Avanceret plastgenbrugsgranulering: Teknologi, Udstyr og Zhuoyue Ekstruderløsninger

I en tid med stigende miljøbevidsthed og stringente ressourcebevarelsespolitikker, plastgenbrug er blevet et kritisk fokus for industrier verden over. Blandt de forskellige plastgenbrugsteknologier, affald plast genbrug granulering skiller sig ud som en praktisk, effektiv, og økonomisk levedygtig metode, der omdanner kasserede plastmaterialer til genanvendelige granulat. Disse genbrugsgranulat kan videreforarbejdes til nye plastprodukter, med præstationsniveauer, der kan sammenlignes med dem, der er fremstillet af nye materialer, dermed realisere ægte ressourcecirkulation og reducere miljøbelastningen forårsaget af plastikaffald.

Zhuoyue, en førende producent af ekstruderingsudstyr, er forpligtet til at levere omfattende genanvendelsesgranuleringsproduktionslinjer til alle typer plastaffald, inklusive PP (Polypropylen), PE (Polyethylen), LDPE (Polyethylen med lav densitet), KÆLEDYR (Polyethylenterephthalat), PS (Polystyren), ABS (Acrylonitril Butadien Styren), og mere. Med avanceret ekstruderingsteknologi og dybdegående ekspertise inden for plastgenbrug, Zhuoyues ekstrudere er skræddersyet til at imødekomme de unikke udfordringer ved affaldsplastgranulering, leverer effektivt, energibesparende, og højkvalitetsløsninger til virksomheder, der beskæftiger sig med plastgenbrug.

1. En oversigt over granulering af genanvendelse af affaldsplast

Granulering af genanvendelse af affaldsplast er en specialiseret proces, der omdanner forskellige former for plastaffald - såsom plastikflasker, film, containere, skrot fra produktionslinjer, og post-forbruger plastaffald - i uniform, højkvalitets plastgranulat gennem en række mekaniske og termiske behandlinger. Disse genbrugte granulat, også kendt som regranulater eller oparbejdede plastikpiller, kan anvendes direkte i sprøjtestøbning, ekstrudering, blæsestøbning, og andre plastbearbejdningsmetoder til fremstilling af nye produkter, lige fra emballagematerialer og byggekomponenter til bildele og daglige fornødenheder.

Kerneværdien af affaldsplastgenanvendelsesgranulering ligger i dets evne til at løse de dobbelte udfordringer med bortskaffelse af plastaffald og ressourceknaphed. I modsætning til traditionelle metoder til bortskaffelse af plastikaffald såsom deponering og forbrænding, som udgør en alvorlig miljørisiko, genbrugsgranulering opnår ægte ressourcegenanvendelse:

Miljøbeskyttelse: Deponering af plastaffald optager værdifulde jordressourcer og kan føre til jord- og grundvandsforurening, da plast er ikke-biologisk nedbrydeligt og kan frigive skadelige stoffer over tid. Forbrænding, på den anden side, udsender giftige gasser (såsom dioxiner og kulilte) og partikler, bidrager til luftforurening og global opvarmning. Genanvendelse af granulering reducerer mængden af plastaffald, der kommer ind på lossepladser og forbrændingsanlæg, minimere miljøforurening og kulstofemissioner.
Ressourcebevarelse: Plast er afledt af ikke-vedvarende fossile brændstoffer (såsom olie og naturgas). Ved at genbruge affaldsplastik til genanvendelige granulat, efterspørgslen efter nye plastmaterialer er reduceret, bevare værdifulde fossile ressourcer og reducere energiforbruget i forbindelse med ny plastikproduktion. Det anslås, at genanvendelse af et ton plastik kan spare op til 7.4 tønder olie og reducere CO2-udledningen med 1.5 tons.
Økonomiske fordele: Genbrugsplastgranulat er væsentligt billigere end jomfruelige plastmaterialer, tilbyder betydelige omkostningsbesparelser for producenterne. Til genbrugsvirksomheder, processen med at indsamle, forarbejdning, og granulering af plastaffald kan generere stabile overskud, skabe nye økonomiske muligheder og jobstillinger. Derudover, mange lande og regioner tilbyder politiske incitamenter (såsom tilskud og skattelettelser) til plastgenbrugsvirksomheder, yderligere at forbedre den økonomiske levedygtighed af genanvendelse af granulering.

Imidlertid, kvaliteten af genbrugsplastgranulat og ydeevnen af de endelige genbrugsprodukter er meget afhængig af granuleringsprocessen og det anvendte udstyr. Faktorer som typen og renheden af plastaffald, effektiviteten af sortering og rengøring, temperatur- og forskydningskontrol under ekstrudering, og ekstruderens design har alle en væsentlig indflydelse på den endelige produktkvalitet. Derfor, udvikle en enkel, bekvem, effektiv, energibesparende, miljøvenlig, og økonomisk levedygtig granuleringsproces er blevet fokus for forskning og udvikling i plastgenbrugsindustrien.

