Granulasi Kitar Semula Plastik Termaju: Teknologi, Peralatan dan Penyelesaian Penyemperit Zhuoyue

Dalam era peningkatan kesedaran alam sekitar dan dasar pemuliharaan sumber yang ketat, kitar semula plastik telah menjadi tumpuan kritikal bagi industri di seluruh dunia. Antara pelbagai teknologi kitar semula plastik, granulasi kitar semula plastik sisa menonjol sebagai praktikal, cekap, dan kaedah berdaya maju dari segi ekonomi yang mengubah bahan plastik terbuang kepada butiran yang boleh diguna semula. Butiran kitar semula ini boleh diproses selanjutnya menjadi produk plastik baharu, dengan tahap prestasi yang setanding dengan yang diperbuat daripada bahan dara, sekali gus merealisasikan peredaran sumber sebenar dan mengurangkan beban alam sekitar yang disebabkan oleh sisa plastik.

Zhuoyue, pengeluar terkemuka peralatan penyemperitan, komited untuk menyediakan barisan pengeluaran granulasi kitar semula yang komprehensif untuk semua jenis plastik sisa, termasuk PP (Polipropilena), PE (Polietilena), LDPE (Polietilena Ketumpatan Rendah), PET (Polietilena Tereftalat), PS (Polistirena), ABS (Akrilonitril Butadiena Stirena), dan banyak lagi. Dengan teknologi penyemperitan termaju dan kepakaran mendalam dalam kitar semula plastik, Alat penyemperit Zhuoyue disesuaikan untuk memenuhi cabaran unik granulasi plastik sisa, penyampaian cekap, penjimatan tenaga, dan penyelesaian berkualiti tinggi untuk perusahaan yang terlibat dalam kitar semula plastik.

1. Gambaran Keseluruhan Granulasi Kitar Semula Plastik Sisa

Pembutiran kitar semula plastik sisa ialah proses khusus yang menukarkan pelbagai bentuk plastik sisa—seperti botol plastik, filem, bekas, sisa daripada barisan pengeluaran, dan sisa plastik selepas pengguna—menjadi seragam, butiran plastik berkualiti tinggi melalui satu siri rawatan mekanikal dan haba. Butiran kitar semula ini, juga dikenali sebagai butiran semula atau pelet plastik yang diproses semula, boleh digunakan terus dalam pengacuan suntikan, penyemperitan, acuan tiupan, dan kaedah pemprosesan plastik lain untuk menghasilkan produk baharu, bermula daripada bahan pembungkusan dan komponen pembinaan kepada alat ganti automotif dan keperluan harian.

Nilai teras granulasi kitar semula plastik sisa terletak pada keupayaannya untuk menangani dua cabaran pelupusan sisa plastik dan kekurangan sumber.. Tidak seperti kaedah pelupusan plastik sisa tradisional seperti pembuangan sampah dan pembakaran, yang menimbulkan risiko alam sekitar yang teruk, granulasi kitar semula mencapai kitar semula sumber sebenar:

Perlindungan Alam Sekitar: Pembuangan sampah plastik menduduki sumber tanah yang berharga dan boleh menyebabkan pencemaran tanah dan air bawah tanah, kerana plastik tidak boleh terbiodegradasi dan boleh membebaskan bahan berbahaya dari semasa ke semasa. Pembakaran, sebaliknya, mengeluarkan gas beracun (seperti dioksin dan karbon monoksida) dan zarah, menyumbang kepada pencemaran udara dan pemanasan global. Pembutiran kitar semula mengurangkan jumlah sisa plastik yang memasuki tapak pelupusan sampah dan insinerator, meminimumkan pencemaran alam sekitar dan pelepasan karbon.
Pemuliharaan Sumber: Plastik diperoleh daripada bahan api fosil yang tidak boleh diperbaharui (seperti minyak dan gas asli). Dengan mengitar semula sisa plastik kepada butiran yang boleh diguna semula, permintaan terhadap bahan plastik dara berkurangan, memulihara sumber fosil yang berharga dan mengurangkan penggunaan tenaga yang berkaitan dengan pengeluaran plastik dara. Dianggarkan mengitar semula satu tan plastik boleh menjimatkan sehingga 7.4 tong minyak dan mengurangkan pelepasan karbon dengan 1.5 tan.
Faedah Ekonomi: Butiran plastik kitar semula jauh lebih murah daripada bahan plastik dara, menawarkan penjimatan kos yang besar untuk pengilang. Untuk perusahaan kitar semula, proses mengumpul, pemprosesan, dan plastik sisa granulasi boleh menjana keuntungan yang stabil, mewujudkan peluang ekonomi dan jawatan pekerjaan baharu. Selain itu, banyak negara dan wilayah menawarkan insentif dasar (seperti subsidi dan pelepasan cukai) untuk perusahaan kitar semula plastik, meningkatkan lagi daya maju ekonomi granulasi kitar semula.

