Advanced Plastic Recycling Granulation: Tecnoloxía, Equipment and Zhuoyue Extruder Solutions

In an era of increasing environmental awareness and stringent resource conservation policies, plastic recycling has become a critical focus for industries worldwide. Among the various plastic recycling technologies, waste plastic recycling granulation stands out as a practical, efficient, and economically viable method that transforms discarded plastic materials into reusable granules. These recycled granules can be further processed into new plastic products, with performance levels comparable to those made from virgin materials, thus realizing true resource circulation and reducing the environmental burden caused by plastic waste.

Zhuoyue, a leading manufacturer of extrusion equipment, is committed to providing comprehensive recycling granulation production lines for all types of waste plastics, including PP (Polipropileno), PE (Polietileno), LDPE (Low-Density Polyethylene), PET (Tereftalato de polietileno), PD (Poliestireno), ABS (Acrilonitrilo Butadieno Estireno), and more. With advanced extrusion technology and in-depth expertise in plastic recycling, Zhuoyue’s extruders are tailored to meet the unique challenges of waste plastic granulation, delivering efficient, aforro de enerxía, and high-quality solutions for enterprises engaged in plastic recycling.

1. An Overview of Waste Plastic Recycling Granulation

Waste plastic recycling granulation is a specialized process that converts various forms of waste plastics—such as plastic bottles, películas, containers, scraps from production lines, and post-consumer plastic waste—into uniform, high-quality plastic granules through a series of mechanical and thermal treatments. These recycled granules, tamén coñecido como regranulados ou pellets de plástico reprocesados, pódese usar directamente no moldeo por inxección, extrusión, moldaxe por soplado, e outros métodos de procesamento de plásticos para producir novos produtos, que van desde materiais de embalaxe e compoñentes de construción ata pezas de automóbiles e necesidades diarias.

O valor fundamental da granulación de reciclaxe de residuos plásticos reside na súa capacidade para abordar o dobre desafío da eliminación de residuos plásticos e a escaseza de recursos.. A diferenza dos métodos tradicionais de eliminación de residuos plásticos, como o vertedoiro e a incineración, que supoñen graves riscos ambientais, a granulación de reciclaxe consegue unha verdadeira reciclaxe de recursos:

Protección Ambiental: O vertedoiro de residuos plásticos ocupa valiosos recursos terrestres e pode provocar a contaminación do solo e das augas subterráneas, xa que os plásticos non son biodegradables e poden liberar substancias nocivas co paso do tempo. Incineration, on the other hand, emits toxic gases (such as dioxins and carbon monoxide) and particulate matter, contributing to air pollution and global warming. Recycling granulation reduces the amount of plastic waste entering landfills and incinerators, minimizing environmental pollution and carbon emissions.
Resource Conservation: Plastics are derived from non-renewable fossil fuels (such as oil and natural gas). By recycling waste plastics into reusable granules, the demand for virgin plastic materials is reduced, conserving valuable fossil resources and reducing the energy consumption associated with virgin plastic production. It is estimated that recycling one ton of plastic can save up to 7.4 barrels of oil and reduce carbon emissions by 1.5 toneladas.
Economic Benefits: Recycled plastic granules are significantly cheaper than virgin plastic materials, offering substantial cost savings for manufacturers. For recycling enterprises, the process of collecting, processing, and granulating waste plastics can generate stable profits, creating new economic opportunities and employment positions. Ademais, many countries and regions offer policy incentives (such as subsidies and tax breaks) for plastic recycling enterprises, further enhancing the economic viability of recycling granulation.

Porén, the quality of recycled plastic granules and the performance of the final recycled products are highly dependent on the granulation process and equipment used. Factors such as the type and purity of waste plastic, the efficiency of sorting and cleaning, the temperature and shear control during extrusion, and the design of the extruder all have a significant impact on the final product quality. Polo tanto, developing a simple, convenient, efficient, aforro de enerxía, environmentally friendly, and economically viable granulation process has become the focus of research and development in the plastic recycling industry.

