Agglomerators. Recycling of polyethylene film for recycling Rotary agglomerator for plastic recycling

Pollution problem environment waste becomes more and more problematic every year. Polyethylene is used everywhere. It is used for packaging products, producing pipes, machine parts and building materials. The long process of decomposition of the material threatens the harmony on the planet. Therefore, it is so important to understand what technologies exist for recycling polyethylene.

Importance of Elimination

Modern materials are not afraid of water and acids of various origins, alkali and solutions of chemical salts. For the production of products such resistance to external influences only on the hand, but she may threaten an environmental disaster.

Polyethylene waste is very dangerous. The substance is subject to thermal aging and slow decomposition under the influence of heat, sun and air. During this period, the material begins to release caustic substances that pollute wastewater and soil.

The decomposition lasts at least a century. Looking at this, environmentalists are sounding the alarm and trying to prevent a catastrophe.

It is impossible to significantly reduce the production of polyethylene products, but organizing the production process correctly is quite possible. To do this, it is necessary to create and improve methods for recycling polyethylene. The modernization process will give waste another life: it can be used as secondary raw materials.

Every year the number of organizations whose activities are related to processing hazardous waste, is growing. This is due not only to the deterioration of the atmosphere. Recycling of harmful substances is considered a profitable business sector.

From used film and polyethylene you can create raw materials for:

1. Garbage bins.
2. Panels.
3. Household and industrial containers.

Despite the emergence of new recycling technologies, the production of goods from such raw materials has limitations.

The recycling of polyethylene waste itself is not difficult. Materials used in Everyday life, remain unchanged, since their use does not last long, and their service life for industrial use is much longer.

Impact on polyethylene in such conditions has a large scale. The sun's rays and constant temperature changes have strong influence on the material. Dust that appears during operation cannot be removed. Recycled raw materials are not known for their high quality, so they are not suitable for production in any field.

Subtleties of waste recycling

The types of products that can be made from recycled products have some limitations. The first phase has minimal effects on the important properties of new products, but each new cycle reduces them. Raw materials become suitable only for the manufacture of products whose mechanical characteristics are not so important for comfortable use.

Stages of classical polyethylene waste recycling:

Selection of equipment for the process

Creating raw materials for reuse from polyethylene is impossible without professional equipment. It is similar to plastic recycling machines.

The fully equipped line includes:

• Washing machine.
• Unit for crushing material.
• Centrifuge.
• Drying unit.
• Extruder.
• Agglomerator.
• Granulator.

It is also recommended to use a conveyor or pneumatic conveyor. They automate production, simplifying the waste feeding process. The agglomerator is the main device. It is here that the main process of film processing takes place. Under the influence high temperatures waste is converted into secondary raw materials called agglomerate. On the machine it becomes a finished product. For high recycling productivity, it is necessary to use agglomerators with high power. The price of these machines is much higher than regular ones, but the quality is comparatively better.

Polyethylene granulation is the next step after grinding and agglomeration. A pellet making machine is most often included in the production line, but its use is not a requirement.

But it is worth remembering that the sale of polyethylene granules is in demand. Their production can significantly increase profits and expand the customer base.

Processing technology polyethylene film improving every year. Cross-linked polyethylene is especially popular. This is a material that has improved properties. It has a wide scope of application. It is used to produce gloves, packaging film for products, heat-shrinkable tubes and polymer pipes. The stitched material is very rigid. Its operating temperature after processing can reach up to 120 degrees.

The annual increase in waste processing volumes in the Russian Federation attracts start-up entrepreneurs into the field of solid waste processing household waste), but, as in any business, there is a risk of not making a profit or going into the red. The fact is that the process of recycling polymer waste requires significant financial investments.

The most expensive stage is the purchase of the necessary equipment - few people can afford to purchase a full-fledged waste processing line from scratch.

One of the ways to implement the site would be to start small, covering one area of ​​processing, gradually increasing capacity and expanding the types of raw materials processed.

Films account for a significant portion of waste subject to recycling. Recycling polymer film waste is quite a profitable business - the difference between raw materials and agglomerate ranges from 8 before 20 R. per kg.

One of the main types of equipment for processing film waste is an agglomerator - a device that processes film into a commercial product for further use, the following film waste:

* HDPE polyethylene low pressure,

* LDPE low pressure polyethylene,

* PP polypropylene,

* Stretch film.