Namun begitu, kualiti butiran plastik kitar semula dan prestasi produk kitar semula akhir sangat bergantung pada proses granulasi dan peralatan yang digunakan. Faktor-faktor seperti jenis dan ketulenan plastik sisa, kecekapan pengasingan dan pembersihan, suhu dan kawalan ricih semasa penyemperitan, dan reka bentuk extruder semuanya mempunyai kesan yang ketara ke atas kualiti produk akhir. Oleh itu, membangunkan yang mudah, selesa, cekap, penjimatan tenaga, mesra alam, dan proses granulasi yang berdaya maju dari segi ekonomi telah menjadi tumpuan penyelidikan dan pembangunan dalam industri kitar semula plastik.

1.1 Ciri-ciri Utama Butiran Plastik Kitar Semula

Prestasi butiran plastik kitar semula berkait rapat dengan jenis plastik sisa, tahap pencemaran, dan proses granulasi. Secara amnya, Butiran kitar semula berkualiti tinggi harus mempunyai ciri-ciri berikut:

Saiz Zarah Seragam: Saiz zarah yang konsisten memastikan penyusuan yang stabil semasa pemprosesan berikutnya (seperti pengacuan suntikan dan penyemperitan), meningkatkan keseragaman dan kualiti produk akhir. Saiz zarah butiran kitar semula biasanya antara 2mm dan 5mm, bergantung kepada keperluan permohonan.
Pencemaran Rendah: Bahan cemar seperti kotoran, habuk, serpihan logam, kertas, and other non-plastic materials can significantly affect the performance of recycled granules and the final product. Oleh itu, 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, allowing for easy processing into new products without affecting the processing efficiency or product quality. This requires precise control of the temperature and shear rate during the granulation process to avoid excessive degradation of the plastic molecular structure.
Stable Mechanical Properties: The tensile strength, elongation at break, impact strength, and other mechanical properties of recycled granules should be as close as possible to those of virgin materials, memastikan bahawa produk kitar semula akhir memenuhi piawaian prestasi yang diperlukan.
Kandungan Lembapan Rendah: Kandungan lembapan yang tinggi dalam butiran kitar semula boleh menyebabkan kecacatan seperti buih dan rekahan pada produk akhir semasa pemprosesan. Oleh itu, langkah pengeringan selalunya diperlukan semasa proses granulasi untuk mengurangkan kandungan lembapan ke tahap yang boleh diterima (biasanya di bawah 0.5%).

1.2 Jenis Biasa Plastik Sisa untuk Granulasi

Hampir semua jenis plastik termoplastik boleh dikitar semula dan berbutir, semasa plastik termoset (yang tidak boleh dicairkan dan diproses semula) tidak sesuai untuk granulasi kitar semula. Jenis plastik sisa yang paling biasa digunakan dalam granulasi kitar semula termasuk:

PP (Polipropilena): Termoplastik yang digunakan secara meluas dengan rintangan kimia yang baik, sifat mekanikal, dan kebolehprosesan. PP buangan biasa termasuk baldi plastik, bekas, topi, and production scraps. Recycled PP granules are often used to produce plastic pipes, auto parts, and packaging materials.
PE (Polietilena): Divided into LDPE (Polietilena Ketumpatan Rendah) and HDPE (High-Density Polyethylene). LDPE is commonly used in plastic films, bags, and bottles, while HDPE is used in barrels, paip, and containers. Recycled PE granules are suitable for producing plastic films, paip, and injection-molded products.
PET (Polietilena Tereftalat): 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.
PS (Polistirena): 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 (Akrilonitril Butadiena Stirena): A high-performance plastic with good impact strength, rigidity, dan rintangan haba. ABS buangan biasa termasuk cangkerang plastik produk elektronik, auto parts, dan mainan. Butiran ABS kitar semula digunakan untuk menghasilkan cengkerang produk elektronik, auto parts, dan komponen acuan suntikan.

