Double Stage Cutter Compactor Recycling Pelletizing Line TT-ADS

The Double Stage Cutter Compactor Recycling Pelletizing Line TT-ADS is a specialized and dependable setup designed for recycling and re-pelletizing rigid plastic scrap. ADS Double Stage Cutter Compactor Recycling Pelletizing Line merges plasticization and pelletizing into a single step, making it perfect for processing crushed regrinds or flakes of materials like PE, PP, ABS, PS, HIPS, PC, and more.

ADS Double Stage Cutter Compactor Recycling Pelletizing Line

The end products generated by the Double Stage Cutter Compactor Recycling Pelletizing Line TT-ADS are pellets or granules. These can be seamlessly integrated into production lines for tasks like film blowing, pipe extrusion, plastic injection, and similar processes.

Features/Advantages

SCREW LOADER

Chunks or dense flakes resulting from crushing are transported into the single screw extruder using a screw loader. Inside the extruder, they undergo compression, plasticization, and the removal of volatiles and moisture through a vacuum system. Following this, the material is filtered via a filtration system before being pelletized into granules. The capacity of this process varies depending on the single screw’s diameter, typically ranging from 100kg/h to 1000kg/h. The loading motor power is 2.2 kW. The conveying pipe is constructed from stainless steel material, with an inner thickness of 2mm and a diameter of 102mm.

MAIN FEEDER (VOLUMETRIC)

The feeder directs materials into the extruder, equipped with a stirring screw to prevent blockages at the bottom. A feeding hopper, complete with a level indicator, facilitates the process. Optionally, if material compounding is desired, side feeders can be included.

GEAR BOX

ASE utilizes a high-strength hardened reducer. Because of its compact structure and small center distance, larger models of bearings cannot be accommodated in the gearbox. To mitigate the impact of additional bending motion on the bearings, it’s crucial to ensure a concentrated coupling between the motor drive and gearbox. This helps minimize any adverse effects on the lifespan of the bearings.

SINGLE SCREW EXTRUDER

Our distinctive single screw extruder delicately plasticizes and blends materials for optimal homogenization. The bi-metal extruder offers exceptional resistance to corrosion and wear, ensuring a prolonged lifespan.

BARREL

Thanks to the exceptional 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 incorporated at the end. This dual-filter setup serves as a standard to enhance the quality and performance of the final product particles.

ADS Double Stage Cutter Compactor Recycling Pelletizing Line

TWO SETS OF SINGLE-SCREW EXTRUDERS

This setup comprises two sets of single-screw extruders. It’s tailored for handling challenging materials such as printing ink with high moisture content, low fluidity, temperature sensitivity, and a high level of impurities. These materials demand a double filtration system, multiple exhaust systems, and meet other stringent requirements, resulting in a longer processing cycle.

DOUBLE VACUUM DEGASSING ZONES

Through dual vacuum degassing zones, volatile elements like micro-molecules and moisture are efficiently eliminated, enhancing the granules’ quality. This setup is particularly well-suited for processing dense printed materials.

LIQUID OUTLET

This process best suits the demand for improved melt filtration and increased production capacity. Initially, two or more single screw extruders are configured for the first stage of the pelletizing production line. Subsequently, they simultaneously feed into the second-stage extruder for further processing.

NONE-STOP PISTON TYPE FILTER

* You can install either a standard single-plate/piston double-station screen changer or a continuous non-stop double plate/piston four-station at the extruder’s head for substantial filtration performance.
* Extended screen lifespan and reduced screen change frequency: The filters last longer due to their larger filter areas.
* User-friendly and continuous operation: Effortless and rapid screen changes without halting the machine’s operation.
* Minimal operational expenses.

PLATE TYPE FILTER

The Plate type filter is designed in a continuous form, featuring two filter plates. At least one filter remains operational during screen changes. A ring-shaped heater ensures consistent and stable heating throughout the process.

SELF CLEAN FILTER

This model integrates our proprietary self-cleaning filter system. The new SCF self-cleaning filtration system enables continuous recycling extrusion, specifically ideal for re-pelletizing highly contaminated materials. The SCF filtration system can manage and eliminate up to 5% contaminants in the flowing melt, separating materials such as paper, wood, aluminum, unmelted plastic, and rubber, among others.

WATER RING PELLETIZING SYSTEM

* Self-regulating pelletizing head ensures superior granulate quality and prolonged uptime by maintaining consistent blade pressure.
* Rotatory blade RPM adjusts automatically in response to the melt extrusion pressure.
* Effortless and swift pelletizer blade changeovers, eliminating the need for adjustment, saving valuable time.

UNDER-WATER PELLETIZING SYSTEM

An extensively automated pelletizing system designed for materials with high Melt Flow Index (MFI) and demanding production capacities. This system comprises a pelletizer, valve, conveying pipeline, dewatering vibrating screen, and silo.

VIBRATION DRY

* The advanced dewatering vibration sieve, coupled with a horizontal-type centrifugal dewatering mechanism, delivers superior drying performance for pellets while consuming less energy.
* Modular sieves: Installed and secured using screws rather than welding, facilitating easy future sieve changes.

PLASTIC PARTICLES

The end product consists of plastic particles or pellets, which can be recycled to produce high-quality plastic products once more.

PACKING SYSTEM

* This area stores the final qualified granules. The drying shaker, combined with the horizontal centrifuge, ensures effective drying and reduces energy consumption.
* Continuous capacity monitoring & Quantitative weighing system in place for accurate measurement.

ADVANTAGES

* Affordable initial investment for a durable, high-quality machine.
* Efficient energy usage with substantial production output.
* Available overseas installation and training services.
* Machine warranty inclusive of stocked spare parts for prompt delivery.

Technical Specifications
Target Recycled Material
HDPE,LDPE,PP,BOPP,CPP,OPP,PA,PC,PS,PU,ABS,PET Final Product Shape: Particles
System Composition
Screw Loader, Single Screw Extruder, Filtration first, Vacuum Degassing, Pelletizer, Water Cooling Device, Dehydration Section,Conveyor Fan, Product Silo.
Feeding Device
Belt Conveyor (Standard), Roll Hualing off device (Optional)
Material of Screw
Bimetal
Heater of Barrel
Ceramic heater or Far-infrared heater
Vacuum Deashing Exhaust
Two Double-zone vacuum degassing system (Standard)
Pelletizing Type
Water-ring pelletizing/ water-strands pelletizing/ Under-water pelletizing
Optional Device
Metal detector, Roll hualing off device, Masterbatch and additives feeder
Technical Services
project design, factory construction, installation and recommendations, commissioning
Model
Screw Diameter(mm)
L/D ratio
Power(kw)
Productivity(kg/h)
TT-ADS100/120
100
32
110
260-350
120
10
30
TT-ADS120/150
120
32
132
330-420
150
10
37
TT-ADS150/180
150
32
185/200
550-650
180
10
45
TT-ADS180/200
180
32
250/315
800-1000
200
10
55

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