recycling machine - battenfeld

Next Generation Recyclingmaschinen GmbH Gewerbepark 22, 4101 Feldkirchen, Austria Phone +43 (0) 7233 70 107-0, Fax [email protected], www.ngr.at

WE TAKE CAREOF YOUR PLASTIC WASTE

Thermoplastics ...

Virtually all thermoplastics, including PE, PP, PA, PS, PC, PET, ABS, EVA, PPS, bio-tech and materials with problematic structures (techni-cal plastics) can be gently recycled into granulate. In this regard, the control system of the A:GRAN offers mastery of difficult material recipes and processing parameters.

3 working steps in one

The text and illustrations may contain requested and special features, which are only available at extra charge. The rights relating to technical changes and printing errors are retained.

A:GRAN 65 V

65 UNIVERSALLY SUITABLE FOR …

... thermoplastics

... in any form

... granulate output of 20 - 100 kg/h (44 - 220 lbs/h)

SUITABLE FOR UNIVERSAL APPLICATIONS INGENIOUS DESIGN

PP fabric net Printed LDPE film

... in any form

• Film edge trims • All types of film waste (on rolls, loose or bundled)• Punching waste• Injection moulded parts and tubes• Start-up lumps• Fibres• Tapes• Fabrics, nonwovens• Yarns

Nonwoven

Start-up lumps

PP synthetic grass

Heavily printed LD film

RECYCLING MACHINE

On average, the industrial manu-facture of plastic products results in 2 - 20 % rejects. These can include start-up rejects, which are produced until the required product data suchas thickness, colour, shape andcharacteristics is attained, andwaste emanating from production changes or the process itself (stamping waste, sprue or edge strips from blown film).

* S:GRAN series

The A:GRAN has been designed for the inline processing of film edge trims and is equipped with a single e-drive for the cutter/feeder/extruder. The efficient cutter and fine control for differing quantities of material greatly expand the range of machine applications. Control takes place by means of two pneumatic pistons, which press the material onto the cutter. The A:GRAN is thus suitable for universal use with plastics in a diversity of forms, irrespective of whether these are simple or difficult to shred.

Two pneumatic pistons press the material against the cutter.

1. Slow-running cutting blades shred any plastic waste.

The shredded material is trans-ported to the extruder immediately by means of a feeder screw.

3. Extrusion and, if required, degassing take place in the extruder.

NGR invented and patented* the “cutter-feeder-extruder combination”, which allows three working processes to be completed in one:

This all occurs in a single operation, without leaving the machine, which is why the process bears the designation, “NGR one-step technology”.

In the case of the A:GRAN, the invention has been so adapted that all three of the main components, i.e. the cutter shaft, feeder screw and extruder are mounted on a single shaft. The ingenious details of this design have been patented.

Roller intake

Cutter/feeder/extruder combination

Operating terminal

Switchgear cubicle

Melt filter

Hot die granulation

*) Yield values for LDPE pursuant to NGR plant standard, depending on the material and its characteristics **) Standard value for transport, depending on version Basic ... short screw design without ventingInfinitely adjustable screw speed with frequency inverter in the standard versionAdditional versions on request:Speed version with increased screw speedTorque version with increased scew torque

Venting variation

Pellet yield *)

Cutter

Extruder

Dimensions

Weight **)

Hopper volumes

Cutting width

Diameter

Screw length

Motor standard

Torque

Standard

up to 100

A:GRAN 65

Thermoplastics ...

A:GRAN 65 V

... thermoplastics

... in any form

Nonwoven

Start-up lumps

PP synthetic grass

RECYCLING MACHINE

* S:GRAN series

Roller intake

Operating terminal

Switchgear cubicle

Melt filter

Hot die granulation

Venting variation

Pellet yield *)

Cutter

Extruder

Dimensions

Weight **)

Hopper volumes

Cutting width

Diameter

Screw length

Motor standard

Torque

Standard

up to 100

A:GRAN 65

Thermoplastics ...

