Plastic manufacturing scrap and waste products can pile up quickly, consuming valuable space and resources. But with the right equipment, these plastic leftovers can be efficiently recycled and reborn as a profitable material stream. Enter the plastic granulator – a workhorse that unlocks the value hidden in plastic debris.
Industrial Plastic Granulators convert discarded sprues, runners, trimmings, and rejected parts into consistently sized granular feedstock ready to re-enter manufacturing. Granulating plastic waste slashes disposal costs while generating revenue through in-house reuse or selling recycled material. Over 2 million tons of plastic are granulated annually for recycling.
In this blog, we’ll explore how plastic granulators transform waste into value and discuss key features that enable their unmatched throughput capabilities for plastic size reduction. Let’s uncover the untapped profit potential inside your plastic scrap.
Plastic Granulator Design Innovations That Deliver
Today’s industrial granulators leverage various innovations for smooth, reliable, and efficient size reduction:
- Powerful motors – From 10 to over 200 HP, provide consistent high torque grinding force.
- Hardened steel cutters – Retain sharp cutting edges through years of abrasive use.
- Fully enclosed design – Contains debris and minimizes noise/dust.
- Automated sorting – Optional screens classify granule sizes and remove dust in-line.
- Adaptive feed hoppers – Safely feed materials consistently with minimal jamming.
- Easy access – Simplified blade changes and maintenance.
These features enable industrial granulators to convert even the most demanding plastic waste streams into reusable granulated feedstock or engineering resin.
Unmatched Material Capacity
With advanced cutter configurations ranging from 2-shaft to 4-shaft designs, today’s industrial plastic granulators offer incredible throughput capacities surpassing traditional grinders and shredders.
Cutting chamber size, motor horsepower, blade design, and options like water-cooled cutters and adaptive feeders allow custom configuration for a given plastic waste volume and characteristics. Granulation rates up to 8000 lbs/hr can be achieved with high-capacity 4-shaft units.
This output potential is crucial for efficiently converting large volumes of plastic debris into reusable granulated feedstock. Powerful plastic granulators transform waste handling from a cost center into a profit center.
Precise Feed Rate Control
To maximize output while minimizing jams, industrial granulators incorporate adaptive feed hoppers to maintain optimal material flow into the cutting chamber.
Features like hydraulically controlled gating, proximity sensors, and variable frequency drives on feed screws modulate the feed rate based on granulator load. This prevents overwhelming the cutters.
Programmable logic controllers automate feed throttling based on amperage draw and other sensor inputs. Advanced feed controls ensure consistent granulator operation at full capacity without material flooding.
Enhanced Serviceability
Industrial plastic granulator designs focus on simplified maintenance and serviceability to maximize uptime. Features include:
- Interlocking removable side panels for quick access.
- Reversible cutting blades to double life.
- Toolless screen changes.
- Drive train and bearings sized for extended life.
- Clear diagnostics from PLC controls.
- Remote connectivity capability.
Quick-change screens, blades, and knives reduce maintenance downtime to a minimum. With automation and remote monitoring, granulators practically run themselves.
Key Plastic Granulator Applications
Anywhere large volumes of plastic waste are generated, a granulator can deliver value through size reduction. Common applications include:
Manufacturing – Grind sprues, runners, trimmings, and rejected parts into reused raw material. Saves on waste expense.
Warehouses – Reduce the size of damaged pallets, crates, and packaging for material recovery. Recycle vs landfill.
Medical – Destroy product rejects, test samples, and surgical plastics while generating recyclable granulate.
Automotive – Recover scrap plastic components, panels, and wraps into reusable feedstock.
Agriculture – Grind plastic greenhouse fittings, trays, pots, and wraps into raw material for re-manufacturing.
Packaging – Size reduce defective blister packs, clamshells, and sleeves into the recycled content stream.
Printing – Granulate plastic signage, displays, and laminates for material reclamation.
Consumer Goods – Recycle defective parts, electronics, plastics, and home goods into regrind.
Typical Granulation Amount
|
Plastic Waste Type |
Granulation Rate |
|
Print Trimmings |
Up to 2000 lb/hr |
|
Injection Sprues |
Up to 3500 lb/hr |
|
Thermoform Skeletons |
Up to 5000 lb/hr |
|
Film Rolls |
Up to 8000 lb/hr |
Faqs About Plastic Granulators
What types of plastics can be granulated?
Granulators process virtually all plastic types, including PP, HDPE, LDPE, PS, ABS, PVC, nylon, PC, and more. Special models for PET and vinyl are also available.
What is the end use of granulated plastic?
Typical uses include reintroducing as raw material in manufacturing, creating recycled resins, converting into composite lumber, and more. Revenue can be generated.
How are granulator blades configured?
Configurations include 2-shaft rectangular, 3-shaft triangular, 4-shaft squares, and specialty designs like underwater pelletizers. More shafts provide greater throughput.
How is granule size controlled?
Interchangeable screen plates installed in the cutting chamber determine final granule dimensions. Automated vibrating screens can also classify sizes.
Plastic Granulators: Eco-Friendly Solution for Sustainable Success
Industrial granulators provide unmatched throughput capacity to convert challenging manufacturing plastic waste into reusable and profitable granulated plastic feedstock.
Powerful size reduction paired with automated features for simplified operation and maintenance makes granulators a fast payback investment. Stop treating plastic waste as a liability and start realizing its untapped value.
To determine how a granulator can start profiting from your plastic scrap streams, speak to the experts at W&Z Machinery Systems today. We offer solutions tailored to your waste types, volumes, and facility constraints.
For over 2+ decades, W&Z Machinery Systems has been a leading supplier of industrial machinery, including granulators, Industrial Air Blowers, hopper dryers, autoloaders, etc. We carry a full range of models and offer complete installation assistance. Contact us today for a free quote!
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