1.1 Key Characteristics of Recycled Plastic Granules

The performance of recycled plastic granules is closely related to the type of waste plastic, the degree of contamination, and the granulation process. In general, 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, dust, fragmentos metálicos, paper, e outros materiais non plásticos poden afectar significativamente o rendemento dos gránulos reciclados e do produto final. Polo tanto, A clasificación e limpeza eficaces dos residuos plásticos son esenciais para garantir uns niveis de contaminación baixos.
Boa plasticidade e procesabilidade: Os gránulos reciclados deben ter boas propiedades de fusión e fluidez, permitindo un fácil procesamento en novos produtos sen afectar á eficiencia do procesamento nin á calidade do produto. Isto require un control preciso da temperatura e da velocidade de cizallamento durante o proceso de granulación para evitar a degradación excesiva da estrutura molecular plástica..
Propiedades mecánicas estables: A resistencia á tracción, alongamento en rotura, forza de impacto, e outras propiedades mecánicas dos gránulos reciclados deben ser o máis próximas posible ás dos materiais virxes, ensuring that the final recycled products meet the required performance standards.
Low Moisture Content: High moisture content in recycled granules can lead to defects such as bubbles and cracks in the final product during processing. Polo tanto, drying steps are often required during the granulation process to reduce the moisture content to an acceptable level (typically below 0.5%).

1.2 Common Types of Waste Plastics for Granulation

Almost all types of thermoplastic plastics can be recycled and granulated, while thermosetting plastics (which cannot be melted and reprocessed) are not suitable for recycling granulation. The most common types of waste plastics used in recycling granulation include:

PP (Polipropileno): A widely used thermoplastic with good chemical resistance, mechanical properties, and processability. Common waste PP includes plastic buckets, containers, caps, and production scraps. Recycled PP granules are often used to produce plastic pipes, auto parts, and packaging materials.
PE (Polietileno): Divided into LDPE (Low-Density Polyethylene) and HDPE (Polietileno de alta densidade). LDPE is commonly used in plastic films, bolsas, and bottles, while HDPE is used in barrels, tubos, e contedores. Recycled PE granules are suitable for producing plastic films, tubos, and injection-molded products.
PET (Tereftalato de polietileno): A transparent, rigid plastic commonly used in beverage bottles, food packaging, and fiber products. Recycled PET granules are widely used in the production of polyester fibers, plastic bottles, and packaging materials.
PD (Poliestireno): Available in rigid (such as foam cups, food containers, and plastic toys) and foam (EPS, expanded polystyrene) forms. Recycled PS granules can be used to produce plastic toys, decorative materials, and foam products.
ABS (Acrilonitrilo Butadieno Estireno): A high-performance plastic with good impact strength, rigidity, and heat resistance. Common waste ABS includes plastic shells of electronic products, auto parts, and toys. Recycled ABS granules are used to produce electronic product shells, auto parts, and injection-molded components.

Zhuoyue’s recycling granulation production lines are designed to handle all the above-mentioned waste plastics, with customized equipment configurations to meet the specific processing requirements of different plastic types.

2. The Waste Plastic Recycling Granulation Process

The waste plastic recycling granulation process typically consists of several key steps: waste plastic collection and sorting, cleaning, crushing, drying, extrusion granulation, arrefriamento, e corte. Each step plays a crucial role in ensuring the quality of the final recycled granules. The specific process parameters may vary depending on the type of waste plastic, the degree of contamination, and the desired quality of the recycled granules.

2.1 Collection and Sorting

The first step in the recycling granulation process is the collection and sorting of waste plastics. Waste plastics are collected from various sources, including households, industries, commercial establishments, and production lines. Due to the wide variety of waste plastics and the presence of contaminants, sorting is essential to ensure the quality of the recycled granules.

Sorting can be done manually or mechanically. Manual sorting is suitable for small-scale recycling operations and involves separating different types of plastics, removing non-plastic contaminants (such as metal, paper, glass, and organic waste), and sorting plastics by color and quality. Mechanical sorting, on the other hand, is more efficient and suitable for large-scale operations, using technologies such as density separation (sink-float separation), magnetic separation, electrostatic separation, and infrared sorting to separate different plastic types and remove contaminants.

Effective sorting is critical because mixing different types of plastics can lead to a significant reduction in the performance of the recycled granules. Por exemplo, mixing PP and PET can cause phase separation during extrusion, resulting in poor plasticity and mechanical properties of the granules.