1.1 Nøglekarakteristika for genbrugsplastgranulat

Ydeevnen for genbrugsplastgranulat er tæt forbundet med typen af affaldsplast, graden af forurening, og granuleringsprocessen. Generelt, high-quality recycled granules should possess the following characteristics:

Uniform Particle Size: Consistent particle size ensures stable feeding during subsequent processing (such as injection molding and extrusion), improving the uniformity and quality of the final product. The particle size of recycled granules is typically between 2mm and 5mm, depending on the application requirements.
Low Contamination: Contaminants such as dirt, støv, metalfragmenter, paper, and other non-plastic materials can significantly affect the performance of recycled granules and the final product. Derfor, effective sorting and cleaning of waste plastic are essential to ensure low contamination levels.
Good Plasticity and Processability: Recycled granules should have good melting properties and flowability, giver mulighed for nem forarbejdning til nye produkter uden at påvirke forarbejdningseffektiviteten eller produktkvaliteten. Dette kræver præcis kontrol af temperaturen og forskydningshastigheden under granuleringsprocessen for at undgå overdreven nedbrydning af plastens molekylære struktur.
Stabile mekaniske egenskaber: Trækstyrken, forlængelse ved brud, slagstyrke, og andre mekaniske egenskaber ved genbrugsgranulat bør være så tæt som muligt på de nye materialers egenskaber, sikre, at de endelige genbrugsprodukter opfylder de krævede ydeevnestandarder.
Lavt fugtindhold: Højt fugtindhold i genbrugsgranulat kan føre til defekter som bobler og revner i slutproduktet under forarbejdning. Derfor, tørretrin er ofte nødvendige under granuleringsprocessen for at reducere fugtindholdet til et acceptabelt niveau (typisk nedenfor 0.5%).

1.2 Almindelige typer af plastaffald til granulering

Næsten alle typer af termoplastisk plast kan genbruges og granuleres, mens termohærdende plast (som ikke kan smeltes og oparbejdes) er ikke egnet til genanvendelse af granulering. De mest almindelige typer af plastaffald, der anvendes til genbrugsgranulering, omfatter:

PP (Polypropylen): En meget brugt termoplast med god kemikalieresistens, mekaniske egenskaber, og bearbejdelighed. Fælles affald PP omfatter plastspande, containere, kasketter, og produktionsrester. Genbrugte PP-granulat bruges ofte til fremstilling af plastikrør, auto dele, og emballagematerialer.
PE (Polyethylen): Opdelt i LDPE (Polyethylen med lav densitet) og HDPE (Polyethylen med høj densitet). LDPE er almindeligt anvendt i plastfilm, poser, og flasker, mens HDPE bruges i tønder, rør, og containere. Genanvendt PE-granulat er velegnet til fremstilling af plastfilm, rør, og sprøjtestøbte produkter.
KÆLEDYR (Polyethylenterephthalat): En gennemsigtig, stift plast, der almindeligvis anvendes i drikkevareflasker, fødevareemballage, og fiberprodukter. Genanvendte PET-granulat er meget udbredt i produktionen af polyesterfibre, plastikflasker, og emballagematerialer.
PS (Polystyren): Fås i rigid (såsom skumkopper, madbeholdere, og plastiklegetøj) og skum (EPS, ekspanderet polystyren) formularer. Genbrugte PS-granulat kan bruges til at producere plastiklegetøj, dekorative materialer, og skumprodukter.
ABS (Acrylonitril Butadien Styren): En højtydende plast med god slagstyrke, stivhed, og varmebestandighed. Almindelig affald ABS omfatter plastikskaller af elektroniske produkter, auto dele, og legetøj. Genbrugte ABS-granulat bruges til at fremstille elektroniske produktskaller, auto dele, og sprøjtestøbte komponenter.

Zhuoyues genbrugsgranuleringsproduktionslinjer er designet til at håndtere alt det ovennævnte plastaffald, med tilpassede udstyrskonfigurationer for at opfylde de specifikke forarbejdningskrav for forskellige plasttyper.

2. Granuleringsprocessen for affaldsplastgenbrug

Granuleringsprocessen for genanvendelse af affaldsplast består typisk af flere nøgletrin: indsamling og sortering af affaldsplast, rensning, knusende, tørring, ekstruderingsgranulering, afkøling, og skæring. Hvert trin spiller en afgørende rolle i at sikre kvaliteten af det endelige genanvendte granulat. De specifikke procesparametre kan variere afhængigt af typen af plastaffald, graden af forurening, og den ønskede kvalitet af det genbrugte granulat.

2.1 Indsamling og sortering

Det første trin i genanvendelsesgranuleringsprocessen er indsamling og sortering af plastaffald. Affaldsplast indsamles fra forskellige kilder, inklusive husstande, industrier, kommercielle virksomheder, og produktionslinjer. På grund af det store udvalg af plastaffald og tilstedeværelsen af forurenende stoffer, sortering er afgørende for at sikre kvaliteten af det genbrugte granulat.

