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Recycled plastic pelleting Equipment

Pelleting equipment transforms powdered, mashed, or grounded material into a denser cylindrical shape. Pellet processing compresses the fine material against a perforated die, where it will be shaped and cut. Although granulating and extrusion also produce pellet-like products, manufacturing pellets is a distinct process.

Pelleting

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

Form pellets with the uniform length for a dust-free, cylindrical granulate, pellets with smooth surface and high stability of the granulate.


<h2>Stable pelleting with uniform length</h2>
The Gear pelletizer from Hosokawa Alpine is also known as the low-pressure extruder or pelleting machine. This process is known as extrusion, and helps to get stable pellets with uniform length are formed. The extrusion takes place by a pair of counter-rotating hollow toothed rollers. The product is drawn in by the rollers and pressed by nozzle bores or press nozzles.

The compression is determined by the relationship of the nozzle diameter to the nozzle length. The nozzle diameter is within the limits of 1 to 10 mm.

The Gear Pelletizer can be run dust and gas-tight. Operation with inert gas and solvents it’s possible without any problem.

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Pelleting machine

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

Control the quality of your pelletizing processes using a pellet hardness tester. Pellet hardness is one of the most critical characteristics indicating process quality, and it is essential to ensure a desirable product and efficient downstream processes. The hardness can now be measured right after the pellets have left the cooler.
<h2>Monitor your pelletizing process with a hardness tester</h2>
Amandus Kahl’s pellet hardness tester is a hand-held device that allows the user to quickly and easily monitor the quality of their pelletizing process at the source without the need for laboratory equipment. Hardness/softness is a good measure of overall pellet process quality. Using this device allows the customer to test pellet softness and immediately adjust the process parameters to achieve the desired results without delays and lost production time caused by waiting for more sophisticated laboratory equipment.

The pellet hardness tester allows a simple in-the-field quality control for the pelletizing process. The pellet tester comes in two versions, manual and automatic. An operator can periodically rotate the adjusting screw on the manual version at different speeds to retrieve multiple readings. The automatic unit is motorized and works independently, offering more consistency and better comparison of the hardness values taken by different operators due to potential variation in operator handling of the manual version.

Pellet hardness tester

Production of certain pelletized products requires working with output products of a pasty consistency. These products include pigments, clay, detergent additives, vitamin products, and many other products where problems of adhesion of fresh pellets are often encountered. Processing of these types of products requires a pelletizing press that allows the fresh pellets to be directly deposited on a gently transporter such as a conveyor.


<h2>A pelletizing press for depositing pellets directly onto your conveyor</h2>
Amandus Kahl produces pelletizing presses with overhead drives that allow pellets to be deposited directly onto a conveyor from above-eliminating the adhesion issues of fresh pellets often encountered with pasty products. This line of presses uses the proven technology of Amandus Kahl’s other pelletizing presses but the drive unit is above the pelletizing die rather than below it allowing gentle direct deposition of the fresh pellets onto a conveyor. The presses use pan grinder rollers to compact the input material and force it through a pelletizing die forming continuous strands of compacted product. The strands are then cut to the desired length using rotating knives.

The pan grinder rollers and knives rotate slowly ensuring optimum pellet quality and minimizing generation of noise and heat. The grinder roller speed is infinitely adjustable. The grinder roller gap and strand cutter are also adjustable for optimized pellet quality for the customer’s particular needs.

Pellet dies are readily changeable without specialized tools for easy experimentation and process development aiding the customer in developing a process that is optimized for their product. A Kahl variable speed proportion screw is often used in conjunction with these units to ensure consistent and uniform feeding of raw materials.

Pelleting press with overhead drive

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

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Recycled plastic pelleting

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