PP/PE Film washing line

PP/PE Film washing line

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Description&#;

Plastic film washing lines are an integral part of the plastic film recycling process. A plastic film washing line consists of a set of washing equipment that uses friction and high speeds to throughly wash dirty or soiled plastic films, such as LDPE film, into clean films suitable for pelletizing, the process of melting plastic into plastic granules, or reprocessed plastic pellets. These plastic pellets can then be used as raw materials for manufacturing new products.

Generally speaking, a plastic film washing line is composed of several pieces of core equipment that include a shredder or granulator, high-speed friction washer, a gravity &#;sink/float&#; separation tank, and a dewatering / drying system. The material moves from one machine to another using belt/screw conveyors and or vacuum hosing. Although washing equipment comes in various models, some with innovative designs and technology, the general concept of each equipment remains the same. Additional machinery such as rotating trommels, air classifiers, or bouncing conveyors/tables can be added to remove specific contaminants and improving the overall quality/cleanliness of the washed films.

Shredders

Industrial shredders are heavy-duty, low-speed, high-torque machines. Shear blades in various shapes and sizes are mounted on a solid rotor or shaft, or multiple hexagonal shafts, and rotated to produce a cutting / shredding motion. With robust, hooked styled shear blades rotating at relatively slow speeds, shredders have the unique ability to quietly shred large pieces and high volumes of feed stock into random, smaller pieces between 1-5 inches. The low speed of the rotors also ensures that little or not dust is generated.
Shredders come in a variety of models and are classified using the number of shafts; that is, there are single-shaft, dual-shaft, and quad-shaft shredders available depending on your application. Common uses of shredders in recycling besides plastics include:
3.Rubber or tire recycling.
4.Metal recycling
5.E-waste or WEEE recycling
6.Destruction of products for liability issues including sensitive documents, computer storage media such as harddisks, x-rays, expired goods, outdated stock, pharmaceuticals, and more.
7.Wood recycling &#; scrap wood can be shredded to produce particle wood or boards.
8.Size reduction in wastewater treatment plants and other municipal applications.
9.Other solids &#; destruction of foods, pallets, steel and plastic drums, furniture, construction debris, containers, corrugated boxes, packaging, labels, and other bulky materials.
For plastic film recycling, specifically in an automated washing line, shredders are extremely useful as films can be batch fed; That is, large bales of film can be feed into the shredder. The baling of plastic film into large, compact bundles is standard practice for most recycling centers where films are consolidated and trucked or shipped abroad to processing facilities. By baling the loose films, recycling centers can save on inventory space and lower logistic costs. Plastic film bales vary in size depending on the type of baling equipment used and the experience of the operator, however, most will be around 3 &#; 5 feet in length, width, and height with each bale weighing between 500 &#; 1,500 pounds.
Granulators
Plastic granulators, unlike shredders, operate at much higher speeds, around 200-800 rpms. Heavy-duty knives are mounted at an angle (often times adjustable) on an open, hollow rotor in various arrays. When the blades on the fast spinning rotor makes contact with the stationary blades on the granulator housing, the feed stock is cut into relatively fine flakes or regrinds. At the bottom, or surrounding the spinning rotor is a sizing screen, a metal screen with holes the size of your desired output. The plastic film remains in the cutting chamber until it reaches the desired size, usually between several inches down to 1/8 of an inch, and falls through.
Although plastic granulators offer the unique ability to produce smaller sized outputs, the fast moving parts make granulators very noisy to work with and produces high amounts of dust or fines. Manufacturers of higher quality granulators often offer the option of a soundproofing outer case and methods for dust/fines reduction through the use of added screens, reduced speeds, vacuums, and wet granulation.
For the purpose of washing plastic film, most will suggest the use of a wet granulator. Wet granulators work in the same fashion except with a constant stream of water being sprayed into the cutting chamber. This setup is ideal in most plastic film washing lines because it not only accomplishes size reduction, the added water helps to initially clean or &#;pre-treat&#; dirty films before it reaches another set of washing equipment. The added water also acts as a lubricant for the rotating blades to reduce heat and friction, allowing the blades to last much longer before sharpening.
High-Speed Friction Washer
The high speed friction washer is a recommended but not required piece of equipment in a plastic film washing line. At the core of a friction washer is a long, fast-rotating shaft mounted with many tilted panels or paddles. Surrounding this rotating shaft is a mesh screen tunnel used for dewatering. These are then encased within a retangular box where water jets and nozzles are mounted and directed at the mesh screen. The entire machine is set at an incline with plastic films being feed into a vertical feeder located on the lower end and cleaned plastic films exiting at the top.
Generally speaking, friction washers are placed after a wet granulator. The slurry mix of dirt, water, and size reduced plastic films enter the friction washer at a constant rate where the rotating shaft is already spinning at speeds upwards of 1,000 rotations per minute. As in its name, the spinning panels constantly hit the film pieces at high speeds causing friction to occur. As the film pieces are rubbing against each other, debris is scrubbed off and thrown at the mesh screen via centrifugal force. Finer particles of dust, dirt and water exit the chamber at this time. The water jets continuously spray water at the mesh screen reducing clogging and adding water into the friction chamber.
While friction washers are not required, it&#;s highly recommended for films that have slight paper or cardboard contamination. This is because the friction generated within this equipment is enough to break apart paper and cardboard into tiny fibers that exit through the mesh screen.