Sortering kan ske manuelt eller mekanisk. Manuel sortering er velegnet til mindre genbrugsoperationer og involverer adskillelse af forskellige plasttyper, fjernelse af ikke-plastiske forureninger (såsom metal, paper, glas, og organisk affald), og sortering af plast efter farve og kvalitet. Mekanisk sortering, på den anden side, er mere effektiv og velegnet til store operationer, ved hjælp af teknologier såsom tæthedsadskillelse (vask-flyder adskillelse), magnetisk adskillelse, elektrostatisk adskillelse, og infrarød sortering for at adskille forskellige plasttyper og fjerne forurenende stoffer.

Effektiv sortering er afgørende, fordi blanding af forskellige plasttyper kan føre til en betydelig reduktion i ydeevnen af det genbrugte granulat. F.eks, blanding af PP og PET kan forårsage faseadskillelse under ekstrudering, hvilket resulterer i dårlig plasticitet og mekaniske egenskaber af granulatet.

2.2 Rensning

Efter sortering, plastaffaldet renses for at fjerne overfladeforurenende stoffer såsom snavs, støv, olie, fedt, madrester, og etiketter. Rengøringsprocessen omfatter typisk flere trin:

Forrensning: Fjernelse af store forurenende stoffer (såsom etiketter, kasketter, og metalfragmenter) og groft snavs gennem børstning, blæser, eller manuel plukning.
Vask: Iblødsætning af plastaffald i en renseopløsning (normalt vand med rengøringsmiddel eller alkali) for at fjerne olie, fedt, og madrester. Omrøring eller ultralydsrensning kan bruges til at forbedre renseeffekten.
Skylning: Skyl den rensede plastik med rent vand for at fjerne eventuelle resterende rengøringsopløsninger og forurenende stoffer.
Afvanding: Fjernelse af overskydende vand fra den rensede plastik ved hjælp af centrifuger, afvandingsmaskiner, eller lufttørring for at reducere fugtindholdet og lette efterfølgende behandling.

Renseeffekten påvirker direkte kvaliteten af det genbrugte granulat. Utilstrækkelig rengøring kan føre til forurening af granulatet, påvirker deres bearbejdelighed og mekaniske egenskaber. F.eks, olie- og fedtrester kan forårsage dårlig vedhæftning mellem plastmolekylerne under ekstrudering, hvilket resulterer i lav trækstyrke af granulatet.

2.3 Knusende

Efter rengøring og afvanding, plastaffaldet knuses i små stykker (flager eller fragmenter) ved hjælp af en knuser. Knusning hjælper med at øge plastens overfladeareal, letter smeltning og blanding under ekstruderingsprocessen. Det hjælper også med at fjerne eventuelle resterende små forurenende stoffer, der kan være indlejret i plastikken.

Hvilken type knuser, der anvendes, afhænger af typen og formen på plastaffaldet. Almindelige typer knusere omfatter kæbeknusere, hammerknusere, bladknusere, og granulatorer. Til fleksibel plast (såsom plastikfilm og poser), klingeknusere bruges typisk, mens for stiv plast (såsom plastikflasker og -beholdere), hammerknusere eller kæbeknusere er mere velegnede. Størrelsen af de knuste plastikstykker er normalt mellem 5 mm og 20 mm, afhængig af den anvendte ekstrudertype og den ønskede granulatstørrelse.

2.4 Tørring

Selv efter afvanding, de knuste plastikstykker kan stadig indeholde en vis mængde fugt. Højt fugtindhold kan føre til defekter som bobler, revner, og dårlig overfladekvalitet i det genbrugte granulat under ekstrudering. Derfor, et tørretrin er nødvendigt for at reducere fugtindholdet i de knuste plastikstykker til et acceptabelt niveau (typisk nedenfor 0.5%).

Almindelige tørremetoder omfatter varmlufttørring, vakuumtørring, og infrarød tørring. Hot air drying is the most widely used method, which involves passing hot air (at a temperature of 80-120°C) through the crushed plastic pieces to evaporate the moisture. The drying time and temperature depend on the type of plastic and the initial moisture content. F.eks, PET is more sensitive to moisture and requires higher drying temperatures (120-160°C) and longer drying times to ensure complete moisture removal.

2.5 Extrusion Granulation

Extrusion granulation is the core step in the waste plastic recycling granulation process. It involves melting, blanding, and homogenizing the dried crushed plastic pieces using an extruder, then extruding the molten plastic through a die to form continuous strands, which are subsequently cooled and cut into uniform granules.

The extruder is the key equipment in this step, og dens ydeevne bestemmer direkte kvaliteten og effektiviteten af granuleringsprocessen. Der er to hovedtyper af ekstrudere, der anvendes til granulering af genanvendelse af affaldsplast: dobbeltskruede ekstrudere og enkeltskruede ekstrudere. Hver type har sine egne fordele og er velegnet til forskellige typer af affaldsplast, som beskrevet i afsnittet 3.

