Agglomerator is used for recycling film wastes (washing, drying, milling and agglomeration of PE wastes)

There are simple and washing agglomerators used, depending on model, for milling, washing, agglomeration, preliminary drying of secondary film wastes of polymeric materials. Sometimes they are used as dryers for drying and heating of wet raw materials.

The resultant product called agglomerate (balls of various size (3-10 mm) and color) is a semi-finished product used as a secondary raw material

Agglomerator is a batch operation device, it may be used both for complete recycling, including all the above mentioned stages and in combination with other machines for performance of one or several stages following by recycling other machines and in secondary materials recycling lines.

Agglomerator consists of body and bed, on which all units and drive electric engine are mounted. Inside the body, on the shaft of bearing mount assembly, located below, there guides with blades of various shape. There is a water feeding devices fastened on the body

Control cabinet can be located on the body or is assembled as a single unit (depends on model).

It is desirable to fasten the beds using anchor bolts. All agglomerators works from 380 V -50 HZ.

Earthing is compulsory for all models of agglomerators.

Principle of operation of agglomerator is very simple. An operator just feeds the film wastes into working chamber

(the machine must be turned on 1-2 minutes prior to the beginning of operation to make the lubricant distribute in the bearing unit

Then the material is cut following by washing (if required) (Film washing reduces the productivity of agglomerate formation but allows to receive raw materials from foul and cheap film) then it is dried by friction, heated ( more thn 100 C) and turns into homogenous paste. It is important to timely feed shocking water to the chamber for abrupt cooling of the paste. The water cools, the blade cuts, the resultant agglomerate is dried for 1 -2 min to make a ready prodcutt

 

The finished product called agglomerate is used in industry as a ready fraction.

The agglomerate has irregular granular shape of 3-10 mm.

This product can be ready for processing on foundry machines (any type of foundry) extrusion equipment (production of film). You can see the above at out factory and see our machines in opera-tion. Our production line operates 24 hours/days ;

 

The machine must be installed on level surface.

Then it is necessary to set the belt drive from the main engine and adjust the tension of belts.

Then the cooling bath is mounted. It is mounted below butt outlet of the main unit with holes of 2-3 cm for dragging plastic paste

After that cutting device is mounted

Then the devices are connected to feeding net.

After mounting of electric equipment it is necessary to check the insulation resistance and make sure that thres no power leakage.

If theres no power leakage, than the mounting is finished successfully

It is necessary to pay special attention to earthing of the machine .

The bath is made by the User, the control panel place and operators place are determined in accordance with the layout for the specific place. Near the machine the place for grid cleaning should be stipulated.

Electric equipment is mounted by the specialists.

It is necessary to set the operation temperature required using regulators on the control panel. After setting the required operation temperature it is necessary to manually turn rotating parts of the main unit and auxiliary machines shafts.

It is necessary to make sure that the rotation of shafts and details takes place in normal mode

Then it is necessary to to unscrew the body in the end part of the machines.

To fill completely the bunker with raw materials.

Turn the main unit on

watch the movement of liquated plastic paste from the outlet. The fibers must go to the bath for cooling.fill completely the bunker with raw materials

Then turn off the main engine and mount a latticed filter on the outlet part of the machine. For each type of plastic 2-5 latticed filters should be mounted. Over the lattice the stopper is mounted and butt device body is with fiber dragging holes is attached.

Then it is necessary to use the handle of the control panel to turn the main unit. .

Then turn the machine on

Wait, till fibers of plastic paste will go out of main unit The fibers go along the cooling bath and enter the cutting device. It is necessary to guide the fibers along the bath by hand to the inlet of the cutting device.

Then the machine operates well.

The fibers should go not too slow but not too fast. If fibers are of different thickness, this means that the temperature is too low, so it is necessary to use controller on the control panel to raise it by 10-12⁰C.

Slow movement of materials or thin fibers indicates and the lattices are crammed, so it is necessary to replace the latticed filters.

It is necessary to turn the machine off, unscrew the butt device and take out the latt

It is necessary to clean the lattices 1 time/8hours. .

In the case of normal operation of the machine the raw materials goes continuously from upper part of the bunker inside the machine, so it is necessary to continuously supply the raw materials to upper part of the bunker. .

If the raw material doesnt go from upper part of the bunker inside the machine, it is necessary to stop the machine, dismount the case and timely eliminate defects. .

 

The lubrication points of the machine should be regularly filled with lubricant. Liquid lubricants fill the machine reducer, lubricant grease is filled into the machine bearings

The machine should not be operated at low temperature of the machine.

When the machine is not in operation it is necessary to remove the remains of the mold plastics.

The maintenance of the machine is performed regularly ad properly, the operators working place should be kept clean

The condition of the machine should be controlled in every shift, it is necessary to timely tighten the fastening of the details

It is necessary to check the fastening of the ground wire

Only plastic raw materials can be fed, not other materials can be fed, otherwise premature wear will occur.

 

A set of spanners, adjustable wrench, screwdriverss set, scrubs to remove the remaining plas-tics, latticed filters

Selection of cutting device

Type of device : 400. Engine power 10,5 kW. Driving belt: 160 mm.

Type of device: 500.Engine power 13-15 kW. Driving belt: 180 mm.

 

Blowing machines usually include engine, three feeding pipes, nozzle and cooling system, bun-ker, etc.

Production process.

The raw materials fill up the bunker that it is heated up and molded into tubular sheeting, the compressor boosts inside. The film cools down and turns into finished product, and then reels into rolls.

Make ready:

Make sure that the extruder and its parts are properly mounted and fixed..

If engine, bunker, nozzle are mounted in the wrong place, it is necessary to mount them as required by production conditions

Panel board:

Toggle: heating.

Toggle: temperature control. The temperature is adjusted as required

Toggle: switches on at max. Temperature .