A:GRAN 65 V

... thermoplastics

... in any form

Nonwoven

Start-up lumps

PP synthetic grass

RECYCLING MACHINE

* S:GRAN series

Roller intake

Operating terminal

Switchgear cubicle

Melt filter

Hot die granulation

Venting variation

Pellet yield *)

Cutter

Extruder

Dimensions

Weight **)

Hopper volumes

Cutting width

Diameter

Screw length

Motor standard

Torque

Standard

up to 100

A:GRAN 65

Longevity through robustnessThe A:GRAN has an especially compact and stable design, which in its simplicity saves both space and drive power. The A:GRAN is characterised by long service life even at full performance and with the processing of problematic materials such as PA fibres. In addition, slow cutter shaft speeds secure long knife life.

Designed and built for long-term profitability Robust design, high-grade materi-als and top quality manufacturing in combination with the finest possible controls and proven electronics guarantee a service life that extends far beyond the short amortisation period. It is then that NGR machines really pay off, as hundreds of operators on every continent can confirm.

AutomationThe A:GRAN machine can be fully integrated into the process used in a film production plant. This ensures safe and cost-effective inline operation. Basically, the A:GRAN is designed for continuous feeding in inline operation, but is also able to react automatically to any changes in material quantity and can therefore deliver granulate of uniform high quality. To this end, the pneumatic pistons on the cutter and the screw and granulation speeds are regulated automatically.

Simple maintenance and long operating periodsA high degree of process stability marginalises the influence of the operating personnel. Moreover, simple access to wear parts redu-ces any downtimes to a minimum.

Operator-free running Problem-free restarts after emergency stops

Uniform high granulate quality brings first class end products

Amortisation in 6-12 months! Low labour, energy and maintenance costs

Stationary knife

QUALITY MACHINE HANDLING AMORTISATION OPTIONS

Melt filter

Simple degassing with two maintenance covers

The NGR recycling process merely requires a sufficient inflow of material. Hence the fact, that in order to operate, NGR machines need just one person to handle feeding. During inline operation this material feed is preset through the production process and automated, which creates enormous personnel savings and turns interim material handling into a thing of the past.

Simultaneous processing of material in diverse forms The size and quantity of the charged material is only restricted by the funnel opening and not the process. Therefore, several differing material feeding systems can be employed simultaneously.

Following sudden plant halts (e.g. emergency stops), the system can be immediately restarted without any problem with filled funnel and extruder screw.

The unique design of the A:GRAN feed guarantees especially uniform processing and gentle material melting. This results in high material quality without any tangible loss of physical characteristics.

In addition to high quality, the consistency of the regranulate allows it to be mixed homoge-nously with original material. Therefore, NGR is an indirect guarantor for uniform end product standards and the prevention of production rejects.

Recycling systems can have a major, negative effect on polymer quality. Undesirable deviations such as changes in viscosity or granulate disco-louring may reduce both the possibilities for its utilisation and its value.

Due to their high process stability, throughput performance and low operating costs, NGR machines offer extremely short amortisation periods.

n The fact that interim material storage is no longer required and the small machine dimensions mean that valuable space can be saved in the production hall.

n NGR’s one-step technology provide energy cost savings of up to 40 %*.The shredded plastic is immediately fed to the extrusion process and is therefore “hot”. This reduces the energy requirement for material melting.

n The investment, operating and maintenance costs for a pre-shredding system are no longer required.

n The extremely short material pro-cess path facilitates quick cleaning and material switches, as well as shorter down time.

n Low personnel, compressed air, water and spare part costs.

*Depending on the material

5 Conveyor beltStable design with high sidewalls and metal detector, e-drive, process controlled. Roller intake for film Feed funnel with electrically powered intake rolls, process controlled.

Air separator feeding Film edge trims can be carried to the A:GRAN using compressed air. The air separator, which is mounted above the feed opening, separates the transport air from the edge trims.

Additive dosing deviceIn the section between the shredder and the extruder intake, additives equal to up to 20 % of the material flow can be fed in (e.g. for the improvement of flow characteristics or material colouring), process controlled.

Simple degassing (V) Vacuum degassing consists of two openings, where melt degassing takes place using a water ring vacuum pumps (drying).

Manual screen changer A lever is used to allow the alternate cleaning of two screens, which are swung out of the plastic melt.

