Recycling & scrap reclaim.

Save money, save your hearing with low-speed grinders and shredders.

Quiet, energy-efficient, and easy to clean will be the hallmarks of new size-reduction machinery at NPE '97. Low-speed rotors are a key element in achieving low noise, low horsepower requirement, and low generation of fines and dust. A number of new granulators are designed to handle larger parts so as to eliminate manual precutting.

GRANULATORS & SHREDDERS

The newest name among domestic producers of scrap-reclaim equipment is United States Granulator Corp., a Maguire company in Smithfield, R.I. Until recently a remanufacturer of granulators, U.S.G. now only makes new machines and replacement knives. The firm's first two original models are large ones for grinding auto bumpers, entire film rolls, and abrasive scrap like electrical cables. Models USG 2436 and USG 2454 have drive motors of 100-250 hp and throughput capacities up to 6000 and 10,000 lb/hr, respectively. Base prices are $90,000 and $120,000.

The company claims to achieve significantly greater throughput than other machines. One reason is 25% more open screen area than on competing models. Another is offset placement of the two sets of bed knives so that rotor knives do not make impact on both simultaneously. The result is said to be less knife shock and wear. The machines are also designed to hold a constant cutting circle. Rotor knives are designed so that clearance between knife tip and screen changes relatively little on sharpening.

Ease of maintenance is another key focus of the new machines' design. Major components, including the rotor, can be removed with minimal disassembly. Access doors are provided on both sides of the chamber, in addition to a swing-down screen cradle. And the machines are mounted on legs to provide diverse discharge options, including directly into drums or gaylords.

Also featuring large machines at NPE is New Herbold, Inc., Sutton, Mass. The firm's new SX Series heavy-duty machines grind purgings and thick-walled parts at up to 6600 lb/hr. SX models have a new chevron-type slant-knife arrangement that's said to increase throughput and reduce noise and energy consumption.

What is said one of the largest granulators available today will debut from Rapid Granulator, Rockford, Ill. Model 3260 is said to provide throughput up to 10,000 lb/hr.

Also, the Vortex K-1350K rotary grinder, engineered to speed size reduction of large parts, will be premiered by Nordfab Systems, Inc., Thomasville, N.C. The machine has a 61 x 51 in. feed opening, 60-90 hp, and capacity of 100-1200 lb/hr. A horizontal feed ram is supplemented by a new hydraulic bridge breaker that pushes material down toward the rotary cutter.

A heavy-duty batch grinder, model SHD-9A, will also be introduced by Foremost Machine Builders, Fairfield, NJ.

Low-speed, high-torque shredders are gaining in popularity for heavy-duty size reduction because they are quiet, clean, and energy-efficient. Shred-Tech, Cambridge, Ont., will show its newly redesigned ST-100E and ST-150E high-volume shredders that have a compact, low-profile look, increased throughput capacity, and lower maintenance costs.

A relatively new source of shredders is Polymer Systems, Inc., Berlin, Conn. Aimed at large, heavy-wall parts and purgings, these shredders can be combined with a conventional granulator in a two-stage reclaim system.

Most of the entries at NPE will be beside-the-press models. Polymer Systems is applying the noise, energy, and other advantages of low rotor speed to new press-side granulators for reclaiming sprues and runners using robots or pickers. Because the rotor speed is just 200 rpm, the granulators reportedly generate fewer fines and are less subject to wear. Three models are available with cutting chambers of 6 x 7 in., 8 x 7 in., and 11 x 7 in.

In addition, Polymer's new series of six Shurfeed press-side granulators are said to have absolutely zero flyback, thanks to an improved tangential-feed hopper design. These new machines are also among the quietest available, the company claims.

Low rotor speed for quiet, clean operation is featured on new GR-Series press-side granulators from Comet Automation Systems, Inc., Dayton, Ohio. They have the company's steel-coil feed, said to be a safe auger-type force-feed mechanism.

The Conair Group, Franklin, Pa., is introducing the SPC-400 Dagger, a compact beside-the press granulator for injection machines of 50 tons or smaller. The screenless, very low-speed grinder's rotary cylinder breaks up small sprues and runners while an oscillating cutter dices scrap into regrind.

Another low-speed granulator for sprues, runners, and small reject parts is the new Robot 810 from Granutec, Inc., East Douglas, Mass. The unit is suitable for various applications because it is available with either staggered knives or a three-blade, slant-knife, open rotor.

The Robo 810 may be purchased with an optional low/high rotor-speed control. This allows automatic robot feeding of sprues and runners at low rotor speed and then switching to high rpm for periodic batch feeding of parts.

Nissui Corp., East Lansing, Mich., will introduce the new tabletop model SA-01 of its "S" Cutter, which is the smallest in the line. The unit has no sizing screen, low rpm, quiet operation, low energy use, and no dust. List price is $5400.

ReTech Industries, Inc., High Point, N.C., is premiering a rotary grinder with a "European" concept that reportedly combines the benefits of a shredder and a granulator. Size Reduction Specialists Corp., East Lansing, Mich., will also introduce a granulator with low-speed rotor and low horsepower.

Two new beside-the-press granulators from AEC/Nelmor, North Uxbridge, Mass., include the Talon 6 x 8 model for small injection machines. Cleaning and maintenance can be performed without tools, and knives can be changed in 15 min. Nelmor is also showing the larger Millennium 1600 granulator with ductile-iron cutting chamber and soundproofing.

