Automatic Scrap Recycling Systems
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- Margery Evans
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1 ASR Autmatic Scrap Recycling Restres scrap t full base material value N inventry f lwer value repelletized material Avids additinal heat histry Avids ptential cntaminatin Maintains high prduct quality System fllws extruder rate Lw perating csts and high ROI Turn Yur Scrap int Prfit The recvery f scrap generated during the prductin f blwn film, cast film, tape and extrusin cating prcesses is a key element in reducing manufacturing csts. The ASR system can recycle trim scrap and ff-spec rll scrap in-line and turn yur scrap back int prfit withut the expense f repelletizing. A cmplete ASR system cnsists f several cmpnents. A trim remval inducer will take edge trims, bleed trims r tapes in a cntinuus ribbn frm frm the extrusin line and cnvey it t an air eliminatr munted n a film scrap grinder. At the grinder, rll scrap and/r lse scrap can als be intrduced. The grinder prduces grund scrap and cnveys it t the scrap hpper f the refeed machine. The refeed machine is designed t meter the grund scrap with virgin pellet materials back int the prductin extruder at a cnsistent scrap-t-virgin rati. Fr prcesses with large amunts f startup scrap such as tape lines, the scrap can be grund and stred in a fluff surge hpper and then recycled ver the curse f the entire prductin run. PROCESS CONTROL CORPORATION Wrld Headquarters 6875 Mimms Drive, Atlanta, GA USA Ph Fax Prcess Cntrl GmbH Birstein, Germany Ph Fax
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3 Autmatic Scrap Recycling Systems Turn Yur Scrap int Prfit Recvery f scrap generated by film, tape and extrusin-cating prcesses is a key element in reducing manufacturing csts. ASR systems recycle this scrap in-line, withut the expense f repelletizing, and turn yur scrap int prfit. Benefits f an System Restres scrap t full base material value N inventry f lwer value repelletized material Avids additinal heat histry Avids ptential cntaminatin Maintains high prduct quality System fllws extruder rate Lw perating csts and high ROI Wide Range f Applicatins ASR systems have been successfully installed n thusands f blwn film, cast film, extrusin cating and tape lines wrldwide. They are designed t handle every applicatin frm standard t difficult, including: High-Speed Cast Films Stretch Wrap Silage Films Tacky Films Tapes (including riented tapes)
4 Autmatic Scrap Recycling Typical Scrap Remval System Trim Pickup Manifld Edge Trims Virgin Material IN Trim Remval Inducer Rll Scrap RMX Refeed Machine AEN Air Eliminatr Prcessing Machine RFN Rll Scrap Feeder GFC Film Scrap Grinder Dn t Re-Pelletize, Refeed Instead The ASR System invlves handling and refeeding grund film scrap directly back t the extruder. Edge trims and rll stck frm the extrusin line are size reduced fr the highest pssible bulk density. Trims are inducted by the IN Trim Remval Inducer t the GF Film Scrap Grinder lcated adjacent t the line. The grund scrap is then blwn int a surge bin r back t the extruder fr feeding. The RMX Refeed Machine has dual cmpartments that are used t meter the film scrap independently frm the virgin resin. This type f system is typically less expensive than cmbinatin pelletizing extruders and has a higher reclaim capacity n large, smth bre extruders. The system is easy t maintain with lw peratr interventin and since the film is nt re-melted, there is n additinal heat histry. Energy Savings fr Prcessing Regrind 1.75 kwh/kg fr typical re-pelletizing 900 KPH 0.20 kwh/kg fr fluff reclaim 15% scrap rate 5760 hurs 1.55 kwh 135 KPH 5760 hurs Yearly machine time f and Up t 1,205,280 kwh* and 70 tns f CO2 per year saved *Savings will vary based n material type and repelletizing prcess
5 RMX SERIES Refeed Machine Virgin Material Inlet