2.2 Cleaning

After sorting, the waste plastics are cleaned to remove surface contaminants such as dirt, dust, oil, grease, food residues, and labels. The cleaning process typically involves several steps:

Pre-cleaning: Removing large contaminants (such as labels, caps, and metal fragments) and coarse dirt through brushing, blowing, or manual picking.
Washing: Soaking the waste plastics in a cleaning solution (usually water with detergent or alkali) to remove oil, grease, and food residues. Agitation or ultrasonic cleaning may be used to enhance the cleaning effect.
Rinsing: Rinsing the cleaned plastics with clean water to remove any remaining cleaning solution and contaminants.
Dewatering: Removing excess water from the cleaned plastics using centrifuges, dewatering machines, or air drying to reduce the moisture content and facilitate subsequent processing.

The cleaning effect directly affects the quality of the recycled granules. Inadequate cleaning can lead to contamination of the granules, affecting their processability and mechanical properties. Por exemplo, oil and grease residues can cause poor adhesion between the plastic molecules during extrusion, resulting in low tensile strength of the granules.

2.3 Crushing

After cleaning and dewatering, the waste plastics are crushed into small pieces (flakes or fragments) using a crusher. Crushing helps to increase the surface area of the plastic, facilitating melting and mixing during the extrusion process. It also helps to remove any remaining small contaminants that may be embedded in the plastic.

The type of crusher used depends on the type and form of the waste plastic. Common types of crushers include jaw crushers, hammer crushers, blade crushers, and granulators. For flexible plastics (such as plastic films and bags), blade crushers are typically used, while for rigid plastics (such as plastic bottles and containers), hammer crushers or jaw crushers are more suitable. The size of the crushed plastic pieces is usually between 5mm and 20mm, depending on the type of extruder used and the desired granule size.

2.4 Secado

Even after dewatering, the crushed plastic pieces may still contain a certain amount of moisture. High moisture content can lead to defects such as bubbles, cracks, and poor surface quality in the recycled granules during extrusion. Polo tanto, a drying step is necessary to reduce the moisture content of the crushed plastic pieces to an acceptable level (typically below 0.5%).

Common drying methods include hot air drying, vacuum drying, and infrared drying. 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. Por exemplo, 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 Granulación por extrusión

A granulación por extrusión é o paso fundamental no proceso de granulación de reciclaxe de residuos plásticos. Implica a fusión, mesturando, e homoxeneizando as pezas de plástico trituradas secas mediante unha extrusora, despois extruíndo o plástico fundido a través dunha matriz para formar fíos continuos, que posteriormente se arrefrían e se cortan en gránulos uniformes.

A extrusora é o equipo clave neste paso, e o seu rendemento determina directamente a calidade e a eficiencia do proceso de granulación. Hai dous tipos principais de extrusoras utilizadas na granulación de reciclaxe de residuos plásticos: extrusoras de dobre parafuso e extrusoras dun só parafuso. Cada tipo ten as súas propias vantaxes e é adecuado para diferentes tipos de residuos plásticos, segundo se detalla na Sección 3.

Durante a granulación por extrusión, varios parámetros clave do proceso deben ser controlados con precisión:

Temperatura: The temperature of the extruder barrel and die is critical for melting the plastic and ensuring good mixing and homogenization. Different types of plastics have different melting points, and the barrel temperature is typically set 10-30°C above the melting point of the plastic to ensure complete melting. Por exemplo, the barrel temperature for PP is usually 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.
Shear Rate: 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, e mellorar a plasticidade dos gránulos. Porén, taxas de cizallamento excesivamente altas poden causar degradación mecánica da estrutura molecular plástica, levando a un rendemento reducido.
Velocidade do parafuso: A velocidade do parafuso afecta o rendemento, eficacia de fusión, e calidade de mestura. As velocidades dos parafusos máis altas poden aumentar o rendemento, pero poden reducir a eficiencia de fusión e mestura, mentres que as velocidades máis baixas dos parafusos poden mellorar a calidade da mestura pero reducir o rendemento. A velocidade óptima do parafuso depende do tipo de plástico, tipo de extrusora, e a calidade desexada do gránulo.
Presión de extrusión: A presión de extrusión está determinada polo deseño da matriz, velocidade do parafuso, e viscosidade do material. A presión de extrusión estable garante unha formación uniforme de fío e un tamaño de gránulo consistente. A presión excesivamente alta pode causar bloqueo da matriz, mentres que a presión excesivamente baixa pode producir fíos irregulares.

