Polymers Processors boost Australia’s plastic recycling capacities

With the help of a flagship WEIMA single-shaft shredder, Polymer Processors in Melbourne has successfully commissioned stage one of their plant upgrade. This adds thousands of tons of plastic recycling capacity to Australia.

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Supported by the Australian Government’s Recycling Modernisation Fund and the Recycling Victoria Infrastructure Fund, Polymer Processors is adding significant plastics reprocessing capacity to Australian manufacturing. Polymer Processors is one of the largest plastic recycling facilities within Australia. Australian-owned and operated, since 1987 the company has installed new equipment to keep up with client demand and to divert plastic waste from landfill. State-of-the art machinery is used to shred, wash, extrude and pelletize various types of post-consumer and postindustrial waste.

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Materials processed vary in size, shape, volume and plastic compound and include Polypropylene (PP), Low Density Polyethylene (LDPE), High Density Polyethylene (HDPE), Linear Low-Density Polyethylene (LLDPE), Acrylonitrile Butadiene Styrene and High Impact Polystyrene. The two-stage expansion of the Melbourne facility will include the installation of WEIMA shredding machinery, SOREMA plastics washing plant, two EREMA INTAREMA TVEplus repelletising extruders and WESTERIA material handling.

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The expansion is being supported by CEMAC technologies, the Australian distributor for WEIMA, SOREMA, EREMA and WESTERIA technologies.

Polymer Processors PowerLine 3000 Shredder

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200 kW
hydraulic drive
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80 mm
knives
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800 mm
rotor diameter
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Stage one, which includes film and big bag shredding, material handling and repelletizing, was successfully commissioned in September. Stage two, scheduled to begin in early 2023, will include a SOREMA plastics washing line from Italy, additional shredding and extrusion capacities and a new purpose-built factory. Jonathan Tan, CEMAC technologies Sales Manager, says the WEIMA Powerline shredder, which features the powerful Hägglunds Bosch Rexroth hydraulic drive train with 200 kW power, large 800 mm rotor and 80x80 mm teeth, “chews through bales of film and bulker bags without any problems”.

orange shredding machien from weima on concrete floor in production hall

WEIMA PowerLine 3000 plastic shredder at Polymer Processors

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The PowerLine 3000 shredder is equipped with various features, such as an antivibration frame with adjustable levelling feet and 40mm thick side panels, automatic radar level sensor for automatic feeding, free flying wing ram, large 800 mm diameter rotor with 80x80 mm knives, a heavy duty Vautid coated rotor surface, rotor sealing with additional wear discs made of Creusabro 4800 wear resistant material and reinforced and supported counter knives that are four times usable.

detail view on weima powerline shredder cutting knives

WEIMA PowerLine rotor with 80 mm knives

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After shredding, the material is fed to an automated and level controlled WESTERIA Multifeeder bunker, which in turn directly feeds the new EREMA INTAREMA TVEplus re-pelletizing line. Founded in 1983 as a pioneer in the industry, more than 7,000 EREMA systems are now in operation around the globe. “The machines are respected for their level of innovation, durability and operational reliability,” he says. “In total, EREMA machines produce more than 18.5 million tonnes of recycled plastics pellets every year.” Polymer Processors has relied on EREMA technology from its early days and has been part of the plastics recycling industry as it has evolved in Australia and worldwide.

rectangular bunker for shredded plastic in a production hall

Bunker for shredded plastics at Polymers Processors

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Jonathan said the project presented several challenges including fitting new machines into an existing building with a low roof line in stages and into existing infrastructure. Further, parts of the line needed to be designed for stage one while allowing for a seamless integration of the SOREMA wash plant in 2023.

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CEMAC technologies designed the overall layout of the plant and worked through the design and engineering challenges.

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“Starting with a full 3D scan of the existing facility, the project team worked with the various stakeholders to allow the plant to fit into the existing envelope and to bring it to the subsequent successful installation and commissioning. In stage two, the SOREMA wash line will be installed in parallel to the existing and operating infrastructure. The complete line will enable Polymer Processors to increase plant capacity while processing a range of difficult materials with the highest level of automation. They’ll be producing quality recycled materials at a competitive level.”

Jonathan Tan, CEMAC

Source: Waste Management Review, Australia

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More than 40,000 machines sold worldwide! WEIMA has been manufacturing robust shredders, briquetting and drainage 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, briquette presses, packaging and drainage presses. The popular orange machines are used in the wood, plastics, paper, metal and waste-to-energy industries.

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