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Recycling systems: product lines reviewed.


Company is the North American agent for the Munchy line of recycling systems from Extrudaids of the U.K. Systems consist of a specially designed reclaim extruder, filtering device, die-face pelletizer for air- or water-cooled pellets, and a variety of manual and automatic feeding systems. Units handle all thermoplastics, including coextrusions of PE/PA and PE/EVOH in forms such as film, sheet, nonwovens, bottles, flake, and blocked-bag cut-outs. The high-bulk-density pellet produced reportedly is so similar to virgin product that it can be fed back into first-quality products. Sizes range from 250 to 1100 lb/hr. Washing and drying systems are available in sizes up to 2500 lb/hr.


Company has designed a novel flake-sorting prototype system to separate PE, PVC, rubber and other plastic components from residual metals in wire scrap. It consists of 50 small hydrocyclones in three vertical tiers. (Other separation systems use a sequence of pumps to move material through a few large hydrocyclones.) In the Polycyclone Separation system, a water slurry of ground plastic flake is fed under consistent head pressure from a large manifold downward through tiers of 20, then 18, then 12 hydrocyclones of 6-in. diam. The prototype is available for customer testing and processes 4000 lb/hr.


Company has designed and built its ASB post-consumer film reclaim system to continuously process one metric ton/hr of thin films such as HDPE and LDPE into flake or pellets. System is designed to receive and pre-shred bales and feed them to the washing tank, where detergent is automatically added and further shredding/agitation occurs. All heavy contaminants are removed at this stage. While in solution, the material is cut to size with the patented DSF film cutter. The geometry of the film cutter provides a uniform 0.002- to 0.003-in. knife-to-knife clearance that enables continuous reduction of films as thin as 0.00025 in.

After cutting, the wash water is removed from the film on a Hydrasieve static screen, isolated from the rinsing area, filtered and recycled. Ground film is dewatered in a screw press and transported to the rinsing area where a series of Hydrasieves removes the remaining fiber and other contaminants from the film. Effluent from this section is filtered on ASB Microsieve pressure screens to remove fiber from the rinse water. The cleaned water is recycled within the system to minimize fresh water consumption. The rinsed film is then dewatered in a screw press and dried to less than 1% moisture.

The production system is modular with several segments pre-piped, pre-wired and mounted on structural steel. Modules are then moved into position and connected at the site. Company can provide flake-handling, extrusion and pellet-handling systems as required. A pilot system is available for testing at company's Muncy, Pa. facility.


Company offers the recycling line from Sikoplast GmbH of Germany. Sikoplast custom builds proprietary recycling systems for HDPE, LDPE, LLDPE, ABS, PS, PP, polycarbonate, polyetherimide (GE's Ultem), nylon and PET--specializing in the last two. The line uses proprietary grinding and drying technology, and a conical, single-screw extruder connected directly to a polycondensation reactor, which upgrades the I.V. from 0.66 i.v. to 0.80. Sikoplast has also built systems for direct recycling of scrap into blown film, pipe or profile.


Produces complete recycling systems for post-consumer PET/HDPE milk and/or soda containers, oil or detergent bottles, and PE film. Post-consumer plastics can be processed into high-quality, clean flake or pellets at rates from 1000 to 3000 lb/hr.

Systems typically include bale breakers; granulators; materials handling, prewash, hot wash and hydrocyclone separation systems; and complete extrusion, polymer filtration and pelletizing systems (strand or water-ring), plus all system-wide control packages. Water purification is additionally available. Major components are supplied by John Brown divisions: Egan Machinery, Beringer and Cumberland Engineering.


Company markets a Hong Kong-built double-vented, two-stage recycling line. Model WH-140DI includes a granulator, two-stage extruder and pelletizer for under $100,000. The extruder has two oversized screen packs--10-in. diam. screens on 5.5-in. diam screws. It also has a strand pelletizer with an air-stripper that blows air over the strands to remove water, and a movable cyclone for more efficient loading of gaylord. Washing equipment is not included in the system.