2.6 Refrixeración e Corte

Despois da extrusión a través da matriz, arrefríanse os fíos continuos de plástico para solidificalos. O arrefriamento pódese facer mediante arrefriamento por aire ou por auga. A refrixeración por auga é máis eficiente e úsase amplamente en operacións de granulación a gran escala, que implica facer pasar os fíos a través dun depósito de auga ou un pulverizador de auga para arrefrialos rapidamente a temperatura ambiente. A refrixeración por aire é adecuada para operacións a pequena escala ou para plásticos sensibles á auga (como algúns plásticos de enxeñería).

Unha vez que os fíos están arrefriados e solidificados, córtanse en gránulos uniformes mediante un peletizador. O granulador adoita instalarse á saída do sistema de refrixeración e pódese axustar para controlar a lonxitude dos gránulos. (normalmente entre 2 mm e 5 mm). Os tipos comúns de peletizadores inclúen peletizadores de cordón, peletizadoras de aneis de auga, and underwater pelletizers. Strand pelletizers are the most widely used type for waste plastic recycling granulation, as they are simple in structure, easy to operate, and suitable for most types of plastics.

2.7 Screening and Packaging

After cutting, the recycled granules are screened using a vibrating screen to remove any oversized or undersized granules, ensuring uniform particle size. 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. Hai dous tipos principais de extrusoras utilizadas na granulación de reciclaxe de residuos plásticos: extrusoras de dobre parafuso e extrusoras dun só parafuso. Each type has its own unique advantages and is suitable for different applications.

3.1 Twin-screw Extruders for Recycling Granulation

Twin-screw extruders are widely used in the recycling granulation of engineering plastics and plastics with high contamination levels, such as ABS, PD, and PET. They consist of two parallel screws that rotate in the same direction (co-rotación) or opposite directions (counter-rotating) within a barrel. As extrusoras de dobre parafuso co-rotativas úsanse máis habitualmente na reciclaxe de plásticos debido ás súas capacidades superiores de mestura e transporte..

3.1.1 Principais vantaxes das extrusoras de dobre parafuso

Fácil alimentación de material: As extrusoras de dobre parafuso teñen unha forte capacidade de transporte, que permite facilitar a alimentación de pezas de plástico trituradas, aínda que teñan forma irregular ou teñan certa cantidade de contaminantes. Isto reduce a necesidade de pre-procesamento do material e mellora a eficiencia da produción.
Tempo de residencia material curto: O tempo de permanencia do material na extrusora de dobre parafuso é curto (normalmente 1-5 minutos) en comparación coas extrusoras dun só parafuso. Isto axuda a evitar a degradación térmica do plástico, especialmente para plásticos termosensibles como PET y ABS, que pode degradarse facilmente cando se expón a altas temperaturas durante moito tempo. 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 (such as stabilizers, antioxidants, e colorantes) uniformemente. Isto garante que os gránulos reciclados teñan propiedades consistentes e boa procesabilidade.
Baixo consumo específico de enerxía: A pesar do seu alto rendemento, as extrusoras de dobre parafuso teñen un baixo consumo específico de enerxía (consumo de enerxía por unidade de saída), facéndoas máis eficientes enerxéticamente en comparación coas extrusoras dun só parafuso para determinadas aplicacións. Isto axuda a reducir os custos operativos das empresas de reciclaxe.
Potencia de alto volume: As extrusoras de dobre parafuso teñen un gran volume de potencia (potencia por unidade de volume do barril), o que significa que poden procesar unha gran cantidade de material nun espazo reducido. Isto fai que sexan axeitados para operacións de produción a gran escala con espazo limitado.