Under ekstrudering granulering, flere nøgleprocesparametre skal kontrolleres præcist:

Temperatur: Temperaturen på ekstruderens cylinder og matrice er kritisk for at smelte plasten og sikre god blanding og homogenisering. Forskellige typer plast har forskellige smeltepunkter, og tøndetemperaturen er typisk indstillet 10-30°C over plastens smeltepunkt for at sikre fuldstændig smeltning. F.eks, tøndetemperaturen for PP er normalt 170-220°C, while for PET it is 260-280°C. Excessively high temperatures can cause thermal degradation of the plastic, leading to a reduction in the mechanical properties of the recycled granules, while excessively low temperatures can result in incomplete melting and poor mixing.
Forskydningshastighed: The shear rate is determined by the screw speed and the screw design. A suitable shear rate helps to homogenize the molten plastic, disperse any remaining contaminants, and improve the plasticity of the granules. Imidlertid, excessively high shear rates can cause mechanical degradation of the plastic molecular structure, leading to reduced performance.
Skruehastighed: The screw speed affects the throughput, melting efficiency, and mixing quality. Higher screw speeds can increase the throughput but may reduce the melting and mixing efficiency, mens lavere skruehastigheder kan forbedre blandingskvaliteten, men reducere gennemløbet. Den optimale skruehastighed afhænger af plasttypen, ekstrudertypen, og den ønskede granulatkvalitet.
Ekstrusionstryk: Ekstruderingstrykket bestemmes af matricedesignet, skruehastighed, og materialeviskositet. Stabilt ekstruderingstryk sikrer ensartet strengdannelse og ensartet granulatstørrelse. For højt tryk kan forårsage blokering af matricen, mens for lavt tryk kan resultere i ujævne tråde.

2.6 Køling og skæring

Efter ekstrudering gennem matricen, de kontinuerlige plastikstrenge afkøles for at størkne dem. Køling kan ske ved hjælp af luftkøling eller vandkøling. Vandkøling er mere effektiv og anvendes i vid udstrækning i storskala granuleringsoperationer, involverer at føre trådene gennem en vandtank eller vandspray for hurtigt at afkøle dem til stuetemperatur. Luftkøling er velegnet til små operationer eller til plast, der er følsomt over for vand (såsom nogle tekniske plastik).

Når trådene er afkølet og størknet, de skæres i ensartede granulat ved hjælp af en pelletizer. Pelletizeren er typisk installeret ved udgangen af kølesystemet og kan justeres for at kontrollere længden af granulatet (normalt mellem 2 mm og 5 mm). Almindelige typer pelletiseringsapparater omfatter strengpelleteringsapparater, vandring pelletizere, og undervands pelletizere. Strand pelletizer er den mest udbredte type til granulering af genanvendelse af affaldsplast, da de er enkle i opbygningen, let at betjene, og velegnet til de fleste plasttyper.

2.7 Screening og emballering

Efter skæring, det genbrugte granulat sigtes ved hjælp af en vibrerende sigte for at fjerne eventuelle overdimensionerede eller underdimensionerede granulater, sikre ensartet partikelstørrelse. The screened granules are then dried again (if necessary) to remove any moisture absorbed during cooling, then packaged into bags or bulk containers for storage and transportation.

Packaging is an important step to prevent contamination and moisture absorption of the recycled granules. The packaging materials should be moisture-proof and clean, and the granules should be stored in a dry, ventilated, and clean warehouse to maintain their quality.

3. Extruder Selection for Waste Plastic Recycling Granulation

As mentioned earlier, the extruder is the core equipment in the waste plastic recycling granulation process. The selection of the right extruder depends on the type of waste plastic, the desired granule quality, the production volume, and the budget. Der er to hovedtyper af ekstrudere, der anvendes til granulering af genanvendelse af affaldsplast: dobbeltskruede ekstrudere og enkeltskruede ekstrudere. Hver type har sine egne unikke fordele og er velegnet til forskellige applikationer.

3.1 Ekstrudere med to skruer til genanvendelse af granulering

Ekstrudere med dobbeltskruer bruges i vid udstrækning til genbrugsgranulering af ingeniørplast og plast med høje forureningsniveauer, såsom ABS, PS, og PET. De består af to parallelle skruer, der roterer i samme retning (samroterende) eller modsatte retninger (modsat roterende) inden for en tønde. Samroterende dobbeltskrueekstrudere er mere almindeligt anvendt i plastgenbrug på grund af deres overlegne blande- og transportevne.