Toggle D: Maintenance of permanent temperature.

Temperature indicators are mounted on the panel board

Specific indication may vary, depending on recycling process of specific plastic. If the raw mate-rials are melted it is necessary to adjust heating temperature.

Material high pressure PE

In device #1 temp is 1400. In device 2 temp. is 1500. In device #3 temperature is 1550. In tween elbow temperature is 1680. Nozzle: 1500⁰. In tween elbow temperature is 1680. Nozzle: 1500 ⁰.

Material low pressure PE

In device #1 temp is 1700⁰.In device 2 temp. is 1800. ⁰. In device #3 temperature is 1850⁰.In twin elbow temperature is 190 ⁰.

Nozzle: 185⁰.

Material: polypropylene

In device #1 temp is 1800⁰. In device 2 temp. is 2300.⁰. In device #3 temperature is 230-2500⁰. In twin elbow temperature is 2200. ⁰. Nozzle: 200⁰.

If high pressure PE is used, heating plate is not compulsory, If low pressure PE is used, heating plate must be used practically in all cases

Sequence of operations:

1. Put the plastic crumbs into initial materials bunker

2. Start the engine.

The crumb goes into the device and melts there. Using pincher, take the tubular sheeting from the nozzle by catching its top. The tubular sheeting starts to stretch.

Using pincher, take the tubular sheeting from the nozzle by catching its top. The tubular sheeting starts to stretch.

3.Turn the compressor on. Open air pump valve. Feed some amount of compressed air to the nozzle. Excess of air may result in tearing of the hose.

4. The tubular sheeting goes through the feeding box, after that the compressed air pressure can be raised. When air pressure reaches the rated one, the air valve may be closed.

5. Wait till film blowing process becomes stable, and the films thickness and width becomes regular.

6. It is necessary to control the precision of specifications of the film being blown, its width and evenness.

7. If the specifications are at variance to those require, then troubleshooting should be performed.

 

This machine is supplied with automatic control device. Automatic temperature control and program management Tubular film size adjustment device

Bag sealing adjustable device.

Bag sealing adjustable device.<

The devise seals the bags and prints logos on them automatically.

The equipment, performing the above functions (tubular film size adjustment, bag sealing, print-ing of logos) is completely automatic. It is a single unit.

Film specification automatic control breaker serves to regulate the specifications of raw materi-als feeding to the machines inlet.

Film specification automatic control device is off, red signal lamp lights. Film rolling process can be adjusted manually by lifting of guide roller..

The guide rollers goes down, red light is on, the guide roller goes up, red light is off.

 

The machine is mounted on even surface and connected to domestic power supply 220V 50Hz

From this moment the production process may begin.

First check that electric supply is connected properly. Turn of automatic switches inside distri-bution board of the machine. Raise and drop the guide film folding roller, switch the red lamp on and off.

Press start button, make sure the process goes in design mode. Make sure that all the mecha-nisms are ready for the operation

Turn on the heating device. Adjust the temperature and set it to the value required

Temp for PE is 15000⁰. Temperature for PP is 170 ⁰.

Put the tubular sheet under the bar of the sealing device and make control sealing

Adjust the film size as required (on the tension roll)

Adjust clearances, distance between sealing seams and strength of seams. .

If seams are not strong enough, it is necessary to adjust the temperature using controller on the con-trol panel. Control step is 5-10o . Then check the quality of bags and seams

1. The evenness of welding seams is controlled

2. The quality of logo printing is controlled

If the quality meets the requirements, all automatic devices are properly adjusted, then the bag pro-duction process can be starte

The specifications of film is entered into the system of the machine

Since that automatic feeding of the material and bag sealing begin

 

To extend the service time of the machine, it is necessary to tighten the fastenings regularly, timely lubricate the machine and control its units.
All friction parts are lubricated by oil from the grease box.

Details fastening and conditions of bearing are checked every day.

Worn details should timely replaced

After work it is necessary to clean the details of the paint remains, and wipes all rolls and shafts

The printing matrices are wiped using petrol or white spirit.

If machine is idle for a long time, it is necessary to dismantle the printing rolls and replace them y the new ones.

 

As a rule rubber matrices are used.

Matrices can be made by hand or using press formation

Matrices are attached to the roller using adhesive fabric

First separate protective fabric from the gluing layer..

Then adhesive fabric is glued to the drum, and the matrix is stuck on it. The matrix is ready for work.After paint filling the operation may begin

Special typographic dyers for printing on bags are used. .

When new tubular film is fed into the machine, it is usually necessary to re-adjust the matrix posi-tion on the roll by reattaching it.

When printing is not required the matrix can be covered by one or several layer plaster.

To make the optimal viscosity of the paint it may be thickened or diluted.

After preparation, you may begin printing logos on the bags 

It is necessary to energize from domestic power supply system and start working.

A wood board is laid under holing blade. The bag is put on the board. After holing the finished bag is put into the packing bag.

If no holes are made, it is necessary to adjust the press and normalize corresponding clearances or replace the wooden board

 

Technique of recycling of various plastics differs mainly in operation temperature. 

There various types and sizes of bathes. The bathes can be made by the Customer. The bath depth 30- 40 cm. The bath should not be too, otherwise the fibers become fragile and can break

 

Main engine: 10,5 kW

Auxiliary engine: 7,5 kW.

Main engine: 10,5 kW.

Belt drive: 180 mm. 3 units.

Auxiliary engine: 7,5 kW.

Belt drive: 130 mm. 3 units.

Miller: 0,5 kW

Belt drive: 140 mm. 1 unit.

