Double Stage Cutter Compactor Pelletizing Line
The Double Stage Cutter Compactor Pelletizing Line does a lot in a single step: it crushes, compacts, plasticizes, and pelletizes. It's used in recycling plastics.
The Double Stage Cutter Compactor Pelletizing Line is dependable and efficient for re-pelletizing plastic film, raffias, filaments, bags, woven bags, and foaming materials. The final product from the Double Stage Cutter Compactor Pelletizing Line comes out as pellets, ready to go straight into production lines for blown film, tube extrusion, and injection molding. It's made up of two single-screw extruders that work well with materials like printing ink-heavy, high moisture content, less fluid, and temperature-sensitive stuff. These materials need a double filtration system, multiple exhausts, and have higher requirements, leading to a longer process.
This system is used for PE, PP, PS, ABS, XPS, EPS, PVB applications. Torontech Machinery specializes in creating, making, and selling complete waste recycling solutions. If you need a reliable plastics recycling machine manufacturer, just get in touch with us. Feel free to ask any questions or share concerns, and we'll respond as fast as possible.
FEEDING
In the standard setup, plastic scraps like film, filament, and raffias are transported into the compacting room using a belt conveyor. For scraps from rolls, there's an optional roll hauling off device for feeding. The motor drives of both the conveyor belt and hauling device work together with an ABB inverter. The feeding speed of the conveyor belt or roll hauling off is entirely automatic, adjusting based on how much space is left in the compactor’s room.Additionally, a metal detector can be integrated with the belt conveyor. It's connected to the control system, allowing it to alert and halt the system if any metal is detected in the feeding process.
CRUSHING AND COMPACTING
The compactor comes with an air exhausting device. As the rotor knife and stator knife work mechanically at the compactor's base, the temperature of both the compactor and the material gradually rises due to continuous cutting and friction. This process causes moisture and dust on the surface of the raw material to rise to the top of the compactor. The device effectively eliminates this moisture and dust, preventing the need for extra energy consumption to manage the moisture.This compactor merges pre-heating, pre-drying, and size reduction to guarantee a rapid and consistent feeding process.
INTELLIGENT CONTROL
Initiating Intelligence Start: A single button activates the set logistical sequence and material processing requirements. Interlocked system modules can be started with just "one button only."
Initiating Intelligence Stop: Similarly, a single button can shut down each related modular part in the Double Stage Cutter Compactor Pelletizing Line. Each module can be stopped with the simplicity of a single button.
Emergency Stop Function: The Double Stage Cutter Compactor Pelletizing Line is equipped with an emergency stop function to address any unforeseen risks that might occur during machine operation.
REMOTE MONITORING AND INFORMATION TRANSMISSION
The Double Stage Cutter Compactor Pelletizing Line offers both a system program for remote monitoring and a transmission system utilizing Bluetooth. These features enable the Double Stage Cutter Compactor Pelletizing Line to achieve functions related to remote monitoring and information transmission.
THE ROTATORY BLADES OF COMPACTOR
The rotating blade and fixed blade work together to cut the material into small flakes. The high-speed rotation of the blades creates friction, which heats up and preheats the flakes, causing them to shrink.
SINGLE SCREW EXTRUDER
Our specially designed single-screw extruder delicately works the materials, ensuring smooth plasticization and uniformity. Additionally, our bi-metal extruder boasts exceptional resistance to corrosion and wear, guaranteeing a longer lifespan.
BARREL
Thanks for the heads-up! Here it is: Due to its extraordinary 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 included at the end. This double-filter setup significantly enhances the quality and performance of the final product particles.
DOUBLE VACUUM DEGASSING ZONES
Having two vacuum degassing zones allows efficient removal of volatile elements like micro-molecules and moisture, significantly enhancing the quality of granules. This setup is particularly well-suited for handling heavy printed materials.
TWO SETS OF SINGLE-SCREW EXTRUDERS
This setup includes two sets of Single-Screw extruders, ideal for handling materials with heavy printing ink, high moisture content, poor fluidity, temperature sensitivity, and high impurity content. These materials require a double filtration system, multiple exhausts, and other elevated specifications, leading to a longer processing time.
LIQUID OUTLET
This process is the most suitable solution for achieving enhanced melt filtration and increased production capacity. Initially, two or more single-screw extruders can be configured for the first stage of a two-stage pelletizing production line. Subsequently, they can simultaneously feed into the second-stage extruder.
NONE-STOP PISTON TYPE FILTER
- A standard single-plate/piston double-station screen changer or a continuous double plate/piston four-station changer can be installed at the extruder's head, delivering notable filtration performance.