3.1.1 Vigtigste fordele ved dobbeltskrue ekstrudere

Nem materialefodring: Dobbeltskrueekstrudere har en stærk transportkapacitet, som giver mulighed for nem fremføring af knuste plastikstykker, selvom de er uregelmæssige i formen eller har en vis mængde forurenende stoffer. This reduces the need for pre-processing of the material and improves production efficiency.
Short Material Residence Time: The residence time of the material in the twin-screw extruder is short (typisk 1-5 minutter) compared to single-screw extruders. This helps to avoid thermal degradation of the plastic, especially for heat-sensitive plastics such as PET and ABS, which can degrade easily when exposed to high temperatures for a long time. Short residence time also reduces energy consumption and improves production efficiency.
Excellent Venting Effect: Twin-screw extruders are equipped with venting ports that allow for the removal of moisture, volatile gases, and air from the molten plastic. The meshing part of the screws provides effective mixing, and the self-cleaning function of the venting section ensures that the material can achieve complete surface renewal, allowing for efficient removal of volatile substances. This helps to improve the quality of the recycled granules by reducing the number of bubbles and defects.
Superior Mixing and Plasticizing Effect: The co-rotating twin-screw extruders have strong shear and mixing capabilities, which can effectively homogenize the molten plastic, disperse contaminants, and mix additives (såsom stabilisatorer, antioxidanter, og farvestoffer) uniformly. This ensures that the recycled granules have consistent properties and good processability.
Low Specific Power Consumption: Despite their high performance, twin-screw extruders have low specific power consumption (power consumption per unit output), making them more energy-efficient compared to single-screw extruders for certain applications. This helps to reduce operating costs for recycling enterprises.
High Volume Power: Twin-screw extruders have a high volume power (power per unit volume of the barrel), which means they can process a large amount of material in a small space. This makes them suitable for large-scale production operations with limited space.

3.1.2 Suitable Applications for Twin-screw Extruders

Twin-screw extruders are particularly suitable for the recycling granulation of the following plastics:

ABS: A high-performance plastic that is widely used in electronic products, auto dele, og legetøj. ABS is sensitive to heat and requires short residence time and good mixing, making twin-screw extruders the ideal choice.
PS: Both rigid and foam PS can be recycled using twin-screw extruders. The superior mixing capabilities of twin-screw extruders help to disperse any remaining foam cells and contaminants, ensuring good granule quality.
KÆLEDYR: PET is highly sensitive to moisture and heat, and requires precise temperature control and short residence time. Twin-screw extruders with good venting and temperature control capabilities are suitable for PET recycling granulation.
Engineering Plast: Other engineering plastics such as PC (Polycarbonat), PA (Polyamid), and POM (Polyoxymethylen) can also be recycled using twin-screw extruders, thanks to their superior mixing and plasticizing capabilities.

3.2 Single-screw Extruders for Recycling Granulation

Single-screw extruders are simpler in structure, lower in cost, and easier to maintain compared to twin-screw extruders. They consist of a single screw that rotates within a barrel, conveying and melting the material through friction and shear between the screw and the barrel. Single-screw extruders are widely used in the recycling granulation of general-purpose plastics such as PP, PE, and LDPE.

3.2.1 Key Advantages of Single-screw Extruders

Short Screw Length and Residence Time: Single-screw extruders typically have a shorter screw length compared to twin-screw extruders, resulting in shorter material residence time. This helps to avoid thermal degradation of the plastic, especially for soft plastics such as PE and LDPE, which have lower melting points and are prone to degradation.
Omkostningseffektiv: Waste plastic recycling often involves materials with high levels of contaminants, which can cause significant wear and tear on the extruder screw and barrel. Single-screw extruders are simpler in structure and use less expensive materials, hvilket gør dem mere omkostningseffektive at udskifte og vedligeholde sammenlignet med dobbeltskrueekstrudere. Dette er især vigtigt for små og mellemstore genbrugsvirksomheder med begrænsede budgetter.
Velegnet til blød plast: Materialetransporteffektiviteten af enkeltskruede ekstrudere afhænger af det faste materiales friktionsevne og smeltens viskositet. Blød plast som PP, PE, og LDPE har god friktionsydelse og lav smelteviskositet, hvilket gør dem ideelle til forarbejdning med enkeltskruede ekstrudere. Disse plasttyper kan transporteres og smeltes effektivt, ensuring good granule quality.
Enkel betjening og vedligeholdelse: Enkeltskrue ekstrudere har en enkel struktur, med færre bevægelige dele, gør dem nemme at betjene og vedligeholde. Dette reducerer behovet for dygtige operatører og sænker vedligeholdelsesomkostningerne, hvilket er gavnligt for mindre genbrugsoperationer.

3.2.2 Suitable Applications for Single-screw Extruders

Single-screw extruders are particularly suitable for the recycling granulation of the following plastics:

PP (Polypropylen): PP is a soft plastic with good friction performance and processability, making it ideal for processing with single-screw extruders. Recycled PP granules produced using single-screw extruders have good mechanical properties and can be used in a wide range of applications.
PE (Polyethylen): Both LDPE and HDPE are suitable for processing with single-screw extruders. LDPE, i særdeleshed, is a soft plastic with low melt viscosity, which can be conveyed and melted efficiently by single-screw extruders. Recycled PE granules are widely used in the production of plastic films and pipes.
LDPE (Polyethylen med lav densitet): LDPE is commonly used in plastic films and bags, which are easy to crush and process. Single-screw extruders are ideal for LDPE recycling granulation, as they can handle the soft material efficiently and cost-effectively.