Material separation device: 10,5 kW 

UP>> 

135 series secondary soft plastics and PET raw materials recycling equipment

 

Registration Certificate number _____________

Warranty no before export ____________
The equipment was manufactured in the ___th quarter of 200_____

Registration certificate « of» 135 series secondary soft plastics and PET raw materials recycling granulator -

 

MSJ-135 secondary plastics granulator

It consists of four units

1. Preliminary raw materials shredding machine

2. ZS 65 agglomerator

3. Flakes and granules production machine

4. ZR 1000 washing separator

The set is completed by three engines, designed for 380 volts, 5 am, second grade of electric safety, 3 phases

Engine #1, 1,5 kW should be mounted in flakes and granules production machines

Engine #2, 7.5 kW should be mounted on raw materials shredder

Engine #3, 11 kW should be mounted on agglomerator plastic recycling machine

 

The shredder is used for shredding waste and old plastic products, such as barrels, bottles, tubes, bags, films, The equipment has a lot of advantages such as good design, high productivity, long service life. Shredded films and silk balls do not wind on the rotating shaft. Sifter allows to receive crumbled plastic secondary materials of various size and shape. During shredding of the used film, bags and balls, it is possible, if mount a mixer in lower part of the machine to make simultaneous shredding and purification of the materials. This shows versatility of the machine and its suitability for further operations with raw materials (patent L98 203051.7)

 

Model Item
Fixed blade/pc	2
Rotating blade/pc	3
Engine power (kW)	By the customer's order, is mounted on the site
Productivity (kg/hr)	50~200
Outer size (L W H) mm	1400×850×1350
If install stirrer (for rinsing of the materials)
Stirrer's power (kW)	3
Rotations (rpm)	750
Outer size ( L W H ) mm	1400×2250×1350
Weight (kg)	325

1.2.Machine 2 ZS 65 Agglomerator

Agglomerator is the machine screw drive of diameter of 135 mm

Engine power vary from 3 kW to 6 kW depending on Customer order, standard power is 5 kW, mounting of engine up to 7.5 kW is acceptable. With the engine power of 7,5 kW productivity in-creases by 15% as compared to the standard one. Engine are mounted on site. The machine is equipped by 4 heating zones by power of 11 kW. Screw is adjusted by rotation speed depending on type of recycled plastics and loading of raw materials

 

Name of raw materials		1-st heating zone	2-nd heating zone	3-rd heating zone	4-th heating zone
crylonitrile-sterol	Dry	1800	1700	1500	1500
Acrylonitrile-sterol	Wet	2200	1800	1600	1500
ABS	Dry	2100	2000	1800	1700
ABS	Wet	2400	2300	1900	1800
Plolyamide	Dry	1500	1650	1650	1750
Polyamide	Raw	1800	1800	1700	1700
Functional type		2500	1800	1800	1800

 

Functional type means that in the process of heating the 4th zone can close

 

Specifications:

Screw rod diameter	135mm
L/D ratio	L/D14:1
Engine power	7.5-15kw
Rod rotation speed	30-70r/min
Productivity	kg/h 200
Weight	800-1000kg

 

ZS 65 agglomerator serves for soft plastics and PET recycling. If necessary, in case of usage of inhomogeneous raw materials, some heating zones can be closed. Shredded and washed plastics is loaded into the machine. The size of loaded raw materials doesnt exceed 505020 mm, prelimi-nary drying of shredded materials is desirable. The machine may be connected to degassing system, in this case recycling of raw materials with moisture content of 15% is possible.

Agglomerator yields 6-12 threads of diameter of 10 mm of the recycled materials, the length of the thred can reach 79 meters. The machine makes sterile product, available for usage in food industry, guarantees complete sterilization of the product. Avoid ingress of metal or stone to the raw materi-als

 

The machine serves to produce granules and flakes of thickness of 10 mm from secondary plastics after their recycling on agglomerator

 

Ready flakes, size	35-50mm
Size	7550120
Engine power	3-5kW
Number of blade	4
Productivity	50-210kg/h
Weight	100kg

 

This machine separates labels from crumbled PET flakes by vibration depending on materials in in-ner part of the compressor.

 

Compressor:#5

Productivity:1000 kg/hr.

Compressor's engine power: 550Kw.

Voltage:220V

Productivity: 1000kg/hr

 

 

No.___________________

Letter: No._______________________
Letter: Quality control, Beijing, #: ______________
Mesurements and inspection Letter: Beijing #: __________ 

Name: Secondary plastics granulator

Organization to be inspected: Mega Power Hong Kong Group limited

Inspection category: By Proxy inspection

 

Inspection and machinery quality control station, Beijing

Seal of Inspection and machinery quality control station, Beijing

 

Reports code number: _________________ 

Name of specimen Secondary granulator of plastics

Name and type ______________

Trade markMega Power

 

INspection categoryBy proxy inspection

Number of specimen1 pc.

Quality The product meets the requirments

 

Name of the company under examination Mega Power Hong Kong Group Limited

Code of specimen __________________
Registered name

of the enterprise Mega Power Hong Kong Group Limited

 

Date of production ________________.

The specimen's condition Standard

 

 

Reason for the inspection

«Secondary plastics granulator»

Objects of inspection

Idle running examination, examination under load, the time of pre-liminary heating of the system, maximal speed of rotation of the worm shaft, measurements of productivity, actual specific power, ratio of the recycled materials, safety and protection, active and passive safety, safety at excessive tension, buttons, electric equip-ment and electric wiring, earthing, electric insulation resistance, control at increased power, noise, quality of worm shaft material, appearance, electric engine, accompanying documents, totally 20 points

 

Date of the test ____________.

