Plastic Basin Crusher: A Comprehensive Guide to Efficient Recycling

Understanding Plastic Basin Crushers

1. Dual-Shaft Shredder:
   • Interlocking blades (e.g., tungsten carbide or SKD11 steel) for aggressive shearing of thick plastic walls, even with residual adhesives or labels .
   • Hydraulic gap adjustment to control particle size (10–50 mm) and adapt to varying basin sizes (200–600 mm diameter).
2. High-Speed Granulation System:
   • Rotors with replaceable screens (5–20 mm) to produce uniform granules for downstream processing .
3. Automated Conveying:
   • Self-cleaning belt conveyors (0.5–2 m/s speed) for seamless material transfer between stages.

How It Works

1. Feeding: Basins are loaded onto the conveyor, which feeds them into the shredding chamber.
2. Primary Shredding: Dual shafts rotate at 10–70 RPM, using interlocking blades to tear and shear materials into irregular pieces .
3. Secondary Granulation: High-speed blades refine particles to 5–20 mm, with adjustable screens controlling output size .
4. Magnetic Separation (Optional): Overband magnets remove metal contaminants, ensuring clean plastic granules for recycling.
5. Washing and Drying: Residual labels and adhesives are removed via water jets or ultrasonic cleaners, followed by hot air drying.

Key Applications

• Household Recycling: Processing discarded laundry basins, storage tubs, and bathroom fixtures.
• Manufacturing: Recycling production offcuts from plastic molding facilities.
• Waste Management: Handling mixed plastic waste streams, including basins, lids, and packaging materials.
• Agriculture: Repurposing damaged plastic troughs and irrigation components into reusable pellets.

Technical Specifications

Maintenance and Troubleshooting

Preventive Maintenance

• Daily Checks:
  • Clean residual plastic from blades and screens to avoid clogs .
  • Lubricate bearings with high-temperature grease every 50–100 hours.
• Weekly Inspections:
  • Adjust blade gaps to 0.5–2 mm for optimal cutting efficiency .
  • Test conveyor belts for tension and alignment.
• Monthly Overhaul:
  • Resharpen or replace blades (tungsten carbide blades last 3–5 years).
  • Inspect hydraulic systems for leaks and fluid levels.

Common Issues and Solutions

Choosing the Right Basin Crusher

Factors to Consider

• Material Type:
  • Rigid PP/PE Basins: Opt for tungsten carbide blades and 10–20 mm screens.
  • Mixed Waste: Choose dual-shaft shredders with adjustable cutting chambers.
• Processing Volume:
  • Small-scale: 1,000–2,000 kg/h systems (e.g., PC-800 with integrated conveyor).
  • Industrial: 3,000+ kg/h systems with automated feeding (e.g., SWP-1000 model) .
• Budget:
  • Entry-level: $20,000–$50,000 for basic crusher + conveyor.
  • Premium: $80,000–$150,000 for IoT-enabled systems with washing and drying modules.

Case Study: Enhanced Efficiency in Household Recycling

• Primary shredder with tungsten carbide blades for initial breakdown.
• Granulator with 15 mm screens for producing uniform pellets.

• 40% reduction in energy consumption due to variable-speed drives.
• 98% material recovery rate, with pellets used in new plastic product manufacturing.
• 30% lower labor costs from automated feeding and conveying.

Future Trends in Basin Crusher Technology

1. IoT Integration: Smart sensors monitor blade wear, energy usage, and system performance, enabling predictive maintenance and downtime reduction .
2. AI-Driven Sorting: Machine vision systems automatically classify plastics by resin type, improving recycling purity.
3. Sustainability:
   • Waterless washing technologies (e.g., dry ice blasting) minimize environmental impact.
   • Modular designs allow easy upgrades to incorporate new technologies.

Conclusion