3.1.2 Aplicacións adecuadas para extrusoras de dobre parafuso

As extrusoras de dobre parafuso son especialmente adecuadas para a granulación de reciclaxe dos seguintes plásticos:

ABS: Un plástico de altas prestacións moi utilizado en produtos electrónicos, auto parts, and toys. O ABS é sensible á calor e require un tempo de residencia curto e unha boa mestura, facendo que as extrusoras de dobre parafuso sexan a opción ideal.
PD: Tanto o PS ríxido como o de espuma pódense reciclar mediante extrusoras de dobre parafuso. As capacidades superiores de mestura das extrusoras de dobre parafuso axudan a dispersar as células de escuma e os contaminantes restantes., garantindo unha boa calidade dos gránulos.
PET: O PET é moi sensible á humidade e á calor, e require un control preciso da temperatura e un tempo de residencia curto. As extrusoras de dobre parafuso con boas capacidades de ventilación e control de temperatura son adecuadas para a granulación de reciclaxe de PET.
Enxeñaría Plástica: Outros plásticos de enxeñería como PC (Policarbonato), PA (Poliamida), e POM (Polioximetileno) tamén se pode reciclar mediante extrusoras de dobre parafuso, grazas ás súas superiores capacidades de mestura e plastificación.

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. Isto axuda a evitar a degradación térmica do plástico, especially for soft plastics such as PE and LDPE, which have lower melting points and are prone to degradation.
Cost-Effective: A reciclaxe de residuos plásticos implica moitas veces materiais con altos niveis de contaminantes, o que pode causar un desgaste significativo do parafuso e do cilindro da extrusora. As extrusoras dun só parafuso teñen unha estrutura máis sinxela e usan materiais menos custosos, facendo que sexan máis rendibles para substituír e manter en comparación coas extrusoras de dobre parafuso. Isto é especialmente importante para as pequenas e medianas empresas de reciclaxe con orzamentos limitados.
Adecuado para plásticos brandos: A eficiencia de transporte de material das extrusoras dun só parafuso depende do rendemento de fricción do material sólido e da viscosidade do fundido.. Plásticos brandos como PP, PE, e LDPE teñen un bo rendemento de fricción e baixa viscosidade de fusión, facéndoos idóneos para procesar con extrusoras dun só parafuso. Estes plásticos pódense transportar e fundir de forma eficiente, garantindo unha boa calidade dos gránulos.
Operación e mantemento sinxelos: As extrusoras dun só parafuso teñen unha estrutura sinxela, con menos partes móbiles, facéndoos fáciles de manexar e manter. Isto reduce a necesidade de operadores cualificados e reduce os custos de mantemento, que é beneficioso para operacións de reciclaxe a pequena escala.

3.2.2 Aplicacións adecuadas para extrusoras dun só parafuso

As extrusoras dun só parafuso son especialmente adecuadas para a granulación de reciclaxe dos seguintes plásticos:

PP (Polipropileno): O PP é un plástico brando con bo rendemento de fricción e procesabilidade, polo que é ideal para procesar con extrusoras dun só parafuso. Os gránulos de PP reciclados producidos mediante extrusoras dun só parafuso teñen boas propiedades mecánicas e pódense usar nunha ampla gama de aplicacións..
PE (Polietileno): Tanto o LDPE como o HDPE son axeitados para o procesamento con extrusoras dun só parafuso. LDPE, en particular, é un plástico brando con baixa viscosidade de fusión, que pode ser transportado e fundido de forma eficiente mediante extrusoras dun só parafuso. Os gránulos de PE reciclados úsanse amplamente na produción de películas e tubos de plástico.
LDPE (Low-Density Polyethylene): O LDPE úsase habitualmente en películas e bolsas de plástico, que son fáciles de esmagar e procesar. As extrusoras dun só parafuso son ideais para a granulación de reciclaxe de LDPE, xa que poden manexar o material brando de forma eficiente e rendible.

3.3 Factores clave para a selección da extrusora

Ao seleccionar unha extrusora para a granulación de reciclaxe de residuos plásticos, deben considerarse os seguintes factores clave:

Tipo de residuos plásticos: Como se comentou anteriormente, as extrusoras de dobre parafuso son adecuadas para plásticos de enxeñería (ABS, PD, PET) e plásticos con altos niveis de contaminación, mentres que as extrusoras dun só parafuso son adecuadas para plásticos de uso xeral (PP, PE, LDPE).
Volume de Produción: Para produción a gran escala (máis de 500 kg/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.
Orzamento: Twin-screw extruders are more expensive than single-screw extruders, both in terms of initial investment and maintenance costs. Polo tanto, enterprises with limited budgets may prefer single-screw extruders for general-purpose plastic recycling.
Energy Consumption: Para produción a gran escala, 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, eficiencia, aforro de enerxía, and cost-effectiveness. A serie principal de extrusoras inclúe a serie ZTE e a serie HTE, cada un con características e vantaxes únicas para adaptarse a diferentes escenarios de aplicación.