Barisan pengeluaran granulasi kitar semula Zhuoyue direka untuk mengendalikan semua plastik sisa yang dinyatakan di atas, dengan konfigurasi peralatan yang disesuaikan untuk memenuhi keperluan pemprosesan khusus bagi jenis plastik yang berbeza.

2. Proses Pembutiran Kitar Semula Plastik Sisa

Proses granulasi kitar semula plastik sisa biasanya terdiri daripada beberapa langkah utama: pengumpulan dan pengasingan sampah plastik, pembersihan, menghancurkan, pengeringan, granulasi penyemperitan, penyejukan, dan memotong. Setiap langkah memainkan peranan penting dalam memastikan kualiti butiran kitar semula akhir. Parameter proses tertentu mungkin berbeza bergantung pada jenis plastik sisa, tahap pencemaran, dan kualiti butiran kitar semula yang dikehendaki.

2.1 Pengumpulan dan Pengisihan

Langkah pertama dalam proses granulasi kitar semula ialah pengumpulan dan pengasingan plastik sisa. Sisa plastik dikumpul dari pelbagai sumber, termasuk isi rumah, industri, pertubuhan komersial, dan barisan pengeluaran. Disebabkan oleh pelbagai jenis plastik sisa dan kehadiran bahan cemar, pengisihan adalah penting untuk memastikan kualiti butiran kitar semula.

Pengisihan boleh dilakukan secara manual atau mekanikal. Pengisihan manual sesuai untuk operasi kitar semula berskala kecil dan melibatkan pengasingan pelbagai jenis plastik, menyingkirkan bahan cemar bukan plastik (seperti logam, kertas, kaca, dan sisa organik), dan menyusun plastik mengikut warna dan kualiti. Pengisihan mekanikal, sebaliknya, adalah lebih cekap dan sesuai untuk operasi berskala besar, menggunakan teknologi seperti pemisahan ketumpatan (pemisahan sink-apung), pemisahan magnetik, pemisahan elektrostatik, dan pengasingan inframerah untuk mengasingkan jenis plastik yang berbeza dan membuang bahan cemar.

Pengisihan yang berkesan adalah penting kerana mencampurkan pelbagai jenis plastik boleh menyebabkan pengurangan ketara dalam prestasi butiran kitar semula. Contohnya, mencampurkan PP dan PET boleh menyebabkan pemisahan fasa semasa penyemperitan, mengakibatkan keplastikan yang lemah dan sifat mekanikal butiran.

2.2 Pembersihan

Selepas menyusun, plastik sisa dibersihkan untuk menghilangkan bahan cemar permukaan seperti kotoran, habuk, minyak, gris, sisa makanan, dan label. Proses pembersihan biasanya melibatkan beberapa langkah:

Pra-pembersihan: Mengeluarkan bahan cemar besar (seperti label, topi, dan serpihan logam) dan kotoran kasar melalui memberus, meniup, atau pemilihan manual.
Mencuci: Merendam plastik sisa dalam larutan pembersih (selalunya air dengan detergen atau alkali) untuk mengeluarkan minyak, gris, dan sisa makanan. Pergolakan atau pembersihan ultrasonik boleh digunakan untuk meningkatkan kesan pembersihan.
Membilas: Bilas plastik yang telah dibersihkan dengan air bersih untuk mengeluarkan sebarang larutan pembersih dan bahan cemar yang tinggal.
Penyahairan: Mengeluarkan lebihan air daripada plastik yang telah dibersihkan menggunakan emparan, mesin penyahair, atau pengeringan udara untuk mengurangkan kandungan lembapan dan memudahkan pemprosesan seterusnya.

Kesan pembersihan secara langsung menjejaskan kualiti butiran kitar semula. Pembersihan yang tidak mencukupi boleh menyebabkan pencemaran butiran, menjejaskan kebolehprosesan dan sifat mekanikalnya. Contohnya, sisa minyak dan gris boleh menyebabkan lekatan yang lemah antara molekul plastik semasa penyemperitan, mengakibatkan kekuatan tegangan rendah butiran.