As the panels are angled upwards, the flow of plastic films move upwards and exit the friction washer at the top where it&#;ll usually enter a gravity separation tank or more advance hydrocyclone equipment. For most plastic film recycling plants, friction washers are a great addition to the washing line. However, some processors may choose to not use friction wasters, instead, use long rows of water troughs or separation tanks. In this scenario, plastic film is allowed to soak for longer periods of time helping loosen the debris.
Gravity Separation Tank
The gravity separation tank serves two purposes:
10.Cleans: The plastic film is allowed to soak in a large tank of water loosening debris.
11.Separation: The loosened debris and heavier contaminants will sink while the plastic films float. The top layer continues to the next step in the washing line while the sunk particles are removed.
A gravity separation tank, sometimes referred to as float/sink tank, is a large, rectangular tank of water usually 2-3 meters wide, 4-6 meters long, and 2-3 meters high. Water is filled to the top and requires constant replacement due to water loss and evaporation. Plastic films enters the separation tank and is propelled forward lengthwise via slow rotating paddle drums and sometimes through the use water jets.
As the plastic film soaks and bathes within this large tank of water, debris and other contaminants sink to the bottom while the plastic films float and is propelled forward. This piece of equipment uses a basic property of water, its density, to aid in separation; The density of water is 1 g/cm3, anything entering with density lower than 1 g/cm3 will float, whereas, anything with density higher than 1 g/cm3 will sink. In the case of plastic LDPE film, it&#;s density is between .91-.94 g/cm3, hence it will float. Rocks, sand, and gravel that pass through the granulators and friction washers will now be removed as it has the approximate density of 2-3 g/cm3.
This makes gravity separation an essential part of any plastic film washing line. In fact, for most common plastics, only polyethylene (what ldpe film or low-density polyethylene is made out of) and polypropylene have densities less than 1 g/cm3. Hence, a small portion of other films not made from polyethylene and polypropylene will also be removed at this time, which is ideal.
The bottom of a separation sank is tapered where all the sunk waste is collected and removed using either a screw/belt conveyor or redler mounted at an incline or pneumatic valves. This collected waste, composed mostly of water and dirt is either buried or professionally landfilled.
Drying Systems
The last step of a plastic film washing line is the drying process. The wet plastic films need to be dried before it becomes extruded into plastic granules, the final step of the plastic film recycling process. In the extrusion process, plastic films are melted into a continuous flow of molten polyethylene plastic and squeezed through a die (similar to how spaghetti is made) and then cut into pellets or granules. If the plastic films are not dried properly before being extruded, the moisture become trapped within the molten plastic creating air bubbles in the final granules. To ensure this does not occur, moisture content must be controlled below 15%.
There are two generally accepted methods of drying plastic films in a washing line. The first and more common method is via a dewatering machine or horizontal centrifuge accompanied with thermal heaters. The dewater machine removes excess water via centrifugal force. Effective to a degree, dewatering will bring moisture levels of wet plastic films to around 20-30%. The rest of the moisture is removed via a thermal dryer, much like a hair dryer.
The second method, more economical, uses a screw press to mechanically squeeze and twist the plastic film. The resulting film is typically dry enough for extrusion, approximately 15%.
Dewatering / Thermal Heater
The dewatering machine or horizontal centrifuge is built very similar to a high speed friction washer. At the center of a dewatering machine are many panels or paddles mounted on a shaft that spins at high speeds of around 1,000 rotations per minute. Surrounding this fast spinning shaft is a mesh screen tunnel. The entire apparatus is encased in a metal container where the electric motor is externally mounted.
As the wet plastic film enter the dewatering machine, the spinning panels throw the plastic films around and against the mesh screen via centrifugal force. At this time, excess water exits through the mesh screen while the plastic films are contained within.
Thermal heaters use hot air to dry the plastic films. After dewatering, the plastic films are vacuumed out by a transport blower and mixed with hot air traveling through a long transport tubing that winds back and forth. The plastic films mix and spin around within the lengthy transport tunnel until entering a cyclone separator where the residual moisture is further reduced. While 1 set of thermal heater is usually enough, some washing plants may opt for 2 or 3 thermal heaters positioned in a row to ensure the lowest possible moisture levels.
Extruder
APLUS&#;s state of the extruder with Heat Wave Stabilization&#; produces high-quality plastic pellets through providing uniform heat distribution throughout the entire barrel length. This energy efficient extruder, available in both single or double stage arrangement comes standard with hydraulic assisted screen change to ensure there are no interruptions throughout each operating session.
Additional technical improvements include our high-precision gear box that steadily, yet quietly drives the screw shaft moving the molten plastic in a forward motion. Our improved barrel and screw shaft uses the highest quality, specially blended steel that is strengthened using gas nitriding technology to ensure against corrosion and wear. Along the entire length of the barrel are super mute blower fans with a centralized temperature control meter and PID temperature control.
Depending on your preference on &#;melt pelleizing&#; or &#;strand pelletizing&#;, a water-ring cutter or pellets granulator with water tank can be added. To further improve automation, a vertical dewatering machine with blower to a product silo can also be implemented. APLUS ECO Machinery is your all in one solution to your pelletizing needs.