Date of finishing _______________

 

Inspection's decision	This specimen was examined on the basis of Q/JB MKJ 001-2005 Secondary plastics granulator, the objects of inspection by proxy meet the standard requirements. Seal of Inspection and machinery quality control station, Beijing The place of main seal or special seal for inspection reports Seal of Inspection and machinery quality control station, Beijing
Notes	-

Confirmed: _______________   Controller:_______________ Chief Inspector:_____________________

 

 

p / p	Object of inspection	Technical requirments	Measurement's results	Conclusion
1	Idle run check	Rotations direction should be normal, sta-ble rotation and even rotation. No clogging and cutting of the de-tails surface	Rotations direction is normal, stable rota-tion and even rota-tion. No clogging and cutting of the details surface	Meets the requirments
2	Examination under load	Rotation should be stable and even.	Rotation should be stable and even.	Meets the requirements
3	Time for preliminary heating of the heating system	No more than 2 hrs.	85 min	Meets the requirements
4	Max speed of worm-shaft rotation	No less than 40 rpm.	50 rpm.	Meets the requirements
5	Measurements results	No less than 70 kg. / hr	84,6 kg/hr	Meets the requirements
6	Actual specific power	No more than 0,13 kW / (kg/hr)	0,10 kW / (kg/hr)	Meets the requirments
7	Ratio of the recycled materials	No less than 1,40 (kg/hr) / (rpm)	1,69 (kg/hr) / (rpm)	Meets the requirements
8	Safety and protection	There should be protective fences in dangerous places	There are protective fences in dangerous places	Meets the requirements
9	Active and passive safety	Should correspond to article 6.2 GB5226.1-2002	Corresponds to article6.2 CGB5226.1-2002	Meets the requiremens
10	Safety at excessive power	Should correspond to article 6.2 GB5226.1-2002	Corresponds to article 7.2 GB5226.1-2002	Meets the requirements
11	Buttons	Should correspond to article 10.2 GB5226.1-2002	Corresponds to article 10.2 GB5226.1-2002	Meets the requirments
12	Electric equipment and electric wiring	Should correspond to article 14 GB5226.1-2002	Corresponds to article14 GB5226.1-2002	Meets the requirments
13	Earthing	Should correspond to article 8.2 GB5226.1-2002	Corresponds to article 8.2 GB5226.1-2002	Meets the requirments
14	Electric insulation resistance	Should correspond to article 19.3 GB5226.1-2002 Resistance no less than 1 megaohm	Corresponds to Article 19.3 GB5226.1-2002 Resistance 600 megaohm	Corresponds to requirements
15	Control at excessive voltage	1000 V, time 1 min., there should be no sparking and breakdown	1000 V, time 1 min., there should be no sparking and breakdown	Meets the requirements
16	Noise (Sound pressure)	No more than 85 db ()	83,4 db ()	Meets the requirments
17	Quality of material of the wormshaft	Inspection report should admit it meats the requirements	Inspection report admitted it meets the requirements	Meets the requirments
18	Appearance	Paint and lacquer shold be stable, there should be no splits and stains, the surface should be clean and evenly painted. Weld-ing seams should be treated and smoothed	Paint and lacquer are stable, there are no splits and stains, the surface is clean and evenly painted. Welding seams are treated and smoothed	Meets the requirments
19	Electric motor	Rated power should be 11 kw, the motor should have Certificate of conformity	Rated power is 11 kw, the motor has Certificate of conformity	Meets the requirements
20	Accompanying documents	There should be Op-eration Instruction, Certificate of conformity	There are Operation Instruction, Certificate of conformity	Meets the requirements

 

Inspection and machinery quality control station, Beijing

 

 

.First use controllers on the control panel to set the required operation temperature. When the opera-tion temperature is set to the required value, it is necessary to turn rotating parts of the main units and shafts of the auxiliary units by hand Make sure, that rotation of shafts and details takes place in normal mode

Then unscrew the body of the holed device in the end part of the machine. Fill the bunker with raw materials completely.

Turn the main unit on

Watch the movement of melted plastic paste through the outlet holes of the device. The fibers should go to the bath to cool. Switch on the Main engine set latticed filters on outlet part of the machine. There 2-5 latticed filters for each type of plastic. The stopper is mounted over the lattices and the body of end device with fiber dragging holes is screwed up

Then it is necessary to slightly turn the main unit by turning the handle on the control panel. Then energize the machine

Wait, till fibers of plastic paste will go out of main unit The fibers go along the cooling bath and enter the cutting device. It is necessary to guide the fibers along the bath by hand to the inlet of the cutting device.

The machine operates well.

The fibers should go not too slow but not too fast. If fibers are of different thickness, this means that the temperature is too low, so it is necessary to use controller on the control panel to raise it by 10-12 C. Slow movement of materials or thin fibers indicates and the lattices are crammed, so it is necessary to replace the latticed filters

It is necessary to turn the machine off, unscrew the butt device and take out the lattices. It is neces-sary to clean the lattices 1 time/8hours

In the case of normal operation of the machine the raw materials goes continuously from upper part of the bunker inside the machine, so it is necessary to continuously supply the raw materials to up-per part of the bunker. If the raw material doesnt go from upper part of the bunker inside the machine, it is necessary to stop the machine, dismount the case and timely eliminate defects.

 

The machine must be installed on level surface. Then it is necessary to set the belt drive from the main engine and adjust the tension of belts. Then the cooling bath is mounted. It is mounted below butt outlet of the main unit with holes of 2-3 cm for dragging plastic paste

After that cutting device is mounted Then the devices are connected to feeding net..< /div> Warranty obligations of the manufacturer of maintenance of 135 plastic recycling line are valid during one year since the equipment crossed the border of the Customers country During the year the Seller renders services as follows

 

Name of service	Time of execution	Notes
Consulting of customers	1 day
Replacement of units and machines, broken owing to the factorys faults	5-30 days	Depending on difficulty of repair
Repair operations	7-30 days	Depending whether it is necessary to wait for supply of the conpany's spare parts.
Issuance of conclusion as to reasons of defects	3-5 days
Registration of reception and delivery of war-ranty products, made in the manufacturers plant to the manufacturer.	60 days
Warranty repair	12- 30 days	Depending on difficulty of repair
Delivery of spare parts above warranty spare parts	60 days	Depending on assortment
Complete substitution of some units or the whole production line	90-180 days	Depending on quantity and size of the equipment to be replaced
Issue of copies of the lost documents	14 days	Custom, transportation documents. Certificates, contracts, operation instruc-tions

The manufacturer takes the performance of operations, described in previous section of the Con-tract, in accordance with application from the Buyer

If the case of breakage of the production line during the Warranty time, the Customer sends a written notice to the Manufacturer, describing the problems and faults

During three working days the Manufacturer must give the conclusion whether the case is the war-ranty one. If the Manufacturer refuses to admit it the warranty case, his conclusion should be grounded

.The decision of the Manufacturer may be appealed to the managing body of the Manufacturing plant.