AGGLOMERATOR WITH YOUR HANDS

On this moment Manufacturers offer a huge number of different options, however, their cost turns out to be unaffordable at the stage of starting a business. Of course, purchasing an already fully equipped product is a simpler solution, but we suggest paying attention to a solution that allows you to save up to 60 percent of the cost of new equipment - making it yourself.

The agglomerator consists of a frame, a bearing unit with installed tools, an electric motor, a belt tensioning device, a working body with a loading window, elements for unloading the finished material, and a control panel.

Manufacturing of bearing assembly is the most complex and labor-intensive process, which takes much more time than the manufacture of other components.

Our company offers to purchase the heart of the agglomerator - bearing units, which we install on the APR series agglomerators we produce, which have proven themselves not only in the center of Russia (more than 20 APR agglomerators “work” in Moscow and the Moscow region) but also in the vastness of Russia from Kaliningrad to Khabarovsk .

In case of independent assembly manufacturing You will need:

1. lathe
2. milling machine
3. surface grinding machine
4. cylindrical grinding machine
5. band saw
6. drilling machine
7. welding machine
8. Heating furnace

• materials and components:

1. circles st.3-20 2 , 45, 40x with a diameter of 70-300 mm
2. sheet metal st. 3-20 2 thickness 10-30 mm
3. bearings 3
4. oil seals 3
5. hardware

For manufacturing the frame and working body- "barrels":

• equipment:

1. angle grinder/mounting saw
2. drill/drilling machine
3. arc welding/semi-automatic welding

• materials and components:

1. sheet metal st. 3-20 2 2-14 mm

2. angle/profile pipe for making a frame

3. thick-walled pipe for the body, with a diameter of at least 530 3

4. motor with pulley, power of at least 22 kW 3

5. stud + nut for tensioner

6. belts 3

Of course, to make your own agglomerator, it is necessary to consult professional technologists and designers who will draw up an individual drawing that meets the requirements of GOST and ESKD. Only you will be able to control the agglomerator manufacturing process at all stages, and you will also receive a guaranteed high-quality product made according to correct and competent drawings.

Please note that it is better not to use drawings and sketches found on the Internet without consulting with specialists, of course, if you are not one yourself, because they are first of all:

• outdated
• are unrolled graduation projects
• contain errors and/or omissions

Our company guarantees high quality manufactured parts. Many years of operating experience at many of the largest enterprises in the Russian Federation and foreign countries testify to the effectiveness and profitability of using our units. The design developed by our specialists is unique and patented.

We urge you to take a responsible approach to the issue of equipment, weighing all the pros and cons, and also carefully select artists for the drawings if you decide to make an agglomerator with your own hands. The reliable and efficient operation of the future product depends only on the professionalism of all links in the production chain.

2 weldability without restrictions

3 included in the spare parts and accessories for APR 342 series agglomerators

In recycling industries plastic waste Most often you can find plastic compactors and agglomerators.

IN Lately Many processors also equip their workshops with encapsulating machines.

All these machines ideal for recycling films and bags.

A detailed description of them will help you understand these machines and choose the ideal one for your technology.

The agglomerator is a production unit for processing film polymer waste(mainly polyolefin raw materials PP, LDPE, HDPE, LLDPE), the most popular in the film recycling industry.

Types of waste subject to recycling at the agglomerator:

• film, including stretch;
• packages;
• thin soft sheets;
• polypropylene woven bags and big bags.

The ideal option is recycling similar waste, since polymers have individual softening and melting temperatures.

The presence of foreign impurities can lead to unfinished or vice versa, overheating.

Principle of operation

The agglomerator for polymer processing is round metal(less often plastic) barrel, equipped thin knives around the entire perimeter.

The knives are driven by a high-speed, powerful motor capable of providing shaft rotation of at least 1200 rpm. Electric motor and agglomerator container installed on one metal frame.

A motor equipped with a multi-channel pulley is connected via a belt drive to the rotation unit of the container itself.

The unit is equipped with a pulley of a similar design.

The agglomerator container has a loading hole on the lid and a small window for unloading finished products on the side.

Obtaining raw materials from polyethylene

A fairly simple technology allows you to get both finished product, and semi-finished products for further use. It all depends on the purity of the raw materials.

Main stages:

1. Pre-cut into sheets and washed waste loaded by operator into the agglomerator. Important point: it is necessary to determine the optimal portion of loading the machine. In the future, the operator must measure the raw materials by weighing.
2. Then the knives are set in motion, grinding the polymer to a homogeneous mass. After about 5-10 minutes, the mass begins to fuse under the influence of heating from friction. The moment of separation comes, the raw material begins to rise above the knives.
3. The time has come to serve a portion of water. This is the so-called "shock" water. It causes a sharp cooling of the mass and its disintegration into small friable particles (pellets).
4. Final stage – unloading of finished products. If the agglomerate is clean, then it is ready for further processing. If there are contaminants, it must be further cleaned by granulation on an extruder.

