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
-
Pre-Shredding Phase
-
Low-speed, high-torque shredders (15-30 RPM)
-
Hydraulic compression force: 80-120 tons
-
Metal detection sensors with automatic ejection
-
-
Primary Crushing
Parameter Specification Rotor Diameter 600-1000 mm Screen Size 30-50 mm Capacity 500-2000 kg/hr -
Hot Wash System
-
Temperature-controlled baths (75-90°C)
-
Alkaline solutions for adhesive removal
-
Dual-stage filtration (200μ + 50μ)
-
-
Friction Washing
-
Counter-rotating shafts (40-60 RPM)
-
Residence time: 8-12 minutes
-
Ceramic-lined chambers
-
-
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
| Capacity | Power | Water Usage | Footprint |
|---|---|---|---|
| 500 kg/hr | 55 kW | 4 m³/hr | 10×5 m |
| 1 ton/hr | 90 kW | 7 m³/hr | 14×6 m |
| 2 ton/hr | 160 kW | 12 m³/hr | 18×8 m |
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:
-
Drum filters (>1mm)
-
Hydrocyclones (50-200μ)
-
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
-
Cryogenic Pre-Treatment
-
Liquid nitrogen cooling (-190°C)
-
Brittle fracture optimization
-
-
Laser Sorting Integration
-
Polymer identification during crushing
-
Real-time density adjustment
-
-
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
| Capacity | Investment | Operating Cost |
|---|---|---|
| 500 kg/hr | $210,000-280,000 | $22-28/ton |
| 1 ton/hr | $350,000-480,000 | $18-24/ton |
| 2 ton/hr | $650,000-850,000 | $15-20/ton |
Future Technology Trends
-
Waterless Cleaning
-
CO₂ snow blasting
-
Plasma surface treatment
-
-
Hybrid Recycling
-
Mechanical + chemical processing
-
Monomer recovery modules
-
-
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.
Comments(17)
Wait, 90% water recovery rate for a recycling system? That’s insane!
Anyone know if these systems handle foam plastics too? 🤔
The automotive plastic section is 🔥, exactly what we need for EV battery recycling
2.1 ton CO₂ reduction per ton processed seems too good to be true
lol imagine trying to explain this process at a dinner party
@GigglesMcGrumpy：The real dinner party flex would be casually mentioning you operate one of these systems. Instant conversation starter.
How does this compare to traditional mechanical recycling cost-wise? Article didn’t mention…
The AI control part is where the real magic happens – predicting wear before it occurs!
Wonder if they’ll ever make home version 😂
@BumbleBee：A home version would be hilarious! Can you imagine the water bill? 😅
Shredder tech with tungsten carbide tips sounds expensive but probably worth it
Mobile containerized units could be game changer for developing countries
The CO₂ reduction numbers are actually legit. I’ve seen similar results from other industrial recycling setups. Pretty impressive stuff.
Anyone have experience with the ceramic-lined chambers? Wondering about maintenance costs on those.
90% water recovery is crazy good. Most systems barely hit 60%. What’s their secret?
Those auto-reversing shredder blades sound like magic. Bet they cost a fortune though.
The mobile container units are genius – perfect for disaster areas or military use too!