Upgrading Existing Plastic Recycling Machines

2023-08-30 | Technical Blog | By Janine Cheng |

In the previous article, we have discussed about how to improve the quality of the final pellets by handling the recycling material and monitoring the recycling process.

If you haven’t read it yet, please check it out here: Quality and Consistency of Output - Plastic Recycling - Blog

In this article, we will get deeper into how you can upgrade your existing plastic recycling machines for a better result from the aspects of the engineering and design. Let’s go through those possible issues you might encounter when recycling plastic and see what can do to avoid them.

Jammed material or insufficient input?

Consistent and stable feeding is the very first step to ensure the following procedure go smoothly. Applying an Ampere Quantitative Control Feeding System will help you detect the current load and adjust the feeding speed accordingly. This highly automated and precise system minimizes human error and maximizes productivity.

Inconsistent material properties and imperfect surface?

The screw design can greatly influence the conveying rate and the mixing efficiency. Our screw parameters, including channel depth, pitch, helix angle, and L/D ratio, have been optimized to handle your plastic material effectively, ensuring efficient and thorough mixing.

Furthermore, optimizing the heating profile based on the specific plastic characteristics is essential to achieve complete and uniform melting. This involves carefully controlling factors such as temperature and ramp-up rate to prevent issues like insufficient melting or degradation.

Table of the parameter setting for common plastics
Temperature on the barrels 190°C ~220°C 170°C ~200°C 160°C ~200°C
Preheat time 2~3 hours on average
* The temperatures vary depending on the material shape and the scale of the machine.

*The extrusion process includes degassing and filtration units. POLYSTAR provides unvented, double degassing, and triple degassing systems. Filtration options includes fan-type, slide-type, dual-piston, and third-party screen changers.

Inconsistent pellet size and shape?

Uniform plastic pellets usually come from precise and consistent pelletizing action and proper cooling. Our patented water-ring pelletizing system incorporates air pneumatic pressure control. The pressure applied to the blades and the rotational speed are adjusted based on the flow rate of the molten plastic. The consistent water-ring flow prevents deformation and variations in pellet shape or size.

Undetected operating issues?

Error alert can help operators identify and address the issues over the plastic recycling process. A user-friendly control panel should incorporate clear and visible indicators that display crucial operating conditions, such as temperature levels, screw speed, cooling rate, and potential problems.

Our standard control panel could be sufficient for you with these satisfactory functionality. However, you can still upgrade it with a PLC control system. This intelligent system incorporates a HMI surface, enabling it to perform a wide range of tasks, including data collection and analysis, online troubleshooting, parameter optimization, and more.

These automated and intelligent designs make your plastic recycling machine easier to operate and help you obtain better quality plastic pellets. Upgrade your equipment now!

Our spare part team provides full support

Remember to inspect on your machine regularly and check the condition of every element to maintain the consistent performance. If there’s a need of replacing worn-down components, please place the order here.

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About the Author
Janine Cheng

POLYSTAR Marketing Assistant

Janine creates engaging content for POLYSTAR’s social media presence, including keeping social media channels updated and brand-focused and seeking ways of connecting with plastic producers and recyclers.

You can find Janine on LinkedIn.