Foam Recycling Pelletizing Machine TT-EPS
Polystyrene resin incorporates a foaming agent, and upon heating, it softens, releasing gas to create a rigid, closed-cell plastic foam structure. It finds primary use in insulating building walls and roofs, composite board insulation, preserving agricultural and fishery products in fish boxes, and maintaining temperature in cold storage, air conditioners, vehicles, ships, floor heating, as well as in decorative and carving applications. Its versatility allows for extensive usage across various industries.
EQUIPMENT PROCESS PRINCIPLE
FOAM PRE-TREATMENT EQUIPMENT
Foam board typically ranges in density from 10 to 45kg/m³. Due to its lightweight nature, two main issues arise. Firstly, transportation costs significantly increase. Secondly, lower feeding efficiency occurs during pelletizing, leading to an inability to meet capacity. Drawing from our extensive experience, we advocate pre-treating the foam beforehand. Two approaches are viable: one involves using compression for cold pressing, with a compression ratio typically set at 1:50. The other method utilizes a hot melt machine for heat treatment, melting the foam and then cooling it into a block to alter its bulk density.
SHREDDER
The blocks, whether compressed or hot-melted, have a considerable volume. To facilitate pelletizing, the material needs to be shredded into smaller pieces, typically less than 12mm in size.
FEEDING
As per the standard design, plastic scraps like film, filament, and raffias are transported into the compacting room via a belt conveyor. For managing scraps from rolls, an optional feeding method includes a roll hauling-off device. The motor drives of both the conveyor belt and hauling device are coordinated with an ABB inverter. The feeding speed of either the conveyor belt or the roll hauling-off mechanism is entirely automated, adjusting based on the compactor's room capacity. A metal detector can be integrated with the belt conveyor, operating in tandem with the control system. This setup is designed to alert and halt the system if any metal is detected within the feeding material.
DUST & MOISTURE REMOVE DEVICE
At the top of the compactor, there are exhaust holes that connect to a dust and moisture removal device. This setup is designed to collect the moisture and dust produced during the cutting and compaction processes of the foam within the compactor.
SLIDING GATE WITH SERVO MOTOR
This system is capable of processing both hard and soft materials. Utilizing a sliding gate, it regulates the material's residence time within the compactor, facilitating pre-drying and guaranteeing the entry of clean, dry material into the barrel. Any material that doesn't meet treatment standards is prevented from advancing to the next process. The PLC system precisely controls the quantity of forced feeding materials, ensuring the production capacity is maintained.
INTELLIGENT CONTROL
Intelligence Start: Activated with a single button, the interlocked system modules follow preset logistical sequences and material processing requirements, initiating the entire process.
Intelligence Stop: Similarly, each interconnected module within the ACS system can be shut down with just one button, allowing for efficient halting of related parts.
Emergency Stop: The ACS system incorporates an emergency stop function to swiftly address any unforeseen risks that may arise during machine operation.
FREQUENCY CONVERTER
To enhance operational control and safeguard the compactor's motor, we'll incorporate a frequency converter to regulate the compactor's speed.
SINGLE SCREW EXTRUDER
The plastic material advances through the rotation of the screw, completing the compaction, melting, and homogenization processes. The screw material is made of certified nitride steel (38CrMoAlA), processed using CNC technology, and treated with nitriding, providing corrosion resistance and wear resistance. The screw's specialized design enables efficient melting of polyolefin material at lower temperatures and reduced melting pressures, even when running at high speeds.
THE ROTATORY BLADES OF COMPACTOR
The rotating blades of the compactor cut incoming scraps. The high-speed rotation generates frictional heating, causing the scraps to heat and shrink just below their agglomerating point. An optionally designed guide structure compresses the material and directs it toward the extruder screw. This process crushes, dries, and compacts the material, facilitating a rapid and consistent feed directly from the compactor into the extruder.