Decision of the manufacturing plant concerning grouping of warranty cases is final and compulsory for the Manufacturer.

The Contract is considered to be performed after one year of occurrence in the Customers country, unless the latter lays claims as stipulated in the Contract

The Manufacturer has rights to give permission to use units and details, made in the Customers country when performing repair works

If the equipment got of order not by the Manufacturers fault and the Customer want to purchase spare parts from the Executor, then they should be delivered by additional contract, price and terms should be subject of negotiations

.When the details, made in the Customers country or some other country are used during repair, the Performer solves all the issues concerning compensation of expenses for their purchase.

.The cost of delivery of spare parts and units to the Customer is paid by the manufacturing plant.

The manufacturer must render services of proper quality

&The Manufacturer bears responsibility for service maintenance of the equipment but is not responsi-ble for delivery, its time, assembly, quality of products and other issues that are withing the compe-tence of the manufacturing plant .

The Customer is responsible for exploitation of the equipment in accordance with rules and regulations. If breaking of these rules and regulations caused the breakage of the equipment, the Customer bears the responsibility for

Director of service center ______________

 

Registration certificate #_____________
Pre-export warranty obligations _________________
Date of production _______________quarter of 200_________

 

1 Description

1.1. Preliminary raw materials shredding machine

1.2. Agglomerator

1.3. Flakes and granules production machine

2. Mounting. Adjusting. Operations and the most important points

2.1 Mounting and adjustment

2.2 Mounting and adjustment of the rinser.

2.3. Mounting and adjustment of main unit

2.4Mounting and adjustment of granule cutting device

2.5Production

3. Check of the equipment

4. Mounting of the equipment

5. Tools

6. The problems of the secondary PET plastics recycling

7. Safety rules

8. Warranty

 

It consists of three machines:

1. Preliminary raw materials shredding machines

2. Agglomerator

3. Flakes and granules production machine

 

The shredder is used for shredding waste and old plastic products, such as barrels, bottles, tubes, bags, films, The equipment has a lot of advantages such as good design, high productivity, long service life. Shredded films and silk balls do not wind on the rotating shaft. Sifter allows to receive crumbled plastic secondary materials of various size and shape. During shredding of the used film, bags and balls, it is possible, if mount a mixer in lower part of the machine, to make simultaneous shredding and purification of the materials. This shows versatility of the machine and its suitability for further operations with raw materials (patent L98 203051.7)

 

Model/Specification
Fixed blade\unit	2
Rotating\blades	3
Engine power. (kW)	7,5
Productivity (kg\hr)	50~200
Outer size (L W H) mm	1400×850×1350
Stirrer's power (kW)	3
Rotations (rpm)	750
Outer size ( L W H ) mm	1400×2250×1350
Weight (kg)	325
feedstock size	50mm
Moisture of the feedstock	No less than 30%
Reception bunker size	500*300*300mm

 

Automatic shredder with washer serves to isolate any metals, stones, other solid admixtures from plastic raw materials, for shredding plastics with the blades and for washing the raw materials in swirling water. After that the raw materials go to the extruder to produce plastic crumbs Automatic shredder with washer includes electric engine, blade holder, sieves and other details..

Main functions and specifications

Note: The sieves can be replaced depending on size of raw materials.

 

Agglomerator is the machine screw drive of diameter of 145 mm Standard engine power is 5 kW, mounting of engine up to 7.5 kW is acceptable. The engines on the machines are mounted on site, pulleys and belts are purchased and mounted by the Customer. The machine is equipped by 6 heating zones by power of 20 kW. Screw is adjusted by rotation speed depending on type of recycled plastics and loading of raw materials

Temperature of various plastics in various heating zones are as follows;

 

Raw materials		1 st heating zone	2-nd heating zone	3-rd heating zone	4-th heating zone	5-th heating zone	6-th heating zone
Acrylonitrile-sterol	Dry	1800	1700	1500	1500	Degassing	1500 Heating of head
Acrylonitrile-sterol	Raw	2200	1800	1600	1500	Degassing	1500Heating of the head
ABS	Dry	2100	2000	1800	1700	Degassing	1500 Heating of the head
ABS	Raw	2400	2300	1900	1800	Degassing	1500 Heating of the head
Polyamide	Dry	1500	1650	1650	1750	Degassing	1500 Heating of the head
Polyamide	Raw	1800	1800	1700	1700	Degassing	1500 Heating of the head
Functional type		2500	1800	1800	1800	Degassing	1500 Heating of the head

 

Functional type means that the 4th zone can close during the production

 

Screw rod diameter	145mm
L/D ratio	L/D14:1
Engine power	7.5kw
Speed of rod rotation	30-70r/min
Productivity	kg/h 350
Weight	800-1000kg

 

.Agglomerator serves for soft plastics and PET recycling. If necessary, in case of usage of inhomogeneous raw materials, some heating zones can be closed. Shredded and washed plastics is loaded into the machine. The size of loaded raw materials doesnt exceed 505020 mm, prelimi-nary drying of shredded materials is desirable. The machine may be connected to degassing system, in this case recycling of raw materials with moisture content of 15% is possible. The machine is equipped with device, providing the feeding of soft plastics and films to heating zones. Speed of feeding is up to 3.5 kg/min. The device is in apper part of agglomerator t.