2.3 Menghancurkan

Selepas pembersihan dan dewatering, plastik sisa dihancurkan menjadi kepingan kecil (kepingan atau serpihan) menggunakan penghancur. Menghancurkan membantu meningkatkan luas permukaan plastik, memudahkan pencairan dan pencampuran semasa proses penyemperitan. Ia juga membantu untuk membuang sebarang bahan cemar kecil yang tertinggal yang mungkin tertanam dalam plastik.

Jenis penghancur yang digunakan bergantung kepada jenis dan bentuk plastik sisa. Jenis penghancur biasa termasuk penghancur rahang, penghancur tukul, penghancur pisau, dan granulator. Untuk plastik fleksibel (seperti filem dan beg plastik), penghancur pisau biasanya digunakan, manakala bagi plastik tegar (seperti botol plastik dan bekas), penghancur tukul atau penghancur rahang adalah lebih sesuai. Saiz kepingan plastik yang dihancurkan biasanya antara 5mm dan 20mm, bergantung pada jenis extruder yang digunakan dan saiz butiran yang dikehendaki.

2.4 Pengeringan

Walaupun selepas dewatering, kepingan plastik yang dihancurkan mungkin masih mengandungi sejumlah lembapan. Kandungan lembapan yang tinggi boleh menyebabkan kecacatan seperti buih, retak, dan kualiti permukaan yang lemah dalam butiran kitar semula semasa penyemperitan. Oleh itu, langkah pengeringan adalah perlu untuk mengurangkan kandungan lembapan kepingan plastik yang dihancurkan ke tahap yang boleh diterima (biasanya di bawah 0.5%).

Kaedah pengeringan biasa termasuk pengeringan udara panas, pengeringan vakum, dan pengeringan inframerah. Pengeringan udara panas adalah kaedah yang paling banyak digunakan, yang melibatkan laluan udara panas (pada suhu 80-120°C) melalui kepingan plastik yang dihancurkan untuk menyejat lembapan. Masa dan suhu pengeringan bergantung pada jenis plastik dan kandungan lembapan awal. Contohnya, PET lebih sensitif kepada kelembapan dan memerlukan suhu pengeringan yang lebih tinggi (120-160°C) dan masa pengeringan yang lebih lama untuk memastikan penyingkiran kelembapan sepenuhnya.

2.5 Extrusion Granulation

Extrusion granulation is the core step in the waste plastic recycling granulation process. It involves melting, pergaulan, 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, and its performance directly determines the quality and efficiency of the granulation process. There are two main types of extruders used in waste plastic recycling granulation: twin-screw extruders and single-screw extruders. Each type has its own advantages and is suitable for different types of waste plastics, as detailed in Section 3.

During extrusion granulation, several key process parameters need to be precisely controlled:

Temperature: 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. Contohnya, 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, dan meningkatkan keplastikan butiran. Namun begitu, kadar ricih yang terlalu tinggi boleh menyebabkan kemerosotan mekanikal struktur molekul plastik, membawa kepada penurunan prestasi.
Kelajuan Skru: Kelajuan skru mempengaruhi daya pemprosesan, kecekapan lebur, dan kualiti pencampuran. Kelajuan skru yang lebih tinggi boleh meningkatkan daya pemprosesan tetapi boleh mengurangkan kecekapan pencairan dan pencampuran, manakala kelajuan skru yang lebih rendah boleh meningkatkan kualiti pencampuran tetapi mengurangkan daya pemprosesan. Kelajuan skru optimum bergantung pada jenis plastik, jenis extruder, dan kualiti butiran yang dikehendaki.
Tekanan Penyemperitan: Tekanan penyemperitan ditentukan oleh reka bentuk die, kelajuan skru, dan kelikatan bahan. Tekanan penyemperitan yang stabil memastikan pembentukan untaian seragam dan saiz butiran yang konsisten. Tekanan yang terlalu tinggi boleh menyebabkan tersumbat, while excessively low pressure can result in uneven strands.