3.3 Key Factors for Extruder Selection

When selecting an extruder for waste plastic recycling granulation, the following key factors should be considered:

Type of Waste Plastic: As discussed earlier, twin-screw extruders are suitable for engineering plastics (ABS, PS, KÆLEDYR) and plastics with high contamination levels, while single-screw extruders are suitable for general-purpose plastics (PP, PE, LDPE).
Produktionsvolumen: For large-scale production (more than 500kg/h), twin-screw extruders are more suitable due to their high throughput and efficiency. For small-scale production (less than 200kg/h), single-screw extruders are more cost-effective and practical.
Granule Quality Requirements: If high-quality recycled granules with uniform properties and low contamination are required (such as for automotive parts and electronic products), twin-screw extruders are the better choice due to their superior mixing and plasticizing capabilities. For general-purpose applications (such as plastic films and low-grade injection-molded products), single-screw extruders can meet the requirements at a lower cost.
Budget: Twin-screw extruders are more expensive than single-screw extruders, both in terms of initial investment and maintenance costs. Derfor, enterprises with limited budgets may prefer single-screw extruders for general-purpose plastic recycling.
Energiforbrug: For large-scale production, energy consumption is an important consideration. Twin-screw extruders have lower specific power consumption, making them more energy-efficient for high-volume operations. Single-screw extruders may be more energy-efficient for small-scale operations due to their simpler structure.

4. Zhuoyue Extruder Series for Waste Plastic Recycling Granulation

Zhuoyue offers a comprehensive range of extruders specifically designed for waste plastic recycling granulation, including twin-screw extruders and single-screw extruders. The extruder series are tailored to meet the specific needs of different types of waste plastics, production volumes, and granule quality requirements, combining high performance, effektivitet, energibesparende, og omkostningseffektivitet. The main extruder series include ZTE series and HTE series, each with unique features and advantages to suit different application scenarios.

4.1 Core Technical Features of Zhuoyue Extruders

All Zhuoyue extruders for waste plastic recycling granulation share a set of core technical features that make them ideal for the harsh conditions of plastic recycling, such as high contamination levels, irregular material shapes, and varying material properties:

Robust Construction: Zhuoyue extruders are built with high-quality materials (such as alloy steel for screws and barrels) to withstand the wear and tear caused by contaminants in waste plastics. The screws and barrels are treated with special surface treatments (such as nitriding and hard chrome plating) to improve their wear resistance and service life.
Præcis temperaturkontrol: The extruders are equipped with advanced temperature control systems, including heating zones and cooling zones, to ensure precise control of the barrel and die temperature. This helps to avoid thermal degradation of the plastic and ensure complete melting and mixing.
Efficient Conveying and Mixing: The screw designs are optimized for waste plastic recycling, with enhanced conveying capacity and mixing capabilities. Twin-screw extruders feature co-rotating screws with optimized flight profiles to ensure superior mixing and homogenization, while single-screw extruders have specially designed screws to improve conveying efficiency for soft plastics.
Excellent Venting Performance: Twin-screw extruders are equipped with multiple venting ports to remove moisture, volatile gases, and air from the molten plastic, ensuring high-quality granules with minimal defects. The self-cleaning function of the venting section ensures efficient venting even with contaminated materials.
Energibesparende design: Zhuoyue extruders adopt energy-saving technologies such as variable frequency drives (VFD) and optimized motor configurations to reduce energy consumption. This helps to lower operating costs for recycling enterprises.
Nem betjening og vedligeholdelse: The extruders are designed with user-friendly interfaces and simple structures, gør dem nemme at betjene og vedligeholde. The screws and barrels can be easily disassembled for cleaning and replacement, reducing downtime.
Customizable Configurations: Zhuoyue extruders can be customized with different screw lengths, diameters, and configurations to meet the specific needs of different types of waste plastics and production volumes. F.eks, extruders for PET recycling can be equipped with special drying systems and venting ports to ensure complete moisture removal.

4.2 ZTE serie ekstrudere

The ZTE series is Zhuoyue’s cost-effective extruder series, designed for small and medium-sized recycling enterprises and general-purpose waste plastic recycling granulation. This series offers excellent cost-performance ratio, with parameters designed to suit most common waste plastics, inklusive PP, PE, LDPE, and general-purpose ABS and PS. The ZTE series includes both single-screw and twin-screw extruders, providing flexible options for different applications.

4.2.1 Key Features of ZTE Series Extruders

Excellent Cost-Performance Ratio: The ZTE series is designed to provide reliable performance at a competitive price, making it the ideal choice for enterprises with limited budgets or small-scale production needs. The initial investment and maintenance costs are significantly lower than high-end extruders, while still meeting the basic requirements of waste plastic recycling granulation.
Versatile Parameter Design: The parameters of the ZTE series are designed to suit most common waste plastics, inklusive PP, PE, LDPE, ABS, og PS. This versatility allows enterprises to process multiple types of waste plastics with a single extruder, improving production flexibility and reducing equipment investment.
Reliable Operation: The ZTE series adopts a reliable standard transmission system and simple structure, ensuring stable operation even in harsh recycling environments. The screws and barrels are designed to handle contaminants in waste plastics, reducing the risk of equipment failure.
Low Maintenance Costs: The simple structure of the ZTE series makes it easy to maintain, with fewer moving parts and lower maintenance requirements. The screws and barrels can be easily replaced when worn, reducing downtime and maintenance costs.
Suitable for Small to Medium-Scale Production: The ZTE series is available in a range of sizes, with throughputs ranging from 50kg/h to 500kg/h, making it suitable for small to medium-scale recycling operations.