DIY making

Agglomerator cost industrial production relatively low, can be found a good option near 100 thousand rubles. But sometimes, especially at the start of a business, it significant expenses. Therefore, you can try to make an agglomerator for plastic with your own hands.

The following points need to be taken into account:

• It is better to choose a container made of stainless steel to avoid metal corrosion;
• the electric motor should provide an average of 1200 rpm;
• The design of the pulleys must be selected so that it combines maximum speed for sintering and minimum speed for unloading pellets;
• The most problematic part is the bearing assembly.

It cannot be made without special metalworking equipment, let alone making knives. This part It's better to trust a specialist.

Capsulator

The essence of processing waste (for example, film) in an encapsulating machine is to give it shape, convenient for loading into dosing bins extruder or injection molding machine.

The main difference from the agglomerator is the possibility of recycling several types plastic simultaneously.

Polymer waste is sintered with each other, forming a kind of granule.

The following can be processed by encapsulation:

• film waste of polyethylene and polypropylene;
• crushed (flex) bottles, vials, PET, LDPE, HDPE;
• thin leaf trimmings;
• tape waste and thread trimmings.

Before loading into the encapsulator, it is necessary to pre-grind the waste up to a size of no more than 100 microns. Residual humidity should be no more than 10%.

Main difference from agglomeration - this is what during this process no water required.

In case of contamination, it is better to re-granulate the capsules using an extruder.

This method is also good because the plastic not subject to reconstruction, but only heats up to the softening temperature.

Plastcompactor

In terms of its operating principle, the plastic compactor is identical to the capsulator. Cutters rotating on rotors at the bottom of the container cut the material and compact it. Under the influence of self-heating The force of friction softens the capsules.

The finished product is folded into several parts small pieces plastic, tight compacted.

Raw materials for processing on a plastic compactor:

• film waste (polyolefins, PVC, PET);
• scraps of woven production (bags, big bags);
• packaging waste.

The main difference between a plastic compactor and a capsulator is that there is no need to pre-grind the waste into a fine fraction. That is, no additional unit required production equipment - crushers, shredders.

The main 5 advantages of a plastic compactor over an agglomerator:

1. Relatively more low costs on energy consumption.
2. There is no water in the process, and therefore there is no additional drying stage.
3. Capsule granules have higher bulk weight, and, as a result, more convenient to use.
4. The material is not subject to thermal degradation, and therefore does not lose your valuables operational quality.
5. There is no factor of subjectivity; the quality of the product does not depend on the level of professional training of the operator.

Granulator with built-in agglomerator

Granulator (extruder), unlike previous machines, is much more equipment that is difficult to operate and set up. But the output is much more quality product in the form of a granule.

The granulate can be processed by almost any of the known methods (with the exception of rotomoulding).

During the extrusion process, it is possible not only to mold the material, giving it the commercial appearance of a granule, but also to modify it by introducing special fillers, dyes and functional additives.

By passing the raw material through a granulator with a built-in agglomerator, the polymer can be filtered using filter and grids from the smallest contaminants.

You can read more about the production of secondary granules in the article.

Technology system

The extrusion line is quite versatile. Selecting a specific screw configuration you can achieve solutions to almost any problem: from simple processing of waste into granulate to obtaining a compound with more valuable characteristics.

The productivity of the line and the quality of the material depend on the feedstock. Fine crushed material, especially film crushed material, is difficult to process. Therefore, the agglomerator built into the line greatly simplifies the task of uniform dosing raw materials.

Installation diagram:

1. Agglomerator. In terms of performance, it should match the granulator or slightly exceed it. This will help avoid downtime and unnecessary starts.
2. Material supply system. Can be implemented here belt conveyor system with high productivity or forced submission into a hopper or supply container.
3. Feeder hopper. There can be one if only polymer raw materials are processed, or several if additives are needed.
4. Granulator (extruder) is the main unit. He can be single-screw, twin-screw, single-stage or two-stage. It all depends on productivity and tasks. The granulator is equipped with an electric drive with a gearbox. The die can also be different - flat or round.
5. Pellet cutting unit. Possible installation of a strand cutter, in this embodiment, plastic in the form of strands passes through a bath of water and is cut into cylindrical granules. Air cooling possible. The knife system is installed directly on the die. Dissected round granules are transported through a system of cyclones and pneumatic transport into the finished product bunker.

