Plastic Recycling Lines Crushing Washing Lines Extruder Machines

Hello! In this presentation, we will thoroughly cover the crushing, washing, and granule lines that are vital in plastic recycling. These lines are the fundamental stages in the transformation journey of waste plastics into brand new products.

It is an honor for MYHAK MAKİNA to serve you.

1. Introduction: Why Plastic Recycling?

Plastic is an indispensable part of modern life; however, if mismanaged, it causes serious environmental problems. Recycling is one of our strongest weapons against these issues.

• Environmental Benefits: Reduces natural resource consumption, saves energy, lowers greenhouse gas emissions, and alleviates the burden on waste disposal sites.
• Economic Benefits: Creates new job opportunities, reduces raw material costs, and contributes to the national economy.
• Circular Economy: Transforms waste from "trash" back into production, establishing a sustainable cycle.

2. Crushing and Washing Lines: A Clean Start

This is the first and most critical stage of the plastic recycling process. Collected waste plastics are broken down into smaller pieces and cleaned on these lines.

2.1. Crushing Unit

• Purpose: To reduce large plastic waste (bottles, containers, crates, etc.) into smaller, processable pieces.
• Equipment:
  • Plastic Crusher (Granulator): Typically uses rotating blades to cut plastic into small particles (flakes or granules). Different blade designs and screen sizes determine the final product size.
  • Shredder: Performs pre-crushing for very large and thick plastic waste (pipes, pallets, etc.). Operates at lower speeds than crushers and produces larger pieces.
• Process: Waste plastics are loaded into the feeding hopper, pulled into the crusher/shredder, and broken down until the desired size is reached.

2.2. Washing Unit

• Purpose: To remove contaminants such as dirt, labels, adhesives, oil, and soil from crushed plastic flakes. Clean flakes provide high-quality raw material for subsequent stages.
• Equipment:
  • Pre-Washing Tank/Pool: Plastics are mixed with water to settle heavy contaminants or separate them from the surface. Based on density differences, rough separation of different plastic types is also possible (e.g., PET sinks, PP/PE floats).
  • Friction Washing Machine: High-speed rotating blades or paddles rub flakes against each other to remove stubborn dirt and label residues.
  • Rinsing Tank/Pool: Removes remaining contaminants and detergent residues after pre-washing with clean water.
  • Centrifugal Dryer: Removes excess water from washed flakes using centrifugal force.
• Process: Crushed flakes pass through water-filled tanks, are cleaned by mechanical friction and rinsing, then dried.

3. Granule Line: Rebirth

Cleaned plastic flakes are melted on this line to achieve a homogeneous structure and formed into small pellets called granules. These granules can be directly used in the production of new products.

3.1. Agglomerator Machine (Optional)

• Purpose: To densify and compact light and bulky plastic flakes (especially films) to facilitate feeding into the extruder.
• Process: Flakes are fed into the agglomerator, where high-speed rotating blades heat them by friction to slightly melt and form lumps. These lumps are then fed into the granule line.

3.2. Extrusion Unit

• Purpose: To melt cleaned and dried plastic flakes into a homogeneous melt.
• Equipment:
  • Extruder Machine: Consists of a heated cylinder with one or two screws (single or twin-screw extruders). Plastic flakes are fed into the cylinder, melted by heat and screw rotation, producing a homogeneous plastic melt.
  • Filter System (Screen Changer): Used to trap unmelted contaminants or metal particles in the melt. Hydraulic or manual screen changers are available.
  • Degasser (Vacuum System): Removes moisture, odors, or volatile gases from the plastic melt by vacuuming. This improves granule quality and prevents gas bubble formation in products.
• Process: Dried flakes are fed into the extruder, melted, filtered, and degassed.

3.3. Pelletizing (Granule Cutting) Unit

• Purpose: To convert molten plastic strands or threads exiting the extruder into small, uniform granules.
• Equipment:
  • Hot Cutting System (Water Ring Pelletizing): The melt exiting the extruder die is cut directly by rotating blades and immediately cooled in water. It is one of the most commonly used methods.
  • Thread Drawing and Cooling Pool: The melt is drawn from the die as threads, cooled in water-filled pools, then dried and cut by granule cutters.
• Process: Molten plastic is shaped by passing through the die and cut into small granules.

4. Auxiliary Equipment and Automation

Various auxiliary equipment and automation systems are required for the efficient operation of these lines.

• Conveying Systems: Conveyor belts, screw conveyors, pneumatic conveying systems.
• Storage Silos: Storage areas for crushed flakes and finished granules.
• Water Cooling Systems: Chillers and cooling towers for washing water and extruder cooling.
• Electrical Panels and Automation: PLC control systems, motors, sensors, and operator panels.

5. Conclusion: Adding Value and Building a Sustainable Future

Plastic crushing, washing, and granule lines give waste plastics a new life by transforming them into valuable raw materials. These facilities not only protect the environment but also create economic added value. Continuous advancements in recycling technologies will enable more plastics to enter the cycle in the future.

We hope this presentation has provided a comprehensive perspective on plastic recycling processes. Please do not hesitate to ask if you have any further questions!