Plastic recyclers worldwide use a single-stage or two-stage size reduction system before material is fed into an extruder. This is not only beneficial for the capacity of the entire recycling line. Using a shredder reduces wear and power consumptions of the extruder and provides operators with much more flexibility when it comes input materials (e.g. changing from lumps to plastic films or fibers).
With a shredder, the Preconditioning Unit (PCU) has significantly less work to do und thus works more stable.
Stable means less temperature variation in the PCU, which results to consistently high feeding/filling ratio of the extruder screw.
Less cutting in the PCU = Longer Lifetime of the PCU knives = Less downtime for changing knives and less costs.
Sample calculation. Let's do the maths!
Average extruder capacity without shredder: 1,000 kg/hr
Average extruder capacity WITH shredder: at least 1,200 kg/hr
8,000 hours/year x 1,200 kg = 1,600 additional tons/year!
You can use the hopper of the shredder as a buffer. Gives the operator the possibility to feed the hopper infrequently with big quantities of material and let the automatic Stop/Start system automatically feed the downstream extruder. This avoids the need of a second full-time operator (necessary for machines with throughput over 350 kg/h) who feeds the material homogenously on the conveyor belt of the extruder, which in this case is necessary to achieve stable PCU process.
Also, feeding of bulky material is easier. Feeding is possible by forklift, wheel loader, feeding conveyor or manually. The WEIMA discharge conveyor can be equipped with magnet roll to remove small FE particles automatically before EREMA metal detector.
WEIMA delivers over 1,000 machines per year. Many of them are used for inhouse recycling, post-consumer and post-industrial plastic waste recycling. You can find an excerpt of current reference projects here:
Did you know?
Putting a shredder before a recycling extruder (like EREMA or GAMMA MECHANICA) can lead to a capacity increase of 15-20 % for the recycling extruder.
The robust design of WEIMA shredders makes them less sensitive to metal contamination in comparison with an extrusion line and of course easier/cheaper to repair in case of foreign objects entering the cutting chamber. Furthermore, the discharge conveyor can be equipped with magnet roll to remove small FE particles automatically before EREMA metal detector.
The flexible use of shredders for different applications (e.g. bulky materials, lumps, films, rigid plastics) gives recyclers a lot of flexibility and more possibilities regarding input materials.
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The WEIMA showroom is equipped with shredding and compacting machines of all sizes and technologies. This allows us to simulate your application as realistically as possible. You have the possibility to send us your material or to visit us directly in Ilsfeld. From our gallery you have the best view directly into the cutting room. This allows you to observe the shredding process live.
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Alternatively, you can send us material for testing. Click here for the form.
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