Agglomerator yields 6-12 threads of diameter of 10 mm of the recycled materials, the length of the thred can reach 79 meters. The machine makes sterile product, available for usage in food industry, guarantees complete sterilization of the produc.

Avoid ingress of metal or stone to the raw materials .

 

Agglomerator melts under high temperature shredded and washed raw materials and forces through the resultant plastic paste. It consists of 3 parts control panel, electric engine and main unit.

Operation principle. Plastics goes through the funnel to inside the agglomerators drum. Then plas-tic is pushed by the aggomerators screw towards the head.. Filter lattices, separation plate and ma-trix head makes resist the movement of plastic paste. Gradual compaction of spiral shredding rein-force the resistance of spiral shredding. Thus, the moving plastic paste is complexly affected by squeezing, cutting, mixing, etc. Friction of plastic against the drums wall and against the screw, as well reciprocal inner friction plastic paste emit a great amount of heat, as a result, the temperature inside the agglomerators drum continuously raises. The state of plastic paste changes from glass-like stare to high plasticity. At last, the plastic turns into viscous paste of wet consistency and be-comes perfectly plastics. As the agglomerators screw rotates continuously and evenly, plastic paste goes evenly through the agglomerators head. As a result it turns into viscous plastic fibers. Then the fibers are cooled, shredded to become the secondary plastic granules.

Therefore, plastics formation includes loading, plastification, even forcing through. Then plastic goes through the head and turns into fibers. These three processes can be called loading phase, plas-ticification phase and even mixing phase

 

Screw and drum of the agglomerator is one of the most important part of the equipment. The main purpose of the screw is even feeding of plastic paste to the head. Besides, in the process of feeding the plastics transforms into plastic liquid melt and is mixed to homogeneous paste. Raw materials containing water turns into vapor and expires

Electric heating and heating

Heating system operates during agglomerators operation, it heats drums and head. Owing to it raw materials in agglomerator transfers into liquid melt. Besides, some heat is secreted due to the friction of raw materials against the drums wall, screw and inner friction of raw materials.Simultaneously, heat penetrates from the outside owing to the drums heating, and due to it the raw materials trans-forms into plastics. For recycling of the secondary plastics the agglomerator uses heating with heat-ing plates made of mica and stainless steel and by heating with infra-read rays.

Machines drive

The agglomerators drive system is also very important part of the machine. It consists of engine and belt drive. It serves for even rotation of the agglomerators screw.

 

lattices Flow separation spacer and filtration lattice are auxiliary details of the agglomerator. They are mounted between the drum and the head. They serve to turn circular rotation of plastic paste inside agglomerator into linear rotation. Filtration lattices are located in front of flow separation spacer the latter presses it to the end part of the agglomerators drum They prevent the movement of alien materials through the head. These two parts increase the pressure of the paste movement, thus compacting the plastics and securing the quality of the final products. .

 

The machine serves for production of granules and flakes of threads of thickness of 100 mm from the secondary plastics after its recycling in agglomerator.

 

SIze of ready flakes	35-50mm
Size	7550120
Engine power	3 kW
Number of blades	6
Productivity	50-350kg/h
Weight	100kg

 

Plastic fibers, going from the agglomerators head are cooled in the water bath and become solid. Then they are cut into granules, their length can be adjusted by the pulleys of various diameters. Granules cutter usually consists of belt drive, broach shafts, blade holders, electric engine and other details. (It can be completed by speed regulated engine by special order)

 

The whole line consists of 4 units

Preliminary raw materials shredding machine
Flakes and granules production machine
ZR 1000 washing separator

The whole set has three motors, 380 V, 5 amper, second category of electric safety
Three phases

Engine 1 power 1,5 kW is to to mounted on granule and flake making machine .

Engine 2, power 7,5 kW is to be mounted on the raw materials shredder .

Engine 3, power 11 kW, is to be mounted on agglomerator.

 

Mounting and adjusting

As secondary plastics granulator goes from the factory as a whole assembly, its mounting is not dif-ficult. After mounting and adjusting it possible to begin operation. But as there are various types of the secondary plastics used as recycled materials, and theres dirt, sand and other alien substances in raw materials, so it is necessary to wash the raw materials and remove admixtures in order to im-prove the quality of the final product. Thats why shredder and the washer should be completed with water capacity to be used for washing of the materials.

 

Mounting and adjusting of washerMount electric engine and belt drive of shredder with washer

Adjust the positions of size of blades of shredder with washer. First, fix two immovable blades.Boom of immovable blades and clearance between blades are determined in accordance with the recycled material. For plaited bags, agricultural films, terrestrial covering films and other soft materials the clearance should be 5 mm, the blades size should not exceed 10 mm, then it is necessary to tighten immov-able blades to make a clearance 0.01 and 0.05 between movable and immovable blades. The least clearance is the best

Turn over the belt drive by hand, make sure theres no sound of whipped blades. If the blades touch each other, it is necessary to adjust them to eliminate the sound. If there are no alien sounds, ener-gize the machine and turn over the machine for several minutes. Stop the engine and tighten threaded fastenings. Then start the operation. First, the machine should be checked by small amount of materials. If everything is in good order, then it is possible to start operation.

(Notes) Every time before the start it is necessary to tighten threaded fastening of shredder with washer. This prevents untightening of nuts and accidents at work. Every time before the start it is necessary to add grease to each bearing to prevent their breakage

 

Chose the place for mounting of the main unit. Granule production unit should be safe and conven-ient for operation. It should also be close to warehouses of raw materials and finished products. To provide safety, the engines should be mounted in the corners or close to the wall. Place of mounting in the shop should provide convenience of control and be lit properly.

