Recycling & scrap reclaim.

Post-consumer recycling takes a novel approach to melt filtration. Meanwhile, quieter and more compact granulators are replacing the behemoths of the past.

A mix of post-consumer recycling (PCR) and in-plant scrap-reclaiming systems will shown at NPE, including a lot of size-reduction equipment that can be used for both. There won't be much that's totally new in PCR systems, though some recent enhancements and modifications will be shown. In granulators and shredders, you'll find that large, noisy machines are mostly things of the past. Newer models have smaller footprints and are sound-proofed or designed to minimize noise generation. Saving energy is becoming more important, as is uptime, so new equipment satisfies those needs with easy-cleaning capabilities and increased energy efficiency.

NEW APPROACH TO FILTRATION

Erema North America Inc., Topsfield, Mass., has made some substantial changes to the configuration of its post-consumer recycling lines. The Model 80T, which will be on display, features a new tangential orientation of the 80-mm extruder barrel to the unit's densifier. Compared with the straight-line feed of earlier models, the new configuration allows the unit to take advantage of centrifugal force when feeding, according to Erema v.p. Tim Hanrahan. Systems come in 60-160 mm sizes.

New options for the system's modular barrel have been added as well. Among the more interesting ones is the VE configuration, which integrates a screen changer into the barrel upstream of the venting section. While traveling through the filter, the melt actually bypasses part of the screw.

Gneuss Inc. of Charlotte, N.C., will show an updated RSF automatic back-flushing, rotary screen changer designed for recycling applications. One recent change is the addition of an optional piston-assisted backflushing method for low-viscosity materials that can't build enough pressure for effective backflushing. Gneuss will emphasize the RSF's applicability to PVC recycling.

And John Brown's Beringer Div. of Marblehead, Mass., will introduce a new backflush filtration system with pressurized backflow. The design features optional dual-pump capability to maximize clean screen area and reduce head pressure when processing highly contaminated materials.

Louis P. Batson Inc. of Greenville, S.C., will introduce to this country the Revive post-consumer recycling line from Sant'Andrea Novara of Italy, which processes commingled material at high contamination levels--for example, with up to 20% paper, 8% aluminum, 10% wood, or 5% other organic matter. The line includes a shredder, granulator, 30:1 low-pressure extruder, vented calendering rolls, pH-neutralizing water tank, cyclone dryer, and deduster (see PT, Jan. '94, p. 72)

Another new reclamation system is for in-plant reclamation of film edge trim or other low-volume applications. Munchy Ltd. of England will introduce the platform-based P55 Mini, a smaller-scale version of the company's integrated repelletizing systems.

COOL WAY TO GRIND

Nelmor Div. of AEC Inc., North Uxbridge, Mass., and Air Products and Chemicals, Inc., Allentown, Pa., are sharing a booth to highlight the companies' new strategic alliance to develop and market integrated systems for cryogenic recycling. The concept involves using liquid nitrogen at -320 F to embrittle heat-sensitive or hard-to-grind materials such as flexible PVC and elastomers. Air Products, which has sold "Cryo-Grind" systems for 25 years, says this technique can help separate polymers from embedded reinforcements in products such as hoses and conveyor belts. Together the two companies will introduce a system consisting of a low-temperature Nelmor central granulator, Air Products automatic liquid-nitrogen feed and monitoring system, and a new cryogenic "freeze tunnel."

BIG GRANULATORS FOR MULTIPLE USES

Many larger size-reduction units can serve multiple uses. Shredders, for example, have proven efficient for grinding heavy parts and thick purgings, as well as PCR. Batson will exhibit Sant'Andrea Novara's high-torque, low-speed shredders, available in 5- to 80-hp models. Though the Sant'Andrea name is new to the U.S., its shredders were formerly sold under the Conair Wor-Tex and Ball & Jewell Shredbuster nameplates (PT, Jan. '94, p. 64).

Granutec of East Douglas, Mass., will show the TFG 2030 tangential-feed granulator with a redesigned hopper opening to accommodate bulky PCR items like bottles, jugs, and milk cases. Tangential feed reportedly ensures continuous feeding of large parts for high throughput capacity without flyback. Combined with a one- or two-stage conveyor and metal detector, the 2030 becomes an effective reclamation system for post-consumer plastics, according to company sources.

Granutec is also showing the new TFG 1216 tangential-feed granulator, which adds a rear-feeding chute to the front hopper feed. And the company will also show the new Model 1416 AM Grinding Center for simultaneously reclaiming scrap thermoforming skeleton, reject parts, and edge trim from the feed rolls.

Irwin Research & Development Inc. of Yakima, Wash., will show an improved model of its Chesaw shredder. Now the unit operates more quietly, cuts more uniformly, and has higher throughput. Although originally developed to regrind thermoforming web scrap, Chesaw granulators are also used to recycle containers, sheet, and chunks of extruder drool. These units slice the product between pairs of rotary slitter knives that are designed to be self-sharpening and low in maintenance.