CRUSHING AND COMPACTING
The compactor is outfitted with an air exhausting device. Through the mechanical action of the rotor knife and stator knife at the compactor's base, continuous cutting and friction gradually raise the temperature of both the compactor and the material. As this happens, moisture and dust from the raw material surface float to the top of the compactor. This device efficiently removes the moisture and dust, eliminating the need for additional energy consumption to address moisture-related issues.
BARREL
Due to its super L/D ratio, the single-stage extruder in the production line can function as a double-stage extruder. Following the middle double-piston type screen filter, an additional filter can be installed at the end. This double-filter setup enhances the quality and performance of the final product particles to meet higher standards.
2 IN 1 OPTION
This model integrates our proprietary self-cleaning filter system. The new SCF (Self-Cleaning Filtration) system enables continuous recycling extrusion, specifically tailored for re-pelletizing highly contaminated materials. The SCF filtration system efficiently manages and eliminates up to 5% contaminants within the molten flow, effectively separating contaminants like paper, wood, aluminum, unmelted plastic, rubbers, and more.
MELT FILTRATION
At the extruder's head, you can install either a regular single-plate/piston double-station screen changer or a non-stop double plate/piston four-station setup, both offering substantial filtration capabilities. The choice of filter technology greatly hinges on the quality of the input material and the intended application of the granules.
LIQUID OUTLET
For enhanced melt filtration and increased production, the most suitable approach involves using a two-stage pelletizing production line. In the initial stage, two or more single-screw extruders can be configured, followed by simultaneous entry into the second-stage extruder.
PELLETIZING
The die-face water ring pelletizing system is established as the standard granulating method in the ACSS-HTM system. It features a self-adjusting pelletizing head that ensures optimal granulate quality and prolonged uptime by maintaining consistently accurate blade pressure. The RPM (rotations per minute) of the rotary blades adjusts automatically based on the melt extrusion pressure.
VIBRATION DRY
The advanced dewatering vibration sieve, coupled with a horizontal-type centrifugal dewatering system, delivers highly efficient drying of pellets while minimizing energy consumption.
PLASTIC PARTICLES
The end product is plastic particles.
PACKING SYSTEM
The drying shaker, in conjunction with the horizontal centrifuge, achieves effective drying with reduced energy consumption.
Combining crushing, compacting, and pelletizing in a single system reduces labor costs. It offers efficient feeding, ideal for film, filament, raffia, and foaming materials.
The machine ensures lower initial investment costs without compromising quality or durability. It features low energy consumption yet yields high production output.
We offer overseas installation and training. Additionally, the machine warranty includes stocked spare parts for timely delivery.
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Machine Model
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TT-EPS
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Final Product Shape
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Particles |
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System composition
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Belt Conveyor, Air Exhausting Device, Sliding Gate, Cutting Compactor with Inverter, Single Screw Extruder, Filtration first,
Vacuum Degassing, Pelletizer, Water Cooling Device, Dehydration Section, Conveyor Fan, Product Silo. |
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Output Range
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320kg/h-2100kg/h
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Feeding Device
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Belt Conveyor (Standard), Roll Hualing off device (Optional)
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Compactor Volume
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300L-1600L
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Diameter of screw
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100mm-180mm
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Material of screw
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Bimetal |
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L/D of screw
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36/ 1
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Heater of barrel
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Ceramic heater or Far-infrared heater
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Cooling of Barrel
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Air cooling of fans through blowers
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Vacuum deashing exhaust
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Two Double-zone vacuum degassing system (Standard)
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Pelletizing type
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Water-ring pelletizing/ water-strands pelletizing/ Under-water pelletizing
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Voltage Standard
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According to the Voltage of the Customer's Location
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Optional device
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Metal detector, Roll hualing off device, Masterbatch and additives feeder
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Warranty
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13 months from the date of bill of lading
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Technical services
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project design, factory construction, installation and recommendations, commissioning
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How Can We Help You?
Contact our sales team for a quotation.