Company is the U.S. agent for recycling equipment manufactured by FBM srl of Italy. Complete systems are available for recycling post-consumer scrap film and/or bottles from PE or PET resins--including grocery sacks, stretch wrap, redemption bags, agricultural film and bottles--into clean pellets. Dedicated as well as flexible systems are offered at outputs ranging from 500 to 2000 lb/hr. All major components are designed and produced in compliance with U.S. electrical and safety standards.

Systems include washing, drying, filtering and repelletizing. Special features include "single/float" separation, prewash and sizing, drying systems, granulate feed storage, extruder design for reclaim with single- or double-vent systems, hot-melt die-face cutter and closed-loop cooling system, and slide-plate screen changers or continuous filter and separation device.


Joint venture company of Future Design Inc., Brampton, Ont., and FBM of Italy, which provides a line of turnkey plastics recycling systems. Systems are assembled using FBM's extruders and other major components, and North American electronic components and motors. The recycling line uses hot water to pre-rinse and wash shredded material. After being dried, scrap is ground into fluff, air-conveyed to a hopper, and force-fed into an extruder and hot-face pelletizer. Systems can be customized with single- or twin-screw extruders having a range of venting configurations and L/D ratios. Materials such as PE, PS, PP, ABS and PET can be processed at rates from 200 to 2600 lb/hr.


Company's recycling equipment can be used to wash, rinse and dry. Washing and rinsing equipment removes foreign material from flakes and chuck, such as fine particles, loose paper and chemical solutions, as well as sand and dirt. The equipment is designed to handle rates from 10 to 5000 lb/hr, depending on the type and thickness of the product. The recycling dryer can handle rates from 10 to 10,000 lb/hr. The centrifugal dryer can handle rates to 100,000 lb/hr and even higher for some products. Company's underwater pelletizer can pelletize virgin or recycled thermoplastic material. Complete lab facilities are available to demonstrate the capabilities of the system.


Company has proprietary chemical process technologies for the treatment/reclamation of a variety of waste plastic mixtures; most are closed-loop. Suitable feedstocks include both industrial wastes and post-consumer rigid containers. Typical mixtures could be composed of two or more plastics--i.e., HDPE, PVC, PET, PP, PUR, and PS, with or without water, oils, paper, metal and glass. Materials produced may be used in lieu of, or in combination with, their virgin counterparts. Company offers to license its technology or to form joint ventures.


Offers complete turnkey systems for recycling PE film and stretch films, and PE, PET and PVC bottles. Company also provides hydrocyclone separation technology, which can be added as an upgrade to existing Herbold recycling lines. The hydrocyclone is a conical device, which feeds recycled flake from the top, together with water, and spins until the material separates by density. Heavy PET goes out the bottom, light PE goes out the top. After one hydrocyclone separates HDPE and PET, each stream passes through another one to three hydrocyclones.


Offers new, used and rebuilt sorting, granulating, washing and drying systems for post-consumer or post-industrial recycling.


Company has developed a patented cryogenic cleaning system that uses liquid nitrogen as the freezing agent and pure water for the flotation/separation system. No soaps or caustic chemicals are used, and the only water used is makeup water for the float/sink separation process.

Ground material is fed into the cryogenic chamber, where the temperature of the material is reduced to -200 F, making it extremely brittle. The frozen material is metered into a high-speed impactor where labels, glues and contaminants are broken and drawn off by aspiration. The clean material is auger fed to the float/sink process that separates PET from HDPE. It is hot-air spun dried, and then enters a screening process to remove PVC and fines.

Systems are available in output capacities of 1000 and 2000 lb/hr. Flotation separation, spin drying, and screening equipment is standard on all systems. A complete production system is available for demonstration.


Company has developed the technology for its recycling joint venture with Phillips 66 Co.--Phillips Plastics Recycling Partnership, which is operating its full-scale plant in Tulsa, Okla. Several components of the custom-built system and the overall process concepts have patents pending.

