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Keywords of this article:  extrusion 
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Granulator 
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blow molding 
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Pallmann has developed the new series of heavy duty granulators, type PS-I, for granulating plastic purgings.
Pallmann has developed the new series of heavy duty granulators, type PS-I, for granulating plastic purgings.

The function of a granulator sounds simple – turning the input materials into pieces. But in actual fact, it is a combination of detailed engineering and innovation. Take a look at the latest offerings in the market and you can find these size reduction machines are capable of something more.

For efficient granulating of plastic purgings

Highly efficient and robust machines are required for granulating plastic purgings. Pallmann Maschinenfabrik in Germany meets these requirements with the new “heavy duty” granulators, PS-I series.

During the extrusion of granules, pipes, profiles and film so-called purgings occur during startup, process interruption or at the end of the extrusion process.

Extruded materials such as low density polyethylene (LDPE), high density PE (HDPE), polypropylene (PP), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polyamide (PA), polyethylene terephthalate (PET) or any other types of plastics used for extrusion are normally collected in tub-shaped containers.

Significant amounts can be collected, as large purgings or lumps being shaped by the tub. Specific for this type of the material are the large dimensions and the high weight. When size-reduced into granules, they can be directly reintroduced into the production cycle thereby saving resources and costs.

Pallmann’s new series of heavy duty granulators, type PS-I, is developed exactly for this type of application.

The series, PS-I 8-12 allows for purgings and lumps up to a size of 1,000x800x800mm and a piece weight of up to 300kg to be reduced to a high quality reusable granulate in one step. For larger lumps, the PS-I 12-12 is applied.

The massive HC “Heavy Cut” rotor with its optimized knife arrangement allows for size reduction of startup purgings, respectively lumps of any plastic that is difficult to size reduce.

Depending on the incoming material and specifications, the rotor knives, the knife holding plates and the machine housing are optionally available in special wear resistant material. The screens, which determine the granule size, can also be delivered in a special wear resistant material, as an option.

Feeding of purgings into the granulator is performed directly from the top by means of a conveyor belt. The robust welded housing can be opened hydraulically for exchanging the knives and the wear parts. All rotor knives are adjusted outside the machine. A 200kW main drive motor allows for throughput capacities of up to 2,000kg/h depending on the feed material and the mesh size of the screen.

Ease of operation ensured

Sweden-based Rapid Granulator’s newest family of shredders for plastics, the Raptor Series, features a world first “open-hearted” design that makes it easy to operate.

The Raptor Series is a shredder and granulator hybrid with the shredder’s heavy-duty cutting technology combined with granulator features, according to Rapid Global Sales and Marketing Director Bengt Rimark.

Raptor 800 – One of the “Open Hearted” shredders from Rapid new shredder series.As we develop and manufacture both granulators and shredders, we make sure that the machines are tailored for each other and that we can provide complete recycling systems,” he said.

The Rapid “open hearted” design of the Raptor enables quick and direct access to the shredder rotor and cutter chamber, drastically simplifying the cleaning and service process.

The front door, hinged on the side, provides unrestricted access to the rotor and to the screen, which is mounted in the door. Once the front door is open, the shredder hopper mounted on a rear hinge can be tilted back.

The company said that the machine can be in a completely open position in less than one minute after it has stopped running. Once the machine is open, all fasteners are accessible from the outside using air driven tools. The access made possible by the “open hearted” designs makes any contamination immediately visible.

The tilting hopper opens with an electrically operated jack, while the screen and granule bin can be handled by a single operator. The unique screen cradle design does not require the removal of bolts in order to remove the screen, and the granule bin slides out easily.

The same tool is used to unlock the front door and to rotate the rotor. As an option, a light can be fitted to provide extra illumination.

With a modular design, Rapid offers 36 base configurations of the Raptor in order to handle various customer applications. The modular systems feature two diameters and two widths (800mm and 1,350mm). There are two system designs for pushing material into the rotor – FlexiPUSH and PowerPUSH.

FlexiPUSH is a pneumatically driven pusher and is intended for handling basic applications, including lumpy materials. It can handle large products such as a 1,200L intermediate bulk container (IBC) for example.

The hydraulically powered PowerPUSH maximizes output for shredding sheet and film. The cutting chamber features a textured floor to reduce the risk of material adhering or finding its way under the pusher and is offset by five degrees to enable liquids to drain away.

There are also three different cutting systems: Quad Cut, Claw, and Power Wedge. The unique QuadCUT cutting system for general plastic waste features a solid knife that allows the full use of all four cutting edges. The knives are supported by a sacrificial washer in order to protect the rotor should non-plastic material accidently enter the cutting chamber.

With self-cleaning ability

Continuous market evolution and technical development of plastics blow molding cause more and more frequent materials and colors changes, therefore considering that to clean a standard machine are required 20 minutes at average, the operators’ need is to do it as quick as possible minimizing human intervention.

In this respect, the Italian company TRIA has worked out a high-tech solution available on four granulators of Series 30 and Series 42 that can be integrated to the blow molding machine or installed as standalone grinders.

A number of devices make possible the self-cleaning function.Several devices, applied to standard machines, make self-cleaning possible, introduced the Italian equipment supplier.

Compressed air jets have been placed into the grinding chamber and the hopper. An active ionization bar integrated in the hopper removes electrostatic charges from regrind material and dust.

Air jets, granulator motor, suction system and a directional air vibrator applied to the funnel are driven by an automatic Stop&Go cycle controlled by a simple PLC.

These devices operate in a sequence of five minutes only, move and detach regrind material and dust from all internal parts of the granulator making evacuation by aspiration easier.

Frontal conveyor, hopper and discharge funnel are internally coated by non-stick, anti-static, low-roughness, resistant up to 200°C material, suitable for food contact and functional to avoid regrind material accumulation on treated surfaces.

The same conveyor, hinged to the hopper, is easy to open and the flap mounted into the hopper, it is removed using the same operation. Inside the grinding chamber there is a special plate to avoid fly-back.

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