Cumberland Engineering Div. of John Brown Plastics Machinery, South Attleboro, Mass., will introduce the X-700, X-1000, and X-1400 granulators for bulky injection and blow molded parts, thermoforming web, film, fiber scrap, and other extrusion waste, as well as reclamation of post-consumer plastics. They have throat widths of 700 to 1400 mm, respectively, and outputs of 1760-3300 lb/hr. Key features include low heat generation, owing to a chamber design that's said to reduce friction; reduced energy consumption, thanks to double-scissors-cutting action; reduced down-time, owing to a motorized hopper and screen cradle; improved soundproofing; reduced footprint; and improved infeed/discharge design.

Three large Shur-Feed granulators for in-house or post-consumer applications are being added to the SF 2000 line from Polymer Systems, Inc., Berlin, Conn. These machines (SF 2030, SF 2036, and SF 2042) can have various hopper configurations to accept manual, robotic, or conveyor feeding. Not only are these granulators relatively quiet, but they have a low profile, low feed height, and compact overall dimensions, the company says.

Also new at the show will be Polymer Systems' Heavy Duty Large Central Granulators, Model 1626 with 100 hp and Model 2441 with 150 hp. These are for heavy-duty in-house and post-consumer use.

Rapid Granulator, Arlington Heights, Ill., will add a new granulator to its Heavy Duty line. Model 2436 was designed to handle a wide variety of materials in central granulation or large beside-the-press applications. A 20-blade rotor design and two fixed bed knives are said to be keys to the unit's energy efficiency. A 75-hp motor with fly-wheel also helps minimize energy use. A second flywheel is available for further energy reduction. Model 2436 can be purchased with integral sound-proofing to meet or exceed the OSHA standard of 85 dbA.

Foremost Machine Builders, Inc., Fairfield, N.J., will introduce its HD7 grinder that's designed to handle in-house and post-consumer PET bottles and preforms, bulky blow molded parts, or PVC siding and profiles. The new model has a 24 x 24 in. cutting chamber with four-bladed, high-shear rotor.

Nelmor will introduce three granulators with multi-purpose cutting chambers that are designed to handle a wide range of feedstocks with minimum noise and maintenance. Models G2238, G1620, and G1628 have modular designs making them adaptable to future field-installed options, such as adding a third or fourth bed knife or a pre-breaker for increased throughputs.

FOR IN-PLANT RECLAIM

Conair Martin, Agawam, Mass., is introducing the Conair Meltic line of beside-the-press granulators from Meltic of Sweden. They're designed for safety, fast cleaning, and simplified maintenance. Each model includes two bed knives and a five-bladed, staggered rotor with a "Quatro" symmetrical knife design that has four cutting edges. Three Meltic models are designed for robotic, conveyor, or manual feeding. There are also the MA611 auger-feed version and the larger MQ300 upright granulator with soundproof cabinet.

Cumberland's new 8X12SE and 4050 granulators are offered for beside-the-press and general-purpose applications. They, too, are said to offer improved soundproofing and energy conservation.

From Foremost comes the new HD5C grinder, which is an update of the HD5. Its three-bladed, high-shear, skewed rotor is designed to handle PET preforms and bottles.

Foremost is also introducing the HSFG1116 high-shear film grinder with reported noise levels of only 80-83 dbA.

Getecha USA, Duluth, Ga., will be exhibiting granulators from its German parent firm for the first time in the U.S. Five granulators will be on hand: three hand-fed, one auger-fed, and one beside-the-press model. These granulators are said to be very quiet because German noise regulations are even more stringent than those in the U.S.

Herbold Granulators U.S.A., Inc., Sutton, Mass., will introduce the PUC-500 Universal Mill with interchangeable rotors for fine grinding. It comes from Condux of Germany, which Herbold recently acquired.

MPG Service & Sales, Inc., Hillsboro, Texas, is introducing granulators with a segmented, or "stepped," rotor that incorporates adjustable knives. These models boast low-horsepower, small footprint, and easy cleanout--no hand tools are required to open the hopper and screen cradle.

Rapid Granulator will bring out three mid-size SR-Series granulators, Models 614SR, 611SR and 69SR. They have low rotor speeds for quiet operation with low energy consumption. Also new from Rapid is a compact addition to the K Series for beside-the-press or central granulation. The model 1018K reportedly meets or beats OSHA's standard of 85 dbA.

Sterling Systems, div. of Sterling Blower Co., Forest, Va., will unveil a film edge-trim collector and cutter system, which company sources say is safer, lower-cost, and more efficient than those currently on the market. It also eliminates the need for feed rolls.

Zenith Cutter Co. of Rockford, Ill., will introduce some new aftermarket knives for granulators, including replacements for Conair Wor-Tex helicals and Nelmor Microknives.

What to Look For

* Recycling system filters melt before the extruder vent zone.

* Integrated cryogenic grinding systems now available.

* Backflushing screen changers clean up dirty PCR.

* New crop of granulators are energy-efficient.