- Extended screen lifespan and reduced screen change frequency: The large filter areas contribute to longer filter lifetimes.
- User-friendly and continuous operation: Screen changes are swift and straightforward, allowing the machine to continue running without interruptions.
- Minimal operational expenses.
PLATE TYPE FILTER
The Plate type filter is designed in a continuous format using two filter plates. At least one filter remains operational during the screen change process. Additionally, a ring-shaped heater ensures consistent and stable heating throughout.
SELF CLEAN FILTER
This model integrates our proprietary self-cleaning filter system. The new SCF self-cleaning filtration system enables continuous recycling extrusion, making it particularly suitable for re-pelletizing highly contaminated materials. The SCF filtration system effectively manages and eliminates up to 5% contaminants in the molten flow, separating contaminants like paper, wood, aluminum, unmelted plastic, and rubbers, among others.
WATER RING PELLETIZING SYSTEM
- Self-adjusting pelletizing head ensures optimal granulate quality and prolonged uptime by maintaining consistently accurate blade pressure.
- Rotatory blade RPM adjusts automatically according to the pressure of the extruding melt.
- Swift and effortless pelletizer blade changeovers save time, requiring no additional adjustment work.
UNDER-WATER PELLETIZING SYSTEM
An exceptionally automated pelletizing system designed for materials with high Melt Flow Index (MFI) and demanding production capacities. This comprehensive system comprises a pelletizer, valve, conveying pipeline, dewatering vibrating screen, and silo.
VIBRATION DRY
- Advanced dewatering vibration sieve, combined with a horizontal-type centrifugal dewatering system, delivers highly efficient dried pellets while consuming less energy.
- The assembly of sieves involves screw installation instead of welding, enabling easy future changes to the sieves.
PLASTIC PARTICLES
The end result is plastic particles. These plastic pellets can be reused to create high-quality plastic products once again.
PACKING SYSTEM
- This area stores the final qualified granules. The drying shaker, combined with the horizontal centrifuge, achieves effective drying and consumes less energy, resulting in a well-dried product.
- It features capacity online monitoring and a quantitative weighting system for accurate measurement and control of production volumes.
ADVANTAGES
- Combines crushing, compacting, and pelletizing in a single system, reducing labor costs.
- Enables highly efficient feeding, ideal for film, filament, raffia, and foaming materials.
- Offers lower investment costs for a durable, high-quality machine.
- Demonstrates low energy consumption while delivering high production output.
- Provides overseas installation and training services.
- Includes a machine warranty with spare parts stocked and prompt delivery.
Target Recycled Material | HDPE, LDPE, PP, BOPP, CPP, OPP, PA, PC, PS, PU, ABS,PET | |||||
System composition | Belt Conveyor, Cutting Compactor, Single Screw Extruder, Filtration, Pelletizer, Water Cooling Device, Dehydration Section,Conveyor Fan, Product Silo. | |||||
Feeding Device | Belt Conveyor (Standard), Roll Hauling off device (Optional) | |||||
Material of screw | 38CrMoAlA (SACM-645), Bimetal (Optional) | |||||
Heater of barrel | Ceramic heater or Far-infrared heater | |||||
Cooling of Barrel | Air cooling of fans through blowers | |||||
Vacuum deashing exhaust | Two Double-zone vacuum degassing system (Standard) | |||||
Pelletizing type | Water-ring pelletizing/ water-strands pelletizing/ Under-water pelletizing | |||||
Technical services | project design, factory construction, installation and recommendations, commissioning | |||||
TT-ACSS-HTM series single-stage compactor-granulator machine | ||||||
Model | Compactor Volume (L) | Compactor motor | Screw diameter(mm) | L/D ratio | Power(kw) | Productivity(kg/h) |
TT-ACSS-H80/120 | 300 | 37 | 80 | 42 | 45/55 | 160-220 |
120 | 10 | 22 | ||||
TT-ACSS-H100/120 | 500 | 55 | 100 | 42 | 90/110 | 300-380 |
120 | 10 | 30 | ||||
TT-ACS-H120/150 | 800 | 90 | 120 | 42 | 132 | 450-500 |
150 | 10 | 37 | ||||
TT-ACS-H140/150 | 1000 | 110 | 140 | 42 | 160/185 | 500-650 |
150 | 10 | 45 | ||||
TT-ACS-H160/180 | 1200 | 132 | 160 | 42 | 220/250 | 800-1000 |
180 | 10 | 55 | ||||
TT-ACS-H180/200 | 1600 | 160 | 180 | 42 | 315 | 1000-1200 |
200 | 10 | 75 | ||||
HOW CAN WE HELP YOU ?
Contact our sales team for a quotation.