4.1 Características técnicas básicas das extrusoras Zhuoyue

Todas as extrusoras Zhuoyue para a granulación de reciclaxe de residuos de plástico comparten un conxunto de características técnicas fundamentais que as fan idóneas para as duras condicións da reciclaxe de plástico., como altos niveis de contaminación, formas de materiais irregulares, e propiedades variables dos materiais:

Construción Robusta: As extrusoras Zhuoyue están construídas con materiais de alta calidade (como o aceiro de aliaxe para parafusos e barrís) para soportar o desgaste causado polos contaminantes dos residuos plásticos. Os parafusos e canóns son tratados con tratamentos especiais de superficie (como nitruración e cromado duro) para mellorar a súa resistencia ao desgaste e a súa vida útil.
Control de temperatura preciso: 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.
Energy-Saving 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.
Easy Operation and Maintenance: The extruders are designed with user-friendly interfaces and simple structures, facéndoos fáciles de manexar e manter. 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. Por exemplo, As extrusoras para reciclaxe de PET poden estar equipadas con sistemas de secado especiais e orificios de ventilación para garantir a eliminación completa da humidade..

4.2 Extrusoras da serie ZTE

A serie ZTE é a serie de extrusoras rendibles de Zhuoyue, deseñado para pequenas e medianas empresas de reciclaxe e granulación de reciclaxe de residuos plásticos de propósito xeral. Esta serie ofrece unha excelente relación custo-rendemento, con parámetros deseñados para adaptarse aos residuos plásticos máis comúns, including PP, PE, LDPE, e ABS e PS de uso xeral. A serie ZTE inclúe extrusoras dun só parafuso e de dobre parafuso, proporcionando opcións flexibles para diferentes aplicacións.

4.2.1 Características principais das extrusoras da serie ZTE

Excelente relación custo-rendemento: A serie ZTE está deseñada para ofrecer un rendemento fiable a un prezo competitivo, 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, including PP, PE, LDPE, ABS, and 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, reducindo o risco de falla dos equipos.
Baixos custos de mantemento: A estrutura sinxela da serie ZTE fai que sexa fácil de manter, con menos pezas móbiles e menores requisitos de mantemento. Os parafusos e os barrís pódense substituír facilmente cando están desgastados, reducindo o tempo de inactividade e os custos de mantemento.
Adecuado para produción a pequena e mediana escala: A serie ZTE está dispoñible nunha variedade de tamaños, con capacidades de 50 kg/h a 500 kg/h, facéndoo apto para operacións de reciclaxe a pequena e mediana escala.

4.2.2 Parámetros do modelo da serie ZTE

A serie ZTE inclúe extrusoras dun só parafuso e de dobre parafuso, con parámetros adaptados aos distintos tipos de residuos plásticos. A seguinte táboa detalla os parámetros das extrusoras de dobre parafuso da serie ZTE, adecuado para ABS, PD, e granulación de reciclaxe de PET:

Modelo	Par específico (N.m/Cm³)	Potencia do motor principal (Kw)	Velocidade de saída (rpm)	Relación de profundidade de ranura D0/Di	Plásticos adecuados
25	6	7.5	600	1.55	PD, ABS a pequena escala
35	6	18.5	600	1.55	PD, ABS, LDPE
50	6	55	600	1.55/1.68	ABS, PD, PET (A pequena escala)
65	6	110	600	1.55/1.68	ABS, PD, PET
75	6	160	600	1.55/1.68	ABS, PD, PET, PP
95	6	300	600	1.55/1.68	ABS, PD, PET, 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, including PP, PE, LDPE, ABS, and 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, deseñado para cubrir a brecha entre extrusoras rendibles (como a serie ZTE) e extrusoras de gama alta. Esta serie combina un alto rendemento cunha alta rendibilidade, proporcionando unha maior produción reducindo o consumo de enerxía. A serie HTE inclúe extrusoras de dobre parafuso e dun só parafuso, adecuado para a granulación de reciclaxe de residuos de plástico a mediana e grande escala.