Select the engine the belt drive that conform to the machines specification.

Fill the reducer with 6-10 kg of transmission oil. (if the norm of filling is not indicated, the reducer must be filled by 1/3). In the beginning the oil must be changed monthly, then once in three or six months.

Energize then check the temperature of the machine (for each heating temporal heating is 200⁰ C), use the indicator to check whether all the heating plates are fed, make sure the heating plates work properly

When the temperature reaches 200⁰C (the lamp becomes red), turn the reducer shaft and belt drive, using key and make sure the details can rotate. Then load a minor amount of milled PE or PP. Press the start button of the main machine for test running. Check the plasticity of raw materials. If plastification is good, then it is possible to operate the machine.

 

Mount water bath in accordance with the process flow diagram.

.Adjust the clearance between movable and fixed blades. The least clearance is the best, but the blades should not touch one another

Install the engine, control buttons, pulleys and belt drives with trapezoidal belts, conforming the specifications of the main units, fill lubrication points with oil

DO NOT put your hands into the granule cutting devise, raw material shredder, raw materials crusher and main units to avoid occupational injuries and accidents

DO NOT load metal and stone things into granule cutting device and raw materials crusher tp avoid breaking the blades and whole equipment.

DO NOT load metal parts and solid materials to the funnel of the main machine to avoid breaking of the worm rod and drum, that may result to clogging of the worm rod and getting the machine out of order. (Notes. In the case of accidental occurrence of metal inside the drum of the machine, it is necessary to stop the machine immediately, then, using key turn the reducer shaft and belt drive pulley to the opposite direction, to let the metal part from the inside of the machine and remove it. . If the problem is serious, it is necessary to open the drum and remove alien things or contact the seller.)

Every time before the start of granule cutting device and raw materials shredder it is necessary to tighten all the threaded connections. During the rotation, there should be no people in front of the machines head, as filtration lattices can clog, the head will be pressed out and there can be injuries..

 

(IV Intrinsic Viscosity).

Pet recycling is the result of decrease of molecular weight of the product due to hydrolysis, thermal disintegration resultant from the temperature differences and drop in intrinsic viscocity. Intrinsic viscosity for pure PET (IV) is 0,80 dl/g for used PET it is 0,68-0,72 dl/g. During the recycling, the materials having comparatively high IV value usually suffer and drop in values. For instance raw materials with instrinsic viscosity IV =1.05 will have IV= 0.07 dl/g following the recycling Initial IV 0.5 will be 0.05 after recycling

For foundry, dragging, foundry under aerial pressure the IV should be 0.74 and more. As the value of IV drops during the recycling, the process of consolidation is necessary to make up for viscosity

Although IV for secondary PET is 0,68-0,72 dl/g, it may drop to 0,63 dl/g. Low temperature in ag-glomerator may result to precipitation of the material, so it will be difficult to support the process of extrusion. In the case of raise of temperature the plastic will pass freely through the agglomerators head.

 

First it is necessary to set the required operation temperature on the control panel using controllers When the temperature is set as required, it is necessary to turn by hand rotating parts of the main unit and auxiliary device shafts. Make sure, the shaft and details rotation is in normal mode.

Then it is necessary to to unscrew the body in the end part of the machines.

Then turn the machine on

and watch the movement of liquated plastic paste from the outlet. The fibers must go to the bath for cooling. Then turn off the main engine and mount a latticed filter on the outlet part of the machine. For each type of plastic 2-5 latticed filters should be mounted. Over the lattice the stopper is mounted and butt device body is with fiber dragging holes is attach

Then it is necessary to use the handle of the control panel to turn the main unit.

Wait, till fibers of plastic paste will go out of main unit The fibers go along the cooling bath and enter the cutting device. It is necessary to guide the fibers along the bath by hand to the inlet of the cutting device.

Then the machine operates well. .

The fibers should go not too slow but not too fast. If fibers are of different thickness, this means that the temperature is too low, so it is necessary to use controller on the control panel to raise it by 10-12 C. Slow movement of materials or thin fibers indicates and the lattices are crammed, so it is necessary to replace the latticed filters.

It is necessary to turn the machine off, unscrew the butt device and take out the lattices. It is neces-sary to clean the lattices 1 time/8hours.

In the case of normal operation of the machine the raw materials goes continuously from upper part of the bunker inside the machine, so it is necessary to continuously supply the raw materials to up-per part of the bunker. If the raw material doesnt go from upper part of the bunker inside the machine, it is necessary to stop the machine, dismount the case and timely eliminate the reason of defects.

 

The machine must be installed on level surface. Then it is necessary to set the belt drive from the main engine and adjust the tension of belts. Then the cooling bath is mounted. It is mounted below butt outlet of the main unit with holes of 2-3 cm for dragging plastic paste

After that cutting device is mounted

Then the devices are connected to feeding net.

After mounting of electric equipment it is necessary to check the insulation resistance and make sure that thres no power leakage

If theres no power leakage, than the mounting is finished successfully

The bath is made by the User, the control panel place and operators place are determined in accordance with the layout for the specific place. Near the machine the place for grid cleaning should be stipulated..

Electric equipment, (supplied separately) is mounted by the specialists.

 

The lubrication points of the machine should be regularly filled with lubricant. Liquid lubricants fill the machine reducer, lubricant grease is filled into the machine bearings.

The machine should not be operated at low temperature of the machine.

When the machine is not in operation it is necessary to remove the remains of the mold plastics.

The maintenance of the machine is performed regularly ad properly, the operators working place should be kept clean. The condition of the machine should be controlled in every shift, it is necessary to timely tighten the fastening of the detail

It is necessary to check the fastening of the ground wire Only plastic raw materials can be fed, not other materials can be fed, otherwise premature wear will occur. .