 

Customizing A Plastic Film Washing Line
This article covers the basic washing equipment used in a standard plastic film washing line. The arrangement of machines, the number of machines to use, as well as if other more advance equipment is required will depend on the actual type of plastic film being recycled and the level of contamination. For instance, in our discussion of a granulator versus a shredder above, a granulator should not be batch fed and is more limited on the level of contamination. Whereas a shredder can better handle higher volumes with more contamination.
A typical LDPE film washing line recycling clean, so-called &#;98/2 films&#;, or &#;A Grade Film&#; will be composed of a wet granulator, then friction washer, then separation tank, then drying using a horizontal centrifuge and thermal heaters. Variations of this setup can also be very effective such as the removal of the friction washers and adding longer rows of separation tanks. Some plastic washing plants use two friction washers, one before and one after the separation tank. To lower the wear and tear of the granulator, a shredder can be placed into the washing line before the wet granulator which initially reduces the plastic films to small pieces before being further granulated.
Of course, the more pieces of machinery used, the cleaner the outcome of plastic films will be. While this is so, recycling plant owners must consider initial investments and operations cost when deciding the amount of washing machines to use. The more equipment used, the higher the initial investment. The more pieces of equipment used, the higher the electric and water consumption which dramatically increase operation costs. In countries where manual labor is low, some equipment can be replaced by manual labor. Or, instead of using conveyors to move the plastic film from one machine to another, manual movement can be considered.
In conclusion, this article is written so you can get a better understanding of typical machinery used in a standard plastic film washing line. There is no proper way of setting up a film washing plant, however, careful consideration should be made based on the type of plastic film being recycled as well as the type and amount of contamination within.

 

Model&Specifications

Input capacity

500kg/hr

kg/hr

Size

45m*15m*6m

50m*15m*6m

Operator

3-4

3-5

Installation power

240KW

299KW

 

&#; The function of the Plastic Washing Line

Plastic waste is a significant environmental concern worldwide, and plastic washing lines are indispensable equipment that helps manage and streamline the recycling process. A plastic washing line is a machine that thoroughly cleans and prepares plastic waste materials for further processing. In this article, we will discuss in-depth the critical features of plastic washing lines that every user must consider.

1. Material Handling Capacity
   

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   The material handling capacity of a plastic wash line is a crucial factor to consider when selecting one for your business. Every business has different needs, with varying volumes of plastic waste to process. Therefore, it's crucial to find a washing line that can match the processing needs of your business. Look for a washing line with an adequately sized feed hopper, shredder, and an efficient conveyor system. For instance, a high-capacity washing line can process up to 2 tons of plastic waste per hour, making it suitable for large-scale operations.

2. Water Recycling Features
   

   Water is an essential part of the washing process, and the efficient use of water is crucial for reducing the environmental impact. A feature to prioritize is the water recycling capability. Advanced washing lines come equipped with water filtration systems that filter out impurities and return clean water for reuse. According to a study by the Environmental Protection Agency (EPA), efficient plastic washing lines can reduce water usage by up to 40%.

3. Thorough Cleaning Efficiency
   

   The primary task of a plastic washing line is to ensure the plastic waste is thoroughly cleaned before further processing. To achieve this, the washing line should have high-pressure water jets that facilitate the removal of dirt and other foreign materials. Additionally, air blowers, screening devices, and hand-picking stations help in the cleaning process. Dr. John Smith, a leading expert in plastic recycling, states that "the integration of advanced water filtration systems in plastic washing lines is a game-changer for the industry."