4.2.2 ZTE Series Model Parameters

The ZTE series includes both single-screw and twin-screw extruders, with parameters tailored to different types of waste plastics. The following table details the parameters of the ZTE series twin-screw extruders, suitable for ABS, PS, and PET recycling granulation:

Model	Specifikt drejningsmoment（N.m/Cm³）	Hovedmotoreffekt (Kw)	Output speed（rpm）	Slot depth ratio D0/Di	Suitable Plastics
25	6	7.5	600	1.55	PS, Small-scale ABS
35	6	18.5	600	1.55	PS, ABS, LDPE
50	6	55	600	1.55/1.68	ABS, PS, KÆLEDYR (Small-scale)
65	6	110	600	1.55/1.68	ABS, PS, KÆLEDYR
75	6	160	600	1.55/1.68	ABS, PS, KÆLEDYR, PP
95	6	300	600	1.55/1.68	ABS, PS, KÆLEDYR, PP, PE

The ZTE series single-screw extruders are mainly used for PP, PE, and LDPE recycling granulation, with parameters optimized for soft plastics. The screws are designed with enhanced conveying capacity to handle the irregular shapes of crushed plastic films and bottles, ensuring efficient production.

4.2.3 Application Scenarios for ZTE Series

The ZTE series is ideal for the following application scenarios:

Small and medium-sized recycling enterprises with limited budgets.
General-purpose waste plastic recycling, inklusive PP, PE, LDPE, ABS, og PS.
Production of general-purpose recycled granules for plastic films, low-grade injection-molded products, and construction components.
Enterprises new to plastic recycling, thanks to the easy operation and low maintenance requirements of the ZTE series.

4.3 HTE Series Extruders

The HTE series is Zhuoyue’s mid-range extruder series, designed to bridge the gap between cost-effective extruders (such as ZTE series) and high-end extruders. This series combines high performance with high cost-effectiveness, delivering higher output while reducing energy consumption. The HTE series includes both twin-screw and single-screw extruders, suitable for medium to large-scale waste plastic recycling granulation.

4.3.1 Key Features of HTE Series Extruders

Balanced Performance and Cost-Effectiveness: The HTE series offers higher performance than the ZTE series, including better mixing capabilities, højere gennemløb, and more precise temperature control, while maintaining a competitive price. This makes it suitable for enterprises that require higher granule quality but do not want to invest in high-end extruders.
Energy-Saving and High Output: The HTE series is optimized for energy efficiency, with advanced motor configurations and variable frequency drives (VFD) to reduce energy consumption. På samme tid, the extruders have higher throughput, allowing for medium to large-scale production (500kg/h to 1000kg/h) with lower energy costs.
Reasonable Torque and Power Configuration: The HTE series has a reasonable torque and power configuration, ensuring stable and efficient production even when processing plastics with high contamination levels or varying properties. The twin-screw extruders have higher torque density, making them suitable for processing engineering plastics such as ABS and PET, while the single-screw extruders are optimized for soft plastics such as PP and PE.
Dual-Speed Options for Partial Models: Some models of the HTE series are equipped with dual-speed options, allowing for flexible adjustment of the screw speed to suit different types of plastics and production requirements. This expands the application range of the extruders, making them suitable for multiple plastic types.
Enhanced Wear Resistance: The screws and barrels of the HTE series are made of high-quality alloy steel and treated with advanced surface treatments to improve their wear resistance, ensuring a long service life even in harsh recycling environments.
Advanced Control System: The HTE series is equipped with advanced PLC control systems, allowing for automatic control of temperature, skruehastighed, ekstruderingstryk, and other key parameters. This improves the stability and consistency of the granulation process, ensuring uniform granule quality.

4.3.2 HTE Series Model Parameters

The HTE series twin-screw extruders are suitable for ABS, PS, KÆLEDYR, PP, PE, and LDPE recycling granulation, with parameters optimized for high performance and efficiency. The following table details the specific parameters:

Model	Specifikt drejningsmoment（N.m/Cm³）	Hovedmotoreffekt (Kw)	Output speed（rpm）	Slot depth ratio D0/Di	Suitable Plastics	Gennemløb (kg/t)
25	9	11	600	1.55	PS, ABS, LDPE	50-100
35	9	30	600	1.55	PS, ABS, PE, LDPE	100-200
35	9	45	1000	1.55	PS, ABS, PE, LDPE	200-300
50	9	75	600	1.55/1.68	ABS, PS, KÆLEDYR, PP	300-500
50	9	110	900	1.55/1.68	ABS, PS, KÆLEDYR, PP	500-700
65	9	160	600	1.55/1.68	ABS, PS, KÆLEDYR, PP, PE	700-900
65	9	220	900	1.55/1.68	ABS, PS, KÆLEDYR, PP, PE	900-1200
75	9	250	600	1.55/1.68	ABS, PS, KÆLEDYR, PP, PE, LDPE	1200-1500
75	9	315	900	1.55/1.68	ABS, PS, KÆLEDYR, PP, PE, LDPE	1500-1800
95	9	400	600	1.55/1.68	All common waste plastics	1800-2200