 

A set of spanners, adjustable wrench, screwdriverss set, scrubs to remove the remaining plas-tics, latticed filters.

A set of cutting devices

Type of device: 400. Engine power 10,5 kW. Driving belt: 160 mm.

Type of device: 500.Engine power 13-15 kW. Driving belt: 180 mm.

 

The problems with PET secondary recycling equipment

a) Drop in viscosity, caused by thermal disintegration and hydrolysis is one of main problems is PET secondary recycling.

b) During melt connected secondary recycling of PET, disintegration of cycling

linear structures of lower polymers takes place. This affects the quality of the product, eg., its printing ability and paint.

c) As shown by DSI assay, the melt connected process of secondary recycling of PET leads to accel-eration of crystallization, due to strong influence of low molecular weight polymers, dust inclusions and lower cyclic polymers.

d) During secondary recycling PVC and PVDC melts, EVA paper and other wastes reduces the re-producibility of enzymatic substances for catalysis of ester hydrolysis of PET

e) Yellowing and aeration are the most important obstacles for recyling of used PET plastics. The main reason for coloration is interweaving of intermolecular links and oxidizing reactions

f) Each extrusion of used PET decreases its IV by 0,07 dl/g. IV drop results in deterioriations of mechanical data and appearance of many substances of amine group.

Troubleshooting:

1) Check the state and correctness of connection of coupled conductors and filaments of thermal element.

2) Check where the amperemeter is in good order.

3) Check whether the thermal element is in order. .

4) Check whether thermal element is fed from proper current source.

Troubleshooting:

1) Check, whether the amperemeter is in order.

2) Check whether the filament of thermal element is in order

Troubleshooting

1) To stop the machine immediately and replace filtering lattice.

2) To check, whether the head reaches the temperature required

3) If the materials are too dirty, it is necessary to wash them thoroughly.

4) Low temperature of the third heating zone and the extruders head

5) If the materials emits during start, it is necessary open the head, let the remaining material to leave the drum completely, make sure that the normal outcome of the materials is possible, clean the rear part and close the head.

1) Reducers bearing or pinion will be broken.

2) Head or die block will be crushed or the head will be squeezed out completely

3) In most grave cases worm rod will be broken and electric engine will get out of order.

 

a) Combination of deep drying, triple crystallization with drying and extrusion with melting. PET materials goes through Hot air drier for drying/crystallization..

On the first stage 90% of moisture is removed, the degree of crystallization grows by 20-25%.Dirt and resins are removed as well. Dried PET flakes are placed again to circular drying chamber for further removal of water. After recycling the materials go the third drying chamber for complete crystallization.

b) Melt enrichment. The most important feature of PET recycling is the decrease of IV, resulting in restructuring of the melt. If add 3% (by mass fraction) of MSE to PET, the hardness of the allow will increase by 80%. (MSE is one of the dressers for alloys..

c) Phosphites : Phosphoric acid organic salts serve as good stabilizer for recycling of PET by melt extrusion. The material disintegrates into free radicals and dyers. As a result metal micro admix-tures and balance catalysysts separate and perform stabilizing function. Content of phosphite-based stabilizers in PET system prevents the diminishing of molecular mass and reaction of freezing the inlet and reduces emission of aldehydes. Double (2,4-1-2-tretbutylphenyl) tetrapropanolphospate is an effective stabilizer of PET (oxidizer)

Troubleshooting:

1) Stop the machine immediately, turn the reducers shaft by hand (using key) to the opposite direction and take the metal off

 

2) If you fail to take off the metal piece by turning the shaft in opposite direction, it is necessary to take off the screw auger and remove metal.

 

Trouble shooting:

1) Adjust clearance between blades.

2) The blades become blunted, it is necessary togrind them

3) Tighten 4 bolts in upper part of the press roller (tightening torque is medium)

 

(Influence of phosphite stabilizers on viscosity and color)
After extraction of admixtures the material goes through kiln at 170-180o , 3 hrs of treatment. Outer temperature of the machine in the place of material loading - 240 , compression zone:260 , head 255-260

 

1. All the machines should be earthed .

2. in operation with filaments the operator must wear thermal isolation gloves

3. In operation with raw materials the operator must wear thermal isolation

4. When working with agglomerator it is recommended to use respiratory tracts protection devices

5. It is recommended to install compulsory ventilation under agglomerators heating zone

 

Warranty time – year since crossing the border of PR China. The warranty means as follows

1. Warranty repair a complex of operations on restoring good operation conditions and restoration of resource or workability of the whole equipment or its parts.

and restoration of resource or workability of the whole equipment or its parts.

2. Warranty maintenance provision of conformity of quality of the sold equipment to the require-ments of documents, specifications, contractual terms etc during the warranty time, non-repayable removal of faults, found by the Customer during the warranty time, replacement of the equipment in case of its breakdown, provided that Customer keeps to the operating instructions, storage and trans-portation conditions.

 

Name of service	Time of execution	Notes
Consulting of customers	1 day
Replacement of units and machines, broken owing to the factorys faults	5-30 days	Depending on difficulty of repair
Repair operations	7-30 days	Depending whether it is necessary to wait for supply of the conpany's spare parts.
Issuance of conclusion as to reasons of defects	3-5 days
Registration of reception and delivery of war-ranty products, made in the manufacturers plant to the manufacturer.	60 days
Warranty repair	12- 30 days	Depending on difficulty of repair
Delivery of spare parts above warranty spare parts	60 days	Depending on assortment
Complete substitution of some units or the whole production line	90-180 days	Depending on quantity and size of the equipment to be replaced
Issue of copies of the lost documents	14 days	Custom, transportation documents. Certificates, contracts, operation instruc-tions