plastic recycling shredder

Types of Plastic Recycling Shredders

A plastic recycling shredder is a machine used in plastic recycling plants to break down large plastic waste into smaller pieces for easier handling and processing. Different types of plastics are recycled, and various types of shredders are available to create different sizes of plastic that can be easily melted down and remolded into usable material.

• Single-Shaft Shear Shredder: A single-shaft shear shredder has a stationary shear blade stacked against a single shaft with multiple movable shear blades. It shreds materials through a repeated process of compression and cutting. This type of shredder can easily handle most types of plastics but is not suitable for tougher materials like rubber or nylon.
• Granulator: Granulators usually have a rotor with multiple blades, which are smaller than those of a shredder. They are used to reduce plastic further after it has been roughly shredded by a hammer or single-shaft cutter. Granulators can handle fiber-reinforced plastics, polycarbonate, and other tough materials.
• Open-Rotor Shredder: An open-rotor shredder has the rotor mounted between two walls of open space. The shreds move inside the open cavities rather than being pushed against a flat surface. This type of shredder has increased airflow, which results in a cooler process. Open rotors are preferable for shredding electronics, rigid plastics, and boxes.
• Counterblow Shredder: A counterblow shredder has an impeller whose blows counter to gravity. The materials are intercepted by a stationary screen and therefore subjected to shearing and striking until appropriately sized to fall through the screen's holes. Counterblows are useful for preparing biomass, plastics, and paper for recycling.
• Multi-Shaft Shredder: Multi-shaft shredders have three to five shafts, which make them more versatile than single-shaft shredders. They can handle a wide variety of plastics, including rigid material like boxes, crates, and drums, as well as films and fibers. One of the benefits of this type of shredder is that multiple blades reduce the machine's workload, increasing its productivity.
• Inclined Shredder: An inclined shredder has its cutting chamber tilted at an angle. This arrangement assists the fallen material in entering the cutting area and creating an easier workflow. Moreover, an incline fits well in a recycling plant as it can directly accept materials from production lines. An inclined shredder can process all types of plastics.

Specifications and maintenance of plastic recycling shredders

Specifications

• Blade materials: Plastic shredder blades are made of different materials. Carbon steel is popular because it balances strength and cost. Some machines use alloy steel, which has stronger durability, or stainless steel, which resists rust.
• Feed opening: The feed opening is where plastic enters the shredder. It needs to be wide and high enough to fit whole items without cutting, like a trash can mouth. Bigger shredders have larger feed openings for bulkier plastics.
• Power source: Shredders are powered by electric motors or gas engines. Electric motors use AC current and come in single-phase for homes or three-phase for industries. Gas engines give more mobility outside of fixed locations. Electric motors are quieter, while gas produces noise and requires more fuel upkeep.
• Motor power: Measured in horsepower (HP), motor power determines how hefty plastics it can shred. Higher HP handles thicker, tougher materials, while lower is suitable for lighter items. Specifications list typical HP ratings, such as 5-7.5 HP for small machines and 15-20 HP for larger ones.
• Cutting chamber and rotor size: These measurements indicate the shredder's overall dimensions, like its height and weight. They depend on the type - whether it's a small desktop model, a floor-standing machine, or an industrial model mounted in a fixed location. Industrial-sized units take up more floor space.

Maintenance

• Routine cleanings: Shredders should be cleaned frequently, ideally after every use or at least once per work shift. Remove any stuck plastic debris from all parts using brushes, rags, and vacuum suction hoses. Cleaning prevents material build-up that causes overheating and fire hazards.
• Blade maintenance: Plastic waste recycling shredders use blades to cut up items. They should be checked regularly and cleaned of plastic residue. If any blades become dull or damaged, they need to be sharpened or replaced. Sharp blades make cleaner cuts and work more efficiently.
• System checks: Do routine inspections of critical components like the motor and its belts, gearbox, bearings, and electrical system. Check for faults, excessive wear, or loosened parts. Belts should be adjusted to have the proper tightness. Lubricate moving parts per the shredder manual. This prevents mechanical breakdowns.
• Maintenance schedule: Shredder users should create a maintenance log documenting scheduled tasks, inspections, and repairs along with their dates. Following a consistent maintenance schedule improves shredders' reliability over the long term. It also helps to avoid unexpected equipment failures that disrupt workflow.