2.6 Menyejukkan dan Memotong

After extrusion through the die, the continuous plastic strands are cooled to solidify them. Cooling can be done using air cooling or water cooling. Water cooling is more efficient and is widely used in large-scale granulation operations, involving passing the strands through a water tank or water spray to quickly cool them to room temperature. Air cooling is suitable for small-scale operations or for plastics that are sensitive to water (such as some engineering plastics).

Once the strands are cooled and solidified, they are cut into uniform granules using a pelletizer. The pelletizer is typically installed at the exit of the cooling system and can be adjusted to control the length of the granules (usually between 2mm and 5mm). Jenis pelet biasa termasuk pelet helai, pelet cincin air, dan pelet dalam air. Pelet helai adalah jenis yang paling banyak digunakan untuk granulasi kitar semula plastik sisa, kerana ia mudah dalam struktur, mudah dikendalikan, dan sesuai untuk kebanyakan jenis plastik.

2.7 Saringan dan Pembungkusan

Selepas dipotong, butiran kitar semula disaring menggunakan skrin bergetar untuk mengeluarkan sebarang butiran bersaiz besar atau kecil, memastikan saiz zarah seragam. Butiran yang disaring kemudian dikeringkan semula (jika perlu) untuk mengeluarkan sebarang lembapan yang diserap semasa penyejukan, kemudian dibungkus ke dalam beg atau bekas pukal untuk penyimpanan dan pengangkutan.

Pembungkusan adalah langkah penting untuk mengelakkan pencemaran dan penyerapan lembapan butiran kitar semula. Bahan pembungkusan hendaklah kalis lembapan dan bersih, 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. There are two main types of extruders used in waste plastic recycling granulation: twin-screw extruders and single-screw extruders. 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, seperti ABS, PS, dan PET. They consist of two parallel screws that rotate in the same direction (co-rotating) or opposite directions (counter-rotating) within a barrel. Penyemperit skru berkembar berputar bersama lebih biasa digunakan dalam kitar semula plastik kerana keupayaan mencampur dan menyampaikannya yang unggul.

3.1.1 Kelebihan Utama Penyemperit Skru Berkembar

Suapan Bahan Mudah: Extruder skru berkembar mempunyai kapasiti penyampaian yang kuat, yang membolehkan penyusuan mudah kepingan plastik yang dihancurkan, walaupun bentuknya tidak sekata atau mempunyai jumlah bahan cemar tertentu. Ini mengurangkan keperluan untuk pra-pemprosesan bahan dan meningkatkan kecekapan pengeluaran.
Masa Tinggal Bahan Pendek: Masa tinggal bahan dalam penyemperit skru berkembar adalah pendek (biasanya 1-5 minit) berbanding dengan penyemperit skru tunggal. Ini membantu mengelakkan degradasi haba plastik, terutamanya untuk plastik sensitif haba seperti PET dan ABS, yang boleh merosot dengan mudah apabila terdedah kepada suhu tinggi untuk masa yang lama. 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, antioksidan, and colorants) 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 parts, dan mainan. 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.
PET: 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 Plastics: Other engineering plastics such as PC (Polikarbonat), PA (Poliamida), and POM (Polioksimetilena) 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. Ini membantu mengelakkan degradasi haba plastik, especially for soft plastics such as PE and LDPE, which have lower melting points and are prone to degradation.
Cost-Effective: Kitar semula plastik sisa selalunya melibatkan bahan dengan tahap bahan cemar yang tinggi, yang boleh menyebabkan haus dan lusuh yang ketara pada skru dan tong penyemperit. Penyemperit skru tunggal lebih mudah dalam struktur dan menggunakan bahan yang lebih murah, menjadikannya lebih kos efektif untuk menggantikan dan menyelenggara berbanding penyemperit skru berkembar. Ini amat penting untuk perusahaan kitar semula bersaiz kecil dan sederhana dengan belanjawan terhad.
Sesuai untuk Plastik Lembut: Kecekapan penghantaran bahan bagi penyemperit skru tunggal bergantung pada prestasi geseran bahan pepejal dan kelikatan leburan. Plastik lembut seperti PP, PE, dan LDPE mempunyai prestasi geseran yang baik dan kelikatan cair yang rendah, menjadikannya sesuai untuk diproses dengan penyemperit skru tunggal. Plastik ini boleh dihantar dan dicairkan dengan cekap, ensuring good granule quality.
Simple Operation and Maintenance: Single-screw extruders have a simple structure, with fewer moving parts, making them easy to operate and maintain. This reduces the need for skilled operators and lowers maintenance costs, which is beneficial for small-scale recycling operations.

