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Recycled plastic milling Equipment

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

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

With a pre-crusher continuous flakes are made into pieces, before granulation.


<h2>Proper pre-crushing before granulation</h2>
Pre-Crusher type PC from Hosokawa Alpine is a pre-crusher of plates quite suited for the first crushing levels before the granulation and production of clumped materials for free-flowing.

The crushing takes place with counter-rotating grinding rollers which are either equipped with bars or discs, that reach particle sizes up to 30 mm, dust-free coarse crushing in the preliminary crushing of flakes

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Pre-crusher of plates

When you want to mill soft to medium-hard plastics in the fineness range of several hundred µm to 2 mm, a fine cutting mill can be a good solution for you. Such mills are suitable for the communication of rubber, plastics, and other substances.


<h2>Smooth, cubic shape output with good flow properties</h2>
Fine Cutting Mill AFS from Hosokawa Alpine are commonly used in the size reduction of soft, medium-hard, fibrous and tough materials. A rotor inside the mill revolves at high speed. Different rotor geometries make mills adaptable to different material properties (medium-hard, soft, fibrous or elastic materials).

The feed material, usually between 4 and 8 mm in size, is fed into the grinding zone via the intake chute on the mill door. Size reduction takes place between the axially adjustable stator disc and the rotating grinding disc, which rotates at a high peripheral speed in accordance with the shearing and cutting principle. The actual grinding is effected in stages through a grinding gap which tapers from the inside to the outside. The finely ground product exits the grinding zone through an exactly defined gap.

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Fine cutting mill

If you are shredding very difficult materials, you may need to choose a special construction to avoid the risk that plastic film or fibers winds themselves around the shaft and block your process.


<h2>Even the most difficult material can be shredded without problem</h2>
Shredder - DL DuraLine from Hosokawa Alpine are characterized by a heavy, torsion-resistant support construction, knife shafts made from solid and special perforated screens that permit precise determination of the product.

A menu-guided control system permits variable settings to be programmed and operating modes for different materials (as a function of their specific properties) to be stored in memory. The torsion-resistant shredder can reliably shred even the most difficult material without problem.

Because of the positive engagement of the knife blades with respect to the knives on the opposite side, materials such as plastic film or fibers are stripped reliably and cannot wind themselves around the shaft.

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Torsion-resistant shredder

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 choice.


<h2>Cost-effective size reduction of polymers</h2>
The Granulator - PL polymer line from Hosokawa Alpine was specially designed for the cost-effective size reduction of mouldings, blown containers, sprues, flashes and other polymers. They are a synonym for a wide range of different mill designs intended for use as auxiliary and main mills.

This series features three various models, each engineered with dual-scissor-cut rotor mechanisms, an efficient product feeding apparatus, noise-suppressing elements, and a compressed and sleek architectural design.

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Polymer line granulator

Waste products and rejected materials are inevitably generated from any gypsum products manufacturing process. This efficiency can be greatly reduced however, with the use of a specialized crusher designed for recycling them back into the production process.


<h2>A recycling crusher specifically designed for the gypsum processing industry</h2>
Claudius Peters’ Reclaim Crusher is a milling machine specifically designed for processing wet and dry waste products from the gypsum processing industry into materials that can be blended with raw gypsum and re-introduced into the primary production process. The unit consists of a heavy duty housing and two independently rotating screws. The slow rotation action of the screws breaks the materials into pieces ideally suited for further processing into gypsum products. Each screw’s rotation is reversible and is controlled by a shaft mounted gearbox and variable frequency drive motor.

Reclaim crusher

Biomass fuels come in many forms and often include impurities that can damage equipment and cause process disruptions.  Successful biomass energy conversion operations invest in equipment that reliably removes impurities and processes raw fuel material into more consistent forms suitable for use in modern boilers.


<h2>Robust and easy to maintain screening and pre-processing equipment for biomass energy conversion</h2>
Raumaster has been working in the wood processing and energy industries in Finland for over 30 years.  The company is a world renowned expert in biomass material handling solutions and offers a line of screens and crushers that prepare your raw biomass fuel before it reaches your boiler.  All raw biomass fuels inevitably contain some impurities such as stones, metal, and oversized particles.  These are removed from your fuel stream by disc screens, gyratory screens, vibratory screens, and air classifiers before they can damage equipment or interrupt the process.  Magnets, metal detectors, and eddy current separators are also used when a high degree of metal contamination is present.  Crushers are available with slowly turning shredding heads or cutting drums with higher rotation speeds depending on the nature of the raw biomass input and the desired particle size for subsequent processing.  The screens, separators, and crushers are combined and implemented in your plant as a complete optimized solution tailored specifically to your raw materials and process.  All equipment is designed for reliable operation with low maintenance costs.  Effort has been made in all equipment designs to give reliable operation and very easy maintenance.

Solid biomass screening and crushing equipment

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 milling, and connect directly with leading machine manufacturers worldwide