Application

Plastic shredders are helpful at different levels of recycling plastic and are suitable for many uses.

• Recycling plants: Plastic shredders are the key step in a plastic recycling plant. They break down the plastic into smaller pieces for easier recycling, like remolding or reprocessing. After shredding, the plastic will become more manageable and suitable for following treatments such as washing, drying, sorting, or melting.
• Waste Management Facilities: Waste management facilities are in charge of inspecting, sorting, and handling different waste materials. Plastic shredders assist them in classifying and processing plastic waste, making it more compact and space-efficient for storage and disposal.
• Manufacturing Plants: Manufacturing plants that produce goods using recycled plastic need plastic shredders to handle incoming plastic waste. These plants can save material costs by closely controlling the shredding size and integrating plastic shards into the production process.
• Automotive Recycling: Automotive recycling focuses on dismantling and recycling old vehicles. Automotive plastic shredders can deal with complex plastic parts, like dashboards, bumpers, and containers. By processing these plastics, automotive recyclers can recover valuable materials and reduce landfill waste.
• E-Waste Recycling: Electronics waste consists of obsolete electronic devices. Among these devices, many are made of plastic. Plastic shredders for e-waste can handle plastic parts like housings and panels, contributing to recovering materials such as metals and plastics from the entire electronic waste stream.
• Small Business and Startups: Some startups or small companies offer localized plastic recycling solutions. These businesses may focus on specific types of plastic or small-scale processing. Using plastic shredders, they can provide community-based recycling services, reducing local plastic waste and environmental impact.

How to choose plastic recycling shredders

• Material compatibility:

  Make sure the plastic shredder is compatible with the type of plastic waste that needs to be processed. Different plastics have different material properties, and some may be more difficult to shred than others. For instance, rigid plastic bottles, containers, and buckets are appropriate for crushers, while nylon fabric, rubber, and elastic materials are suited for hammer mills.

• Shred size:

  Determine the desired particle size for the shredded plastic and choose a shredder that can achieve it. Industries usually require a shred size of 12 mm to 30 mm. A smaller shredders can yield up to eight mm particles and is preferable for more extensive shredding chambers.

• shredding capacity:

  Consider the volume of plastic waste that needs to be processed and choose a shredder with an appropriate capacity. A high-capacity shredder (over 1,000 kg) is more suited for large-scale production, while a 500 kg one may suffice for mid-level facilities.

• Power requirements:

  Consider the power requirements, such as voltage and amperage, to ensure they are compatible with the available electrical supply. Diesel or gasoline engines are suitable for outdoor shredding activities, while electricity is more fitting for indoor use.

• Shredder design and construction:

  Choose a shredder with a robust construction that can withstand the rigors of plastic recycling. The rotor design also affects how long the machine lasts; whether it has a horizontal or vertical shaft, the number of blades, and the material it is made of are all crucial.

• Budget and ROI:

  Consider the budget constraints and evaluate the return on investment (ROI) potential of the plastic shredders. Choosing a more durable machine might be costlier but can save costs in maintenance and replacement.

Plastic Recycling Shredder Q&A

Q1: What are the latest trends in plastic recycling shredders?

A1: The latest trends in plastic recycling shredders include AI integration for automated sorting, energy-efficient designs to reduce carbon footprints, multi-material shredders that handle different types of plastics simultaneously, and compact machines suitable for urban recycling initiatives.

Q2: What are the challenges faced by plastic recycling shredders?

A2: Plastic recycling shredders encounter several challenges. The increasing complexity of plastic materials makes it difficult to design shredders that can handle various types. Higher contaminant levels in input feedstock lead to premature wear and tear on shredder blades. Limited availability of downstream recyclers willing to take shredded output poses economic viability concerns for plastics. Invested shredders must be economically feasible over time and have replaceable parts. Contamination must be economically feasible. It must be removable and not damaged.

Q3: What is the market size for plastic shredders?

A3: According to expert insights, the global plastic shredder market size was valued at USD 815.9 million in 2021 and is expected to expand at a CAGR of 2.6% reaching USD 953 million by 2028.