The heart of the HDPE recycling line is a proprietary "single-pass" granulation system that produces a unique, highly uniform, square flake, with minimal production of fines and dust. Two granulators each process up to 2500 lb/hr of material. In addition to the granulation system, the line, which begins with a bale breaker and rotating trammel for removing loose caps and dirt, consists of an enclosed, very high-shear, cylindrical washing tank; a hydrocyclone system for separating out "heavies" like PVC, PET, metal and dirt; spin drying units; and kinetic-energy scrubbers that remove labels and glue. Dust and fines are removed from the clean flake by either of two aspirators. Finished flake is metered together with additives into one of two extruders, with 4.5- and 6-in. diam. barrels and special Phillips-designed screws. Each extruder has a vacuum pump that draws off residual moisture and volatiles. Melt is filtered with continuous, rotary screen changers, and pellets are made on a water-ring pelletizer.

Partek offers to license the technology on a nonexclusive basis.


Represents Plastics Densification Ltd. from the U.K., which manufactures the Styromelt PD2000 densifier machine for processing packaging foam waste at up to 75 lb/hr. The unit, measuring 81 x 45 x 23 in., densifies using heat, not blades or grinding, in a cast aluminum chamber ringed with internal heating elements. Close temperature control of the melt (at 428 F) prevents burning, but shrinks more than 95% of the volume of many PS foam products, the company reports. Melted waste is cast into bricks, water cooled, and ejected for recycling or use as efficient fuel. Three to four garbage bags of PS waste or 1000 foam cups make a 2-lb brick in about 3 min. A heated slicer for large block foam can be added for faster feeding. A flue with extractor fan and carbon filter is said to control odors, and the densifier can be safely left on when empty.

A smaller commercial model DP1000 processes up to 25 lb/hr of styrofoam waste.


Offers a turnkey recycling system that accepts 7-8 million lb/yr of mixed plastic bottles and puts out separate streams of clean, ground PET, natural-color HDPE, and mixed-color HDPE. Most important, the system removes PVC bottle material, in addition to aluminum caps, paper labels and glue. The system grinds all bottles up together before washing and separating the components. The water-flotation system combines three separation principles based on differences in specific gravity and modified flotation characteristics.


Provides a wide range of reclaim systems that repelletize up to 2200 lb/hr of various materials, including film. The Erema system features a patented "warm feed" that predensifies and shreds material before the extruder. This method minimizes heat input, resulting in extremely low degradation of the reclaimed material. Erema recycling machines repelletize HDPE, LDPE, LLDPE, PP, EPS, nylon 6 and 66, ABS and PET from film, flake or expanded foam. Company manufactures PVC hot-face pelletizing systems, which include a twin-screw extruder, die, hot-face cutter, transport blower and pellet cooler. Models are available with a maximum production rate of 3300 lb/hr.


Provides turnkey systems for recycling PE, PP, PS, ABS, polyamide, PVC and PET, including film. Systems are available in capacities of 550, 1200, 2200 and 4400 lb/hr. They include proprietary washing, separation and rinsing cycles that use hot and cold water. Washing systems completely separate contaminants such as noncompatible plastics, paper, cardboard, wood, natural fibers, ferrous and nonferrous metals, organics, silica, clay and grease. Prewashing systems are available for extremely contaminated material.

Direct-feed extruders are built especially for the systems and feature automatic force-feed hoppers, feeding bushes, specially designed screws, degassing systems, and automatic screen changers with pressure control. A range of accessory equipment is offered to complete systems.


Designs and manufactures systems for recycling materials such as PET, HDPE and PVC bottles; carpet scrap; cable chop; tires; and automotive scrap. Systems handle up to 10,000 lb/hr and use methods of washing and separation--sorting, elutriation, agitation, float/sink and hydrocyclone--to produce a finished flake ready for reprocessing. Consulting services and retrofit packages to improve existing recycling systems are offered.


Company represents Reg-Mac of Italy, which manufactures washing systems for bottles and film in sizes up to 4000 lb/hr. Intensive washing guarantees 100% paper removal, while a special floating tank provides total HDPE/PET separation. Drying systems with centrifuges and/or continuous presses are customized depending on type and quantity of material. Systems include 430-hp densifiers with outputs of 3500 lb/hr and automatic guillotines with up to 100-ton cutting force.
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Title Annotation:plastics machinery
Publication:Plastics Technology
Article Type:Buyers Guide
Date:Jul 15, 1992
Previous Article:Granulators and pulverizers: product lines reviewed.
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