4.3.1 Características principais das extrusoras da serie HTE

Desempeño equilibrado e rendibilidade: A serie HTE ofrece un maior rendemento que a serie ZTE, incluíndo mellores capacidades de mestura, maior rendemento, e control de temperatura máis preciso, mantendo un prezo competitivo. Isto faino axeitado para empresas que requiren maior calidade de gránulos pero que non queren investir en extrusoras de gama alta.
Aforro de enerxía e alto rendemento: A serie HTE está optimizada para a eficiencia enerxética, with advanced motor configurations and variable frequency drives (VFD) to reduce energy consumption. At the same time, 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, velocidade do parafuso, extrusion pressure, 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, PD, PET, PP, PE, and LDPE recycling granulation, with parameters optimized for high performance and efficiency. The following table details the specific parameters:

Modelo	Par específico (N.m/Cm³)	Potencia do motor principal (Kw)	Velocidade de saída (rpm)	Relación de profundidade de ranura D0/Di	Plásticos adecuados	Rendemento (kg/h)
25	9	11	600	1.55	PD, ABS, LDPE	50-100
35	9	30	600	1.55	PD, ABS, PE, LDPE	100-200
35	9	45	1000	1.55	PD, ABS, PE, LDPE	200-300
50	9	75	600	1.55/1.68	ABS, PD, PET, PP	300-500
50	9	110	900	1.55/1.68	ABS, PD, PET, PP	500-700
65	9	160	600	1.55/1.68	ABS, PD, PET, PP, PE	700-900
65	9	220	900	1.55/1.68	ABS, PD, PET, PP, PE	900-1200
75	9	250	600	1.55/1.68	ABS, PD, PET, PP, PE, LDPE	1200-1500
75	9	315	900	1.55/1.68	ABS, PD, PET, 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, tubos, and injection-molded products.

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, including PP, PE, LDPE, ABS, PD, and PET.
Production of high-quality recycled granules for automotive parts, electronic product accessories, and high-grade injection-molded products.
Empresas que se centran na eficiencia enerxética e na redución de custos, grazas ao deseño de aforro enerxético da serie HTE.

4.4 Solucións personalizadas de Zhuoyue

Ademais das series estándar ZTE e HTE, Zhuoyue tamén ofrece solucións de extrusora personalizadas para necesidades especiais de reciclaxe de residuos plásticos. Por exemplo:

Extrusoras personalizadas para residuos plásticos de alta contaminación, equipado con sistemas de filtrado mellorados para eliminar contaminantes.
Extrusoras para plásticos termosensibles como PET e PC, equipados con sistemas de secado especiais e parafusos de baixo cizallamento para evitar a degradación térmica.
Liñas de produción completas de granulación de reciclaxe, incluíndo trituradoras, secadores, extrusoras, peletizadoras, e equipos de cribado, para proporcionar unha solución única para as empresas.

O profesional de Zhuoyue 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 (such as metal, paper, and glass) as much as possible. Thoroughly clean the waste plastics to remove oil, grease, and food residues, 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 (such as temperature, velocidade do parafuso, and extrusion pressure) 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, antioxidants, and plasticizers to improve the quality of the recycled granules. Consult Zhuoyue’s technical team to select the appropriate additives and dosage.

6. Conclusión

Waste plastic recycling granulation is a critical technology for realizing resource circulation and environmental protection, offering significant economic, environmental, and social benefits. A calidade e a eficiencia do proceso de granulación dependen en gran medida da extrusora utilizada, e seleccionar a extrusora adecuada é esencial para o éxito dunha empresa de reciclaxe de plástico.

As extrusoras da serie ZTE e da serie HTE de Zhuoyue están deseñadas especificamente para a granulación de reciclaxe de residuos plásticos, combining high performance, eficiencia, aforro de enerxía, and cost-effectiveness. A serie ZTE ofrece unha solución rendible para pequenas e medianas empresas e reciclaxe de plástico de uso xeral., mentres que a serie HTE ofrece un rendemento equilibrado e unha rendibilidade para a produción a mediana e grande escala con requisitos de calidade máis elevados.. Con construción robusta, control de temperatura preciso, capacidade de mestura superior, e configuracións personalizables, As extrusoras Zhuoyue poden xestionar todo tipo de residuos plásticos, dende PP e PE ata ABS e PET, proporcionando gránulos reciclados de alta calidade para unha ampla gama de aplicacións.

As a leader in extrusion technology, Zhuoyue is committed to providing advanced, reliable, 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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