There is also an underwater granulation system, which is quite expensive. The scheme is almost identical to the air one, but the granules are picked up by a stream of water and cool. Next, separation and drying of the material occurs.

The system needs peripheral equipment— a chiller or cooling tower for cooling water, a blower system for pneumatic transport.

Advantages of processing recyclable materials using a granulator:

• product presentation: granules;
• high degree of purification from contaminants;
• high bulk density, almost equal to pure polymer;
• higher price of processed products.

Useful video

We bring to your attention a video clip that shows the process of operation of the agglomerator.

Summarizing

Selection of equipment for recycling film waste depends on specific goals, as well as on the condition of the original raw materials. For example, if the manufacturer has found a constant volume of clean film or stretch, then it is enough to purchase an agglomerator or plastic compactor.

The difference in price between an encapsulator and other equipment is not significant, but here it is necessary to carefully calculate the costs. It is possible that higher start-up costs will be recouped faster due to savings on labor costs and a higher price for capsules than for agglomerate.

If you have to deal with a stream of polymer waste of different nature, then you cannot do without an encapsulator or plastic compactor. They allow you to bypass the sorting of material by polymer. If there is no marking on the container, then without the appropriate analytical equipment and experience it is difficult to work.

Read about labeling and sorting of plastic raw materials.

A universal machine is a granulator. With melt extrusion, good homogenization of dissimilar plastics can be achieved by selecting the temperature and processing conditions (screw configuration, speed, etc.). But this option is the most expensive and requires an operator with good level preparation.

In contact with

Polyethylene recycling is one of the few recycling technologies that provides a solution environmental problem waste, and can bring good profits.

The problem of polyethylene pollution on the planet is becoming more serious every year. The use of this material is so widespread that it is found in almost every field. human life. Difficulties in disposal and long decomposition times threaten our planet. To solve the problem, processing technologies and recyclable substances. This is a great way to get rid of the huge amount of garbage in landfills around major cities and building on this basis profitable production. Implementation of this method in on a global scale- a chance to defeat an environmental disaster.

Relevance of polyethylene recycling

Recycle this material not easy - the structure and composition of polyethylene provide resistance to various chemical factors, which makes it so popular. In terms of use, these qualities are exactly what you need. However, these same properties lead to the impact of waste on the environment.

Polyethylene takes about 300 years to decompose. Another dangerous factor is that when decomposed, polyethylene objects can release hazardous substances into the biosphere. chemical elements that pollute the air, soil, and groundwater. These actions add up to environmental and public health impacts.

If this material has such amazing properties and is stored for several hundred years, the question arises, why not take advantage of these qualities of the waste. Modern technology allows for recycling polyethylene waste at such a level that the material becomes suitable for use again. This is both a way to save on new materials and a solution to the problem of environmental pollution.

For the smooth and constant functioning of the processing system, it is necessary to collect raw materials and have the necessary equipment. Subsequent processing will provide waste new life as everyday household items.

The number of enterprises involved in processing polyethylene waste naturally increases every year - this is facilitated by the relevance and demand for this service. The cheapness of the starting material and the wide possibilities for producing goods for which the demand does not fall are the key advantages of such a business.

Important point. The use of products made from recycled polyethylene must be stated on the product packaging, while the quality of the recycled product is inferior to virgin polyethylene. This fact should be considered.

How does the raw material processing process take place?

Waste is processed in several successive steps:

• collection of raw materials;
• sorting;
• primary processing;
• grinding;
• centrifuge processing;
• effect of temperature;
• use of material for the production of products.

Collecting raw materials and sorting them is the beginning of the process. At this stage, waste is divided into categories that correspond to the type of raw material. Sorting can be done manually or using mechanized devices.

Sorted waste must be cleaned of contaminants and parts made of foreign material. Raw materials are cleaned in special washing machines. Some raw material collectors carry out their own this procedure, increasing its price.

Grinding of purified and prepared raw materials is carried out in special machines, using crushing. The next processing step is centrifugation. This removes moisture and impurities from the material. After grinding, heat treatment of the material follows.

The raw materials are ready for recycling and the production of items from them.

