Hard Plastic Recycling Systems: Crushing and Washing Technology

Industrial recycling of rigid plastics requires specialized processing equipment to handle materials like ABS, polycarbonate, acrylics, and engineering resins. These integrated systems transform durable plastic waste into reusable raw materials through advanced mechanical and chemical processes.

Technical Process Overview

Core Processing Stages

1. Pre-Shredding Phase

   • Low-speed, high-torque shredders (15-30 RPM)

   • Hydraulic compression force: 80-120 tons

   • Metal detection sensors with automatic ejection

2. Primary Crushing

   Parameter	Specification
   Rotor Diameter	600-1000 mm
   Screen Size	30-50 mm
   Capacity	500-2000 kg/hr

3. Hot Wash System

   • Temperature-controlled baths (75-90°C)

   • Alkaline solutions for adhesive removal

   • Dual-stage filtration (200μ + 50μ)

4. Friction Washing

   • Counter-rotating shafts (40-60 RPM)

   • Residence time: 8-12 minutes

   • Ceramic-lined chambers

5. Density Separation

   • Multi-stage sink-float tanks

   • Saline solution density control

Material-Specific Processing

Engineering Plastics (ABS/PC)

• Impact-resistant shredder blades

• Low-shear washing to prevent microfractures

• Dedicated drying at 85-95°C

Automotive Plastics

• Oil separation systems

• Reinforced granulators for GF composites

• Electrostatic metal removal

Technical Specifications

Key Equipment Features

Shredding Technology

• Tungsten carbide tipped blades

• Shear-force optimization for brittle materials

• Automatic blade reversal system

Water Management

• Closed-loop circulation

• 3-stage filtration:

  1. Drum filters (>1mm)

  2. Hydrocyclones (50-200μ)

  3. Membrane filtration (<50μ)

• 90% water recovery rate

Industry Applications

Electronics Recycling

• Flame-retardant plastic processing

• Copper separation from housings

• Halogen-free material recovery

Automotive Shredder Residue

• Bumper recycling (PP+GF)

• Interior trim processing (ABS/PVC)

• Battery housing recovery

Performance Metrics

Quality Standards

• Contaminant removal: >98.5%

• Moisture content: <0.3%

• Output purity: 99.2%

Environmental Impact

• Energy consumption: 0.9-1.3 kWh/kg

• CO₂ reduction: 2.1 tons per ton processed

• Water savings: 85% vs conventional systems

Technical Innovations

Advanced Solutions

1. Cryogenic Pre-Treatment

   • Liquid nitrogen cooling (-190°C)

   • Brittle fracture optimization

2. Laser Sorting Integration

   • Polymer identification during crushing

   • Real-time density adjustment

3. AI Process Control

   • Viscosity monitoring

   • Predictive wear detection

Global Compliance

• CE: EN 12012-3:2001

• UL: UL 508A Industrial Controls

• ISO: 14001, 9001, 45001

Operational Economics

Future Technology Trends

1. Waterless Cleaning

   • CO₂ snow blasting

   • Plasma surface treatment

2. Hybrid Recycling

   • Mechanical + chemical processing

   • Monomer recovery modules

3. Mobile Systems

   • Containerized units

   • Rapid deployment configurations

Hard plastic recycling systems represent sophisticated engineering solutions for transforming durable plastic waste into high-value raw materials. These integrated crushing and washing lines overcome unique challenges in processing rigid polymers through specialized shredding technology, precision washing, and advanced material separation. Continuous innovation in process control and sustainability features ensures these systems remain essential for circular economy manufacturing worldwide.