is compressed with an extrusion rotor with a perforating die.


<h2>Gentle pressure for granulates with a loose structure and large surface area</h2>
With the Bextruder BX from Hosokawa Alpine, the product is gently pressed to granulate with a loose structure and large surface area.

In the product chamber of the Bextruder two rotors operate in counter rotation. The upper rotor ensures good mixture and carries the material downwards. The lower extrusion rotor compresses the material and extrudes it through the screen basket.

The Bextruder is often used in pellets with a porous structure and large surface area, easily dispersible granulate, drinks powder, sauces and soups, detergent, pesticides and so on.

Basket extruder

Products can be extruded with a variety of shapes and characteristics by controlling the nozzle geometry and pressure and temperature characteristics of substrates as they are propelled through a screw style mixing machine. Precise control of pressure at the point of extrusion is essential to predictable, desirable results.


<h2>Small scale, precisely controlled extrusion of animal feed</h2>
Amandus Kahl’s Extruder OE 8 is a small batch or laboratory extruder that works on the same principal as the successful Annular gap expander design where a conical stop is used to restrict flow out of a tube as materials are driven through it by a rotating shaft. The stop is moved towards and away from the tube creating an adjustable sized gap through which material leaves the tube. Controlling the size of this gap relative to the material throughput determines the pressure under which the material is extruded and influences many of the product’s final characteristics.

These units can be provided with heating or cooling jackets and provisions for monitoring temperature and pressure. Precisely controlled product extrusion is thus achieved by applying Amandus Kahl’s patented gap control technology from the annular gap expanders to this simpler machine.

Laboratory extruder

Products can be extruded with various shapes and characteristics by controlling the nozzle geometry and pressure and temperature characteristics of substrates as they are propelled through a screw-style mixing machine. Precise control of pressure at the point of extrusion is essential to predictable, desirable results.


<h2>Product shaping with easy start-up and less waste</h2>
Amandus Kahl’s Extruder OE series is an extruder line that works on the same principle as the successful annular gap expander design. A conical stop restricts the flow out of a tube as materials are driven through it by a rotating shaft. The stop is moved towards and away from the tube, creating an adjustable-sized gap through which material leaves the line. Controlling the size of this gap relative to the material throughput determines the pressure under which the material is extruded and influences many of the product’s final characteristics.

Heating or cooling jackets can be added to these units for monitoring temperature and pressure. Precisely controlled product extrusion is thus achieved by applying Amandus Kahl’s patented gap control technology from the annular gap expanders to this more straightforward machine.

Extruder with annular gap expander

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 extrusion, and connect directly with leading machine manufacturers worldwide

Recycled plastic extrusion

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Recycled plastic extrusion Equipment

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Basket extruder

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Extruder with annular gap expander

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