Equipment Spotlight | MAR 2020 Granulators

by MARY M. THORNTON

In August, NPR published, The Plastic Tide, which explores the effects of plastic waste on our environment. Some of the information presented includes the following:

Every year, the average American generates more than 250 pounds of plastic waste. Recycling guidelines among processing facilities vary – as does the equipment used in processing. The downstream markets for plastic are constantly evolving. As an example, a lot of packaging made of plastic ends up in incinerators, landfills and oceans because it isn’t designed to be recycled. MRF operators say they’re working with manufacturers to design packaging that can be recycled within the capabilities of the current system. Even though plastic bottles are a highly desirable product for recyclers, only about a third find their way into a recycling bin. In situations when plastics do end up in the recycling stream, granulators are often involved in the process of converting that plastic into another form, so that the commodity life of the material continues on.

“Cumberland provides the broadest line of granulators and shredders to meet the growing needs of the plastics and recycling industries. Our granulators have flexibility to process large volume parts, with the capability to configure the cutting chamber to grind higher density parts. Tangential or offset geometries are available, allowing users to create a machine especially configured to the process needs involved. High quality output makes it easier to utilize the maximum amount of recycled material in your process,” said Andre Adams, senior product manager.

Adams added, “Whether the application requires single or four shaft shredders, beside the press or central granulators, our customers rely on Cumberland to deliver their throughput requirements and produce the highest quality regrind available in the industry. Our broad range of heavy duty granulator options are designed for the most demanding applications – from low density fiber to heavy purgings, Cumberland’s largest granulators are ready to tackle high capacity size reduction needs. For example, one of our customers processes up to 50,000 pounds per hour (PPH) utilizing 8 heavy duty machines, running 24/7.”

He explained that machine users look for reliability, durability, reduced downtime and predictable, easy maintenance. Reliable machines maximize uptime and offer maximum life of wear items like screens and knives. Users also seek better user interface with digital controls, and optimal safety features. Companies in the industry focus on creating a circular economy, to increase the repurposing of single use plastics. The China import recycling ban and social sustainability are also taken into consideration.

Granutech Saturn Systems provides engineering, manufacturing and commissioning recycling systems and solutions, worldwide. Jon Maly is regional sales manager at the firm and he stated, “For the plastics industry specifically, our customers have had great success with our Roto-Grind Series single shaft shredders. Available since the early 1990s, the series includes a heavy duty, high volume, very low maintenance shredder, offered as electric and hydraulic and in 4 different models – the M80, M110, M160 and M240. Available from 60HP to 400HP, these shredders are built to last, as some of our earliest models are still in operation today. With a horizontal ram and feed bin, our roto-grind shredder offers a very quick, efficient metered feeding system. The machine allows for increased rotational cutter access to the material being processed, which increases output volume.”

For especially tough materials, Maly recommends Granutech’s hydraulic power options, which offer quicker power ramp up and reversals than traditional electric shredders. He noted that processing volumes for customers range from a few tons per hour to over 20 tons per hour. Volume output is dependent on a number of factors such as material, screen size and machine size. Roto-Grind applications include materials such as bulk film, cast nylon/fiberglass mixtures, glass filled purgings and high volume general plastic scrap.

Maly commented on how the industry has been affected by recent events. “As some buyers shut their doors to unrecycled plastics, creating challenges for some suppliers, it has in turn created new usage channels. Increasingly, recycled plastics are used in everything from automotive parts to paint cans. The Roto-Grind series is the perfect solution for reducing tough plastics and films prior to granulation and we are happy to offer our guidance on any plastic type a customer seeks to reduce. One of the major benefits of utilizing machinery from Granutech is our knowledge base and customizations we can provide to ensure that our machine is tailored to your exact need!” The firm’s other products include Granutech shredders, MAC balers and Grizzly grinders.

Herbold manufactures a wide range of granulators equally well suited for the efficient size reduction of both paper and plastics. The popular SML Series and SMS Series are available in a variety of configurations. With throughputs of around 400 PPH to over 20,000 PPH and motor sizes up to 400 HP, they can meet any recycling requirement. They can also be furnished with a variety of rotor styles equipped with four to nine knives to optimize throughput based on specific application requirements. There are even models that meet the NSA requirements for the destruction of top-secret documents.

As cost savings and productivity are always desirable, it can be beneficial when one machine serves more than one specific application or performs the work of two machines. This can also result in big savings in capital expenditures. As well, the less time a machine is down for knife changes or routine maintenance, the more productivity can increase. “Herbold Granulators feature a knife jig which allows all knife adjustments to be made quickly and easily outside of the granulator, significantly reducing downtime for knife changes. With access above and below the rotor, Herbold granulators provide unmatched accessibility allowing for fast, easy material changes and cleanouts,” David Lefrancois, president commented.

He noted, “Over the last few years we’ve noticed an increase in the recycling of various films. Unlike three dimensional plastics, films pose challenges for many recyclers. However, the potential value has caused many recyclers to seek film recycling solutions. Herbold granulators can be configured for wet or dry operation to handle post industrial and post consumer films.”

Published in the March 2020 Edition