Last week, Kitech Machinery successfully completed the trial run of its KCP180 crushing and pelletizing system, a system custom-designed for a foreign furniture injection molding recycling manufacturer.
Main Production Process
BOFF film raw materials are crushed by a crusher, then transferred to the granulation system via a transfer hopper. From there, they are conveyed by a belt conveyor to a cutting and compacting system for further crushing. After being heated and plasticized by two extruders, a water ring pelletizer cuts the melt into uniformly sized granules. These pellets are then dried by a vibration drying system and finally stored in a Euro hopper dryer.
On-site Testing Results
The produced plastic pellets exhibit the following excellent characteristics:
* Uniform Size: High consistency in pellet size.
* Uniform Color: Uniform pellet color distribution.
* Excellent Appearance: Smooth surface, no bubbles.
* Meets Standards: Fully meets all standard requirements for recycled plastic manufacturing.
I. AGF Crushing System Core Advantages
The AGF series crusher is specifically designed for the efficient recycling of LDPE plastic film, PP/PE plastic containers, PET plastic bottles, and BOPP film. It adopts a custom rotor design from Kitech Machinery, precisely matching the unique crushing requirements of different materials.
Working Principle:
The motor-driven rotating blades interact with the fixed bottom blades. The gap between the blades generates powerful shearing and cutting action, effectively crushing large pieces of plastic into smaller fragments. The size of the output fragments can be controlled via a screen.
Core Components and Advantages:
1. Multi-functional Magnetic Separator:
This machine not only uses magnetic rollers but also belt-conveyed magnetic rollers, and adds belts, drums, a main frame, and conveyor belts to achieve higher material sorting efficiency. This model has a wide range of applications, is energy-saving, easy to maintain, has an extremely low failure rate, and operates stably in extremely harsh environments, making it a popular choice for many manufacturers.
2. Electro-hydraulic Control:
This automated system allows for easy and safe opening of the machine casing and screen frame via a hydraulic controller, significantly reducing operational risks for factory personnel and improving work efficiency. Its robust construction ensures a long service life and high reliability in harsh industrial environments.
3. High-performance blades:
The blades are made of high-hardness D2 alloy steel, ensuring durability. V-shaped cutting technology and staggered rotor blade arrangement make them ideal for crushing films and hollow plastics, achieving uniform output particle size and efficient crushing results.
4. Advanced PLC control system:
Kitech's advanced programmable logic controller (PLC) is flexible and programmable, customizable to specific operational needs. Intuitive diagnostic functions and modular design simplify operation and facilitate quick troubleshooting. A safety interlock system automatically cuts off power when operators are inspecting or performing maintenance.
5. Core Advantages of Transfer Hopper:
The transfer hopper can transport stored fragments to downstream equipment at a relatively constant and controllable rate. It effectively coordinates the output of the upstream crusher with the continuous and stable supply needs of the subsequent granulation system. It is a core transfer component ensuring the smooth, efficient, and continuous operation of the entire production line.
II. KCP180 Water Ring Pelletizing System Core Components
1. Automatic Feeding System:
A belt conveyor controlled by a frequency converter enables uniform automatic feeding. An optional metal detector effectively removes metal impurities from the raw materials, protecting the cutter compactor.
2. Crushing and Compacting System:
Developed independently by Kitech Machinery, this crushing and compacting system integrates preheating, mixing, semi-plasticizing, and pre-drying functions, ensuring stable and rapid feeding for subsequent processes. The compactor is equipped with a temperature control system to effectively prevent raw material degradation due to overheating.
3. Two-Stage Extrusion System:
Utilizes a two-stage single-screw extruder, particularly suitable for processing heavy-ink printing films, high-moisture films, and temperature-sensitive raw materials. The raw material undergoes two extrusions, thorough filtration, and degassing, achieving superior plasticizing effects and higher particle quality.
4. Plate Filter System:
A single-plate, double-station plate provides maximum filtration area, ensuring continuous machine operation. Ceramic heaters are equipped on both sides to effectively maintain the raw material melt temperature. Integrated GEFRAN pressure sensor: Automatically alarms when screen replacement is required.
5. Water Ring Pelletizing System:
Employs a new European water ring pelletizer. Pelletizing speed is adjustable via frequency converter and automatically adjusted with melt pressure, ensuring uniform plastic pellet size and effectively solving problems such as uneven pellet size, pellet sticking, and air bubbles in traditional pelletizing equipment.
6. Vibration Drying System:
Combines a vibration dryer and a horizontal centrifugal dryer. High-speed centrifugal vibration achieves efficient and thorough drying of plastic pellets. The water tank is equipped with a heat exchanger for cooling water, which is recyclable, energy-saving, and environmentally friendly.
7. PLC Control System:
Core electrical components use internationally renowned brands such as Siemens, Schneider Electric, and ABB. The system features one-button start/stop, formula memory, and interlocking safety functions. An intuitive 3D visual interface makes operation simple and easy to learn.
8. Euro-Hopper Dryer:
The drying silo effectively removes moisture and volatiles from plastic granules, making it a key industrial piece of equipment in plastic pelletizing systems. It can be customized with parameters such as temperature and airflow based on the plastic type (e.g., PP, PE, PET) to ensure the stability of subsequent molding processes and the quality of the finished product.
III. Your Customized Recycling Solution
Kitech Machinery's KCP180 crushing and granulation system is a reliable and efficient foundation for modern plastic recycling and integrated plastic recycling solutions.
- Your Plastic Waste Type
- Your Target Daily Output
- Your Required Final Pellet Size
- Your Project Budget
Email: remond@kitechpm.com
Send Inquiry: www.kitechrecycle.com/contact-us