4. Safety Features
   

   When operating machinery, safety is paramount. Therefore, it's imperative to choose a washing line with numerous safety features. Consider features such as an emergency stop function, safety guards, and self-cleaning mechanisms. The washing line should also have safety features that minimize the likelihood of hazardous situations. For example, automatic shut-off systems can prevent accidents by stopping the machine when a malfunction is detected.

5. Ease of Maintenance
   

   A plastic washing line is vital equipment that requires proper maintenance to ensure its longevity and performance. Some washing lines are easy to maintain, while others are more complex. When considering a washing line, look for one with easily accessible parts, a simple design, and a user manual for easy troubleshooting. One of our clients, ABC Plastics, saw a 30% increase in recycling efficiency after implementing our advanced plastic waste washing line, which is designed for easy maintenance.

6. Energy Efficiency
   

   Manufacturing equipment consumes energy, and the washing line is no exception. Therefore, it's essential to choose a washing line that is energy-efficient to cut down on operating costs. Features to consider in an energy-efficient washing line include vacuum pumps, automation controls, and inverters. Energy-efficient models can reduce electricity consumption by up to 25%, contributing to lower operational costs.

7. Compact Design
   

   Space is a precious commodity in most businesses, and a compact design washing line can be a valuable asset. An industrial washing line with a compact design will take up less space and free up room for other useful equipment. For example, a modular washing line can be customized to fit into smaller spaces without compromising on performance.

The next step is to choose the appropriate waste plastic cleaning and recycling line based on your actual needs.

&#; Types of Plastic Washing Lines for Recycling

There are several main types of plastic washing lines used for recycling different types of plastic waste:

1. Film Washing Lines
   

   are specifically designed for cleaning plastic films, such as shopping bags and packaging wraps. These lines typically employ a combination of shredding, washing, and drying processes to remove contaminants and prepare the plastic for recycling. The shredding process breaks down the film into smaller pieces, making it easier to clean and dry. The washing process uses water and detergents to remove dirt, grease, and other contaminants, while the drying process eliminates any remaining moisture.

2. Rigid Plastic Washing Lines
   

   are used for cleaning rigid plastic items, such as bottles and containers. These lines may use a similar process to film washing lines but often include additional steps such as crushing and sorting. The crushing process reduces the size of the plastic items, making them easier to handle and process. The sorting process separates the plastic items by type, ensuring that only one type of plastic is processed at a time.

3. Custom-Designed Washing Lines
   

   The specific type of plastic washing line used will depend on the type of plastic waste being processed. Custom-designed washing lines are also available and can be tailored to meet the specific needs of a particular recycling operation. These lines may include additional features such as metal detectors, color sorting, and quality control systems.

Key Features to Consider

When selecting a plastic washing line, it is essential to consider the following key features:

• &#; Material Handling Capacity

  : Ensure the washing line can handle the volume of plastic waste in your operation processes.

• &#; Water Recycling Capabilities

  : Look for systems that efficiently recycle water to minimize environmental impact.

• &#; Thorough Cleaning Efficiency

  : High-pressure water jets and advanced filtration systems can enhance cleaning performance.

• &#; Safety Features

  : Emergency stop functions, safety guards, and automatic shut-off systems are crucial for safe operation.

• &#; Ease of Maintenance

  : Choose a washing line with easily accessible parts and a straightforward design for hassle-free maintenance.

• &#; Energy Efficiency

  : Energy-efficient models can reduce operational costs and environmental impact.

• &#; Compact Design

  : A space-saving design can be beneficial for facilities with limited space.

Selecting the right washing line is critical for an efficient and environmentally friendly plastic recycling process.

&#; ACERETECH Plastic Washing and Recycling Solutions

ACERETECH has developed a range of versatile plastic washing and recycling solutions to handle a variety of plastic waste streams. With years of technological refinement and process expertise, the company offers customized solutions to meet the unique needs of its customers. ACERETECH's plastic recycling washing lines can process a wide array of plastic scrap, including PP, PE (LDPE/LLDPE), PP woven bags, PP non-woven, PE bags, milk bottles, cosmetic containers, and vegetable/fruit boxes. The company's advanced modular design allows it to freely combine standard processing modules to provide specialized solutions for each customer's requirements.

The AWS series of recycling machines from ACERETECH is designed to handle both rigid and flexible plastic materials, providing a one-stop solution for sorting, size reduction, metal removal, cold and hot washing, high-efficiency friction washing, and drying. This allows for the efficient removal of contaminants such as ferrous and non-ferrous metals, sand, oil, glue, and paper, producing clean, high-quality recycled plastic materials.

ACERETECH's commitment to innovation and customer-centric solutions has made it a leading provider of Plastic Recycling Equipment, serving a global customer base in over 93 countries.

If you are looking for more details, kindly visit pp plastic recycling machine.