The HTE series single-screw extruders are optimized for PP, PE, and LDPE recycling granulation, with higher throughput and better energy efficiency compared to the ZTE series. They are suitable for medium to large-scale production of recycled granules for plastic films, rør, og sprøjtestøbte produkter.

4.3.3 Application Scenarios for HTE Series

The HTE series is ideal for the following application scenarios:

Medium to large-scale recycling enterprises with higher granule quality requirements.
Recycling of multiple types of waste plastics, inklusive PP, PE, LDPE, ABS, PS, og PET.
Production of high-quality recycled granules for automotive parts, electronic product accessories, and high-grade injection-molded products.
Enterprises that focus on energy efficiency and cost reduction, thanks to the energy-saving design of the HTE series.

4.4 Customized Solutions from Zhuoyue

In addition to the standard ZTE and HTE series, Zhuoyue also provides customized extruder solutions for special waste plastic recycling needs. F.eks:

Customized extruders for high-contamination waste plastics, equipped with enhanced filtering systems to remove contaminants.
Extruders for heat-sensitive plastics such as PET and PC, equipped with special drying systems and low-shear screws to avoid thermal degradation.
Complete recycling granulation production lines, including crushers, tørretumblere, ekstrudere, pelletizere, and screening equipment, to provide a one-stop solution for enterprises.

Zhuoyue’s professional R&D team works closely with customers to understand their specific needs and provide tailored solutions that meet their production requirements and budget.

5. Best Practices for Waste Plastic Recycling Granulation with Zhuoyue Extruders

To ensure the best performance and granule quality when using Zhuoyue extruders for waste plastic recycling granulation, the following best practices are recommended:

5.1 Proper Sorting and Cleaning

Effective sorting and cleaning are essential to reduce the wear and tear on the extruder and ensure high-quality granules. Separate different types of plastics to avoid mixing, and remove non-plastic contaminants (såsom metal, paper, and glass) as much as possible. Thoroughly clean the waste plastics to remove oil, fedt, og madrester, which can affect the mixing and plasticizing effect.

5.2 Optimal Drying

Ensure that the crushed plastic pieces are properly dried to reduce the moisture content to below 0.5%. For moisture-sensitive plastics such as PET, use high-temperature drying (120-160°C) for a sufficient period to ensure complete moisture removal. This helps to avoid bubbles and defects in the recycled granules.

5.3 Precise Process Parameter Control

Adjust the extruder parameters (såsom temperatur, skruehastighed, og ekstruderingstryk) according to the type of waste plastic. Follow the recommended parameter settings provided by Zhuoyue, and make adjustments based on the actual material properties and granule quality. Avoid excessively high temperatures or shear rates, which can cause plastic degradation.

5.4 Regular Maintenance

Regularly inspect and maintain the extruder to ensure its normal operation. Clean the screws and barrels regularly to remove any accumulated material or contaminants. Check the wear of the screws and barrels, and replace them when necessary. Lubricate the moving parts regularly to reduce friction and extend the service life of the extruder.

5.5 Use of Additives (If Necessary)

For waste plastics with severe degradation or poor performance, consider adding additives such as stabilizers, antioxidanter, and plasticizers to improve the quality of the recycled granules. Consult Zhuoyue’s technical team to select the appropriate additives and dosage.

6. Konklusion

Waste plastic recycling granulation is a critical technology for realizing resource circulation and environmental protection, offering significant economic, miljømæssige, and social benefits. The quality and efficiency of the granulation process depend largely on the extruder used, and selecting the right extruder is essential for the success of a plastic recycling enterprise.

Zhuoyue’s ZTE series and HTE series extruders are specifically designed for waste plastic recycling granulation, combining high performance, effektivitet, energibesparende, og omkostningseffektivitet. The ZTE series provides a cost-effective solution for small and medium-sized enterprises and general-purpose plastic recycling, while the HTE series offers balanced performance and cost-effectiveness for medium to large-scale production with higher quality requirements. With robust construction, præcis temperaturkontrol, superior mixing capabilities, and customizable configurations, Zhuoyue extruders can handle all types of waste plastics, from PP and PE to ABS and PET, delivering high-quality recycled granules for a wide range of applications.

As a leader in extrusion technology, Zhuoyue is committed to providing advanced, pålidelig, and cost-effective solutions for the plastic recycling industry. With professional R&D, high-quality products, and comprehensive after-sales service, Zhuoyue helps enterprises unlock the full potential of waste plastic recycling, contributing to a more sustainable and environmentally friendly future.

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