Automatic melt filterA high-quality, two-piston melt filter represents an intelligent solution for automa-tic melt cleaning. Therefore, a piston screen change is possible without shutting down the process. Process controlled.

Backflush melt filters are recommended for badly soiled material.

GRANULATION SYSTEMS – process controlledIn the case of the A:GRAN, various process granulation systems can be utilised in line with the plastic to be processed.

Hot die granulation (HD) is generally used for the majority of polyolefins.

Strand granulation (SG) or underwater granulation (UWG) are employed for PA, PET or other polymers and PP with a high melt flow index.

Operating terminal A:GRAN 65 V

• Solids such as start-up lumps and stamping waste can be fed through an opening. The A:GRAN funnel cross-section also permits the feeding of bulky items. As an option, this material feed flap can be fitted with a transport belt, in order to allow continuous feeding. A detector provides a warning of metallic foreign objects.

The roller intake allows the processing of unwound film rolls.

The air separator serves the continuous recycling of film edge trims as production back-up. This inline operation makes material handling superfluous and fully automates the NGR recycling machine. Further-more, no material storage is required.

Granulation systems

Glass inspection window/ maintenance opening on the feeder

Start-up rejects are simply reinte-grated into the recycling process.

conveyor (transport belt), e.g. for stamping waste

Strand granulation

Hot die granulation

Air separator4

In addition, NGR also supplies the entire granulate transport equipment such as blowers, piping, cyclones, etc.

Longevity through robustness

The A:GRAN has an especially compact and stable design, which in its simplicity saves both space and drive power. The A:GRAN is characterised by long service life even at full performance and with the processing of problematic materials such as PA fibres. In addition, slow cutter shaft speeds secure long knife life.

Designed and built for long-term profitability

Robust design, high-grade materi-als and top quality manufacturing in combination with the finest possible controls and proven electronics guarantee a service life that extends far beyond the short amortisation period. It is then that NGR machines really pay off, as hundreds of operators on every continent can confirm.

AutomationThe A:GRAN machine can be fully integrated into the process used in a film production plant. This ensures safe and cost-effective inline operation. Basically, the A:GRAN is designed for continuous feeding in inline operation, but is also able to react automatically to any changes in material quantity and can therefore deliver granulate of uniform high quality. To this end, the hydraulic pistons on the cutter and the screw and granulation speeds are regulated automatically.

Stationary knife

Melt filter

Simultaneous processing of material in diverse forms

The size and quantity of the charged material is only restricted by the funnel opening and not the process. Therefore, several differing material feeding systems can be employed simultaneously.

Granulation systems

Strand granulation

Hot die granulation

Air separator4

Stationary knife

Melt filter

Granulation systems

Strand granulation

Hot die granulation

Air separator4

Stationary knife

Melt filter

Granulation systems

Strand granulation

Hot die granulation

Air separator4

Thermoplastics ... Virtually all thermoplastics, including PE, PP, PA, PS, PC, PET, ABS, EVA, PPS, bio-tech and materials with problematic structures (techni-cal plastics) can be gently recycled into granulate. In this regard, the control system of the A:GRAN offers mastery of difficult material recipes and processing parameters.

A:GRAN 65 V

... thermoplastics

... in any form

Nonwoven

Start-up lumps

PP synthetic grass

RECYCLING MACHINE

* S:GRAN series

Roller intakeCutter/feeder/extruder combinationOperating terminalSwitchgear cubicleMelt filterHot die granulation

typeventing optionoutput of pellets *)cutter

extruder

dimensions

weight **)

hopper volumecutting widthscrew diameterscrew lengthmotortorquestandardspeedABCDE

kg/hm3

mmmmL/DkWrpmrpmrpmmmmmmmmmmmt

4.0852.550

5.0003.460

up to 100

0,139065

55175197220

1.8402.1902.230

A:GRAN 65

*) output for LDPE according to NGR standards, material and form**) approx. value for transport; depending on chosen executionsstandard execution: Basic … short screw without venting variable screw speed with frequency converter optional execution: • V … simple degassing • execution ‚speed‘ for increased output • execution ‚torque‘ for increased screw torque

recycling machine - battenfeld

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