A compact, sound-shielded 1200 Series of small granulators is new from Cumberland Engineering Div. of John Brown Plastics Machinery, South Attleboro, Mass. They come in 1212, 1215, and 1220 models with 10-20 hp and throughputs of 500-700 lb/hr. A "scooped" rotor reportedly provides positive feeding of bulky parts.

Rotogran International, Inc., is introducing the A PH-1012 7.5-hp granulator equipped with a Silencer sound-absorbing hopper extension.

The new Auto-Feed Series of Veloci-Cutters from Sterling Systems, Forrest, Va., are said to eliminate need for venturi systems to feed film edge trim or bottles. It also dispenses with belt conveyors and rotary airlocks to feed sprues, tabs, tails, and small parts. Veloci-Cutters can handle any scrap that cannot pass through a blower.

Blackfriars Ltd. of the U.K. is introducing its Model 525 rubber bale granulator and the 40/40 medium-duty sound-deadened machine.

Pierret U.S., Spartanburg, S.C., is prepared to discuss its new high speed rotary cutter for edge trim and fiber waste, which will be available in the Fall. According to company sources, this machine will be small and affordable.

FILM-WASTE RECLAIM SYSTEMS

Process Control Corp., Atlanta, is introducing the RMX Refeed Machine that recycles chopped film flake directly back into the extruder. The unit's hopper has an inner flake compartment and an outer virgin-resin compartment. A variable-speed auger meters the scrap downward at a selectable rate and prevents bridging. As the flake leaves the bottom of the scrap compartment, it is surrounded and compacted by virgin resin. The mix is then gravity fed to the extruder screw without segregation of virgin and flake, the company says. Consistent scrap feeding is said to prevent surging. And if the scrap feed is interrupted, virgin material continues to feed and supplies the entire need of the extruder without starvation.

A continuous agglomerator or densifier that removes volatiles from recycled plastic film will be introduced by Sorema Div. of Previero N.s.r.1. in Italy. Continuous operation is said to significantly reduce labor requirements compared with traditional batch-type densifiers. The end result is said to be of higher bulk density than granulated film fluff, which is said to eliminate need for a force feeder on a repelletizing extruder.

Another new densifier will be shown by Officine Costarelli of Perugia, Italy (represented here by Tex America, Inc., Charlotte, N.C.). Costarelli's 1300-mm densifier has a 410-hp motor and falls in the middle of the firm's size range. Also new is Costarelli's 1400-mm high-intensity washer for post-consumer or post-industrial waste. It has an internal cutting rotor and fixed knives to chop the scrap as well as clean it.

Next Generation Recycling-maschinen GmbH of Wilhering, Austria, offers a combination size-reduction and repelletizing system for film scrap. Film can be fed by roll into the hopper, which has a ram feeder and a cutting rotor and bed knives. The cutting action feeds flake directly into the extruder screw of the pelletizing system, which has an automatic backflushing screen changer to remove heavy amounts of dirt. The system includes a hot-die-face pelletizer.

Warner Sales Associates, Inc., Hanover, Mass., is introducing the Recotrim stand-alone trim-waste repelletizer from Macchi of Italy.

Munchy Ltd., Wallingford, Oxon, England is introducing the Aqua Limit analysis system, which can indicate the level of moisture before the material is reprocessed. This is achieved by using special radio frequencies, which can measure moisture while the polymer is moving, avoiding time-consuming laboratory measurements.

Merritt Davis, Hamden, Conn., is introducing the Polycycle Reclaim System, said to handle all forms of low-bulk-density scrap, including film and fiber. This complete repelletizing system comes with single- and double-vented extruders in sizes from 3 in., 30:1 to 10 in., 39:1. Ram stuffers ensure high throughput.

A new Hartig dual-diameter extruder and a new ram feeder designed to handle light feedstocks will be shown by Davis-Standard Corp., Pawcatuck, Conn. The 4.5-in. Ram Feed Section has a very wide throat opening in a housing separate from the hopper and throat. An air vent and clean-out port above the plunger are said to eliminate air build-up and permit easy clean-out. The plunger guide assembly is designed to prevent jamming when uneven loads are encountered.

SEPARATION SYSTEMS

T&T Technology, Chicago, is introducing its Fines-Sep series of gravitational fines-separation systems. They reportedly provide dust-free pellets or regrind without using vibration or any moving parts. Capacity range is 300 to 3000 lb/hr with a claimed dust-separation efficiency of up to 99.99%.

Sterling Systems has enhanced its elutriator to provide higher-efficiency separation of paper, fiber, foam, fines, or streamers from plastic flake or pellets.

A new metal detector for reclaim and recycling applications mounts on the frame of a belt conveyor. The compact Model 9100 from Advanced Detection Systems, Milwaukee, can flash a warning light or halt the conveyor when metal is detected.

FOR AN EXTRA-FINE GRIND

Reduction Engineering, Kent, Ohio, and Air Products and Chemicals Inc, Allentown, Pa., are jointly introducing a turnkey cryogenic pulverizing system for the production of fine, tight-specification powders from tough-to-grind polymers. The new system reportedly provides the highest throughput and lowest liquid-nitrogen consumption of any system for this application.

New Herbold will show its new Series ZM-500 pulverizers for fine grinding of LDPE, HDPE, and PVC.

What to Look for:

* New U.S. source of large granulators.

* Lots of low-speed grinders and shredders.

* Tiny grinders for small presses.

* Many new choices for handling film scrap.

* Separate paper, foam, or fines from plastic with no moving parts.