Necessary equipment for polyethylene processing

For a complete and high-quality recycling process, the following equipment is used:

• washing machine;
• waste shredding machine;
• centrifuge;
• heat treatment plant;
• agglomerator - to reduce the volume of raw materials;
• granulator;
• extruder - to form homogeneous raw materials using temperature.

Automation of the process is carried out using a conveyor - this speeds up the process and allows you to control it step by step.

Using an agglomerator is one of the ways to increase the efficiency and economy of processing. The output is a commercial product - an agglomerate.

See the video for the operating principle of the agglomerator for polyethylene processing:

Using an extruder makes it possible to obtain low-density polyethylene, which is resistant to physical and chemical factors.

Extruders are also used to process raw materials (agglomerate) into a homogeneous melt and give it a certain shape.

FILM RECYCLING IS PROFITABLE, PROMISING AND ENVIRONMENTALLY FRIENDLY!

The demand for processing polymer waste and at the same time producing new film materials is increasing from year to year. In addition to large factories, quite a lot of small ones have opened recently manufacturing enterprises who need timely recycling of used film. Huge volumes of film waste also provide shopping centers and shops of various profiles. The segment of potential consumers of the product obtained after processing (agglomerate) are companies that are in one way or another engaged in the production of films, as well as various products from non-food polymers. If you build your business on processing film waste, you will be able to work with both their suppliers and consumers of the agglomerate.

What is needed?

Processing does not require large areas and a whole staff of specialists. You can organize this work on your own, even if you have limited space. For these purposes you will need to purchase rotary agglomerator- special equipment for processing HDPE (low-density polyethylene, LDPE (polyethylene high pressure) and stretch films. Using an agglomerator, you can also process polypropylene bags and big bags, but it all depends on the modification of the equipment.

How does an agglomerator work?

This equipment is used for grinding, washing, drying and agglomerating waste. Depending on the configuration, agglomerators are single- or double-rotor. Structurally, the agglomerator consists of a frame, an electric motor, a housing and a unit with knives attached to the shaft. The operating principle is simple: film waste is loaded into the working chamber, after which it is crushed and sintered. Adding “shock” water allows this mass to cool and polymerize. The output is granules irregular shape(pellets) measuring 3-10 mm.

Depending on the performance of the equipment, it may be necessary to pre-shred the film with crushers before filling it into the chamber. This will allow the use of low-capacity agglomerators for processing. Powerful agglomerators (more than 200-250 kg/hour), as a rule, produce large granules. However, what smaller size agglomerate, the more suitable it is for use as a secondary raw material.

Where is the agglomerate used?

The resulting product can be used both as a secondary raw material for the production of films and for granulation, which also expands opportunities for business development. Film materials are in great demand today in almost all areas, so there will be no shortage of customers for agglomerate.

How much can you earn?

The cost of a budget-class industrial agglomerator ranges from 195,000-370,000 rubles. According to average calculations, the difference in price between film and agglomerate is from 10,000 rubles/t. Let's take as a basis that the profit per kilogram of raw materials is 5 rubles (this figure can be twice as much).

In an hour, a two-rotor agglomerator easily processes 200 kg of raw materials - a total of 1000 rubles. (200 kg x 5 rubles = 1000 rubles/hour). For an 8-hour shift it turns out to be 8,000 rubles. (1000 x 8).

If you work in two shifts, then this is already 16,000 rubles/day (1000 x 16).

For a month (22 working days) the profit will be 352,000 rubles. (16000 x 22).

Thus, in one month you can completely recoup the purchase of equipment and start making a profit the next month.

Spin off

• To organize work and place equipment, large areas are not required, therefore, this is a significant saving on rental costs. You can organize film processing in a warehouse or other suitable premises.
• One or two specialists can work with the agglomerator (depending on the scale of processing and the model of equipment). Special qualifications and special knowledge is also not required. Therefore, the costs for wages employees will also be insignificant.
• When purchasing a high-performance, but at the same time energy-efficient agglomerator, energy costs are also reduced.
• Other operating costs, such as maintenance and replacement of parts, also depend on the quality and reliability of the equipment. Based on this, it is advisable to buy agglomerators from leading manufacturers. Even if the payback period in this case increases, this will be compensated by the absence of regular repair costs.

Bottom line.

Organizing the processing of film materials to produce agglomerate is a stable business that does not depend on seasonality or fluctuations in demand. The demand for processing film and purchasing agglomerate for its production will only grow. Purchasing an agglomerator is a win-win investment with a quick payback and the possibility of further expansion of activities. Subsequently, it will be possible to purchase equipment of a different modification for processing a wider range of materials.