Got It Covered. Let’s Go Swimming!

Any manufacturing and production process will no doubt produce waste in some form. So does Plastipack Limited in the UK, a producer of high-quality plastic swimming pool covers and water storage systems. By the help of a WEIMA two-stage size reduction system, plastic scrap is recycled directly on-site – for a closed loop.

01

Plastipack Limited first contacted offical WEIMA UK dealer Fercell, looking to upgrade and expand the capacity of their existing granulating system. The objective was to improve the efficiency and pace at which they were able to repurpose manufacturing waste into plastic granules for reuse within the production process.

02

To determine the correct solution, initial discussions focused on the specific type of materials to be processed, the volumes and the production output the client was looking for. With test facilities onsite, Fercell were able to process a sample of the waste plastic material.

Project Facts

01
ZM 40
four-shaft shredder
02
WNZ
granulator
03
<6 mm
flake size
04

First Step: Size Reduction

The two-stage shredding recycling system consists of a WEIMA ZM 40 four-shaft shredder, outfeed conveyor, WEIMA WNZ 310/800 granulator and fully demountable acoustic box. For the air-handling solution the system included a high-pressure transport fan, heavy-duty transport ducting and filtered cyclonic separation, above a bulk-bag loading system.

Two stage shredding system from WEIMA in production halls of Plastipack

WEIMA ZM four-shaft shredder and WNZ granulator at Plastipack, UK

05

Shredding

When it comes to choosing a shredder, it is important to consider a number of factors including: material being processed, volumes of material and processed outcome of material.
The WEIMA ZM 40 four-shaft industrial shredder is designed to shred bulky materials, making it ideal for plastic pool covers. With a rotational speed of around 25 rpm the noise level is restricted to approximately 76dB. Plastic scraps are fed into the four-shaft cutting chamber from the hopper, where it is trapped by the high-torque teeth of the cutting discs and shredded.

Orange four-shaft shredder by WEIMA at Plastipack facility

WEIMA ZM 40 pre-shredder with conveyor belt

06

The design of the ZM hopper can be modified, to suit the customer, with a safety cage, special infeed rollers and convex viewing mirror. The shredder also features a quick change screen mechanism. The quick change screen will benefit Plastipack Limited with a way to swiftly and easily clean the system, allowing the type of material processed through the system to be changed in a timely manner.

plastic production scrap from pool cover production

GeoBubble production plastic film cover waste before shredding

Cutting and clearing discs from a four-shaft shredding machine by WEIMA

WEIMA Four-shaft technology

07

Granulating

Ideal for a two-stage shredding system, the ZM 40 shreds the plastic, the WNZ granulator then creates granules as small as 6 mm. A permanent drum magnet will ensure any tramp metal is removed from the processed output stream. The WNZ granulator can granulate the material at a throughput of up to 2,500 kg per hour. The plastic granules are collected in a bulk-bag station.

two weima shredder with conveyor belt at plastipack in england

Enclosed WEIMA WNZ granulator for noise protection (r.) and ZM shredder (l.)

view inside weima wnz secondary shredder granulator

WEIMA WNZ granulator technology

Following the connection of the services, one of Fercell’s factory trained engineers returned to site where they completed the cold/hot testing, plant commissioning and operator training.

The recycling system installed will allow Plastipack Limited to turn bulky plastic scrap and spoils into plastic granules that can be used again for manufacturing.

Contact

Marketing

WEIMA Maschinenbau GmbH

Bustadt 6-10

74360 Ilsfeld

Contact

Additional Information

About WEIMA

More than 40,000 machines sold worldwide! WEIMA has been manufacturing robust shredders and briquetting presses for the disposal and processing of all types of waste for more than four decades. Our machines include single-shaft shredders, four-shaft shredders, cutting mills and briquette presses. The popular blood orange machines are used in the wood, plastics, paper, metal and waste-to-energy industries.

Made in Germany. Built for the world.

Shredders and briquette presses from WEIMA are exclusively made in Germany and come from production plants in Saxony-Anhalt and Baden-Wuerttemberg. Every year, more than 300 employees work on around 1,200 customer solutions from around the globe. We have long-standing sales and service locations in the USA, Poland, India and China. More than 80 representatives supplement this global presence.

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