3.2.2 Suitable Applications for Single-screw Extruders

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

PP (Polipropilena): 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 (Polietilena): Both LDPE and HDPE are suitable for processing with single-screw extruders. LDPE, khususnya, 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 (Polietilena Ketumpatan Rendah): 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, PET) and plastics with high contamination levels, while single-screw extruders are suitable for general-purpose plastics (PP, PE, LDPE).
Jumlah Pengeluaran: 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.
Bajet: Twin-screw extruders are more expensive than single-screw extruders, both in terms of initial investment and maintenance costs. Oleh itu, enterprises with limited budgets may prefer single-screw extruders for general-purpose plastic recycling.
Penggunaan Tenaga: 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, kecekapan, penjimatan tenaga, dan keberkesanan kos. 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.
Precise Temperature Control: 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, making them easy to operate and maintain. 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. Contohnya, extruders for PET recycling can be equipped with special drying systems and venting ports to ensure complete moisture removal.

4.2 ZTE Series Extruders

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, termasuk 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, termasuk 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, 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	Specific torque（N.m/Cm³）	Main motor power（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, PET (Small-scale)
65	6	110	600	1.55/1.68	ABS, PS, PET
75	6	160	600	1.55/1.68	ABS, PS, PET, PP
95	6	300	600	1.55/1.68	ABS, PS, 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, termasuk 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, 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, higher throughput, 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. 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, kelajuan skru, tekanan penyemperitan, 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, PET, PP, PE, and LDPE recycling granulation, with parameters optimized for high performance and efficiency. The following table details the specific parameters:

Model	Specific torque（N.m/Cm³）	Main motor power（Kw）	Output speed（rpm）	Slot depth ratio D0/Di	Suitable Plastics	Throughput (kg/j)
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, PET, PP	300-500
50	9	110	900	1.55/1.68	ABS, PS, PET, PP	500-700
65	9	160	600	1.55/1.68	ABS, PS, PET, PP, PE	700-900
65	9	220	900	1.55/1.68	ABS, PS, PET, PP, PE	900-1200
75	9	250	600	1.55/1.68	ABS, PS, PET, PP, PE, LDPE	1200-1500
75	9	315	900	1.55/1.68	ABS, PS, 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, paip, 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, termasuk PP, PE, LDPE, ABS, PS, dan 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. Contohnya:

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, pengering, penyemperit, pelet, 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 (seperti logam, kertas, and glass) as much as possible. Thoroughly clean the waste plastics to remove oil, gris, dan sisa makanan, which can affect the mixing and plasticizing effect.

5.2 Optimal Drying

Pastikan kepingan plastik yang dihancurkan dikeringkan dengan betul untuk mengurangkan kandungan lembapan ke bawah 0.5%. Untuk plastik sensitif kelembapan seperti PET, gunakan pengeringan suhu tinggi (120-160°C) untuk tempoh yang mencukupi untuk memastikan penyingkiran kelembapan sepenuhnya. Ini membantu mengelakkan buih dan kecacatan pada butiran kitar semula.

5.3 Kawalan Parameter Proses yang Tepat

Laraskan parameter penyemperit (seperti suhu, kelajuan skru, dan tekanan penyemperitan) mengikut jenis plastik sisa. Ikut tetapan parameter disyorkan yang disediakan oleh Zhuoyue, dan membuat pelarasan berdasarkan sifat bahan sebenar dan kualiti butiran. Elakkan suhu atau kadar ricih yang terlalu tinggi, yang boleh menyebabkan degradasi plastik.

5.4 Penyelenggaraan Berkala

Periksa dan selenggara extruder secara kerap untuk memastikan operasi normalnya. 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, antioksidan, and plasticizers to improve the quality of the recycled granules. Consult Zhuoyue’s technical team to select the appropriate additives and dosage.

6. Kesimpulan

Waste plastic recycling granulation is a critical technology for realizing resource circulation and environmental protection, offering significant economic, alam sekitar, 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, kecekapan, penjimatan tenaga, dan keberkesanan kos. 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, kawalan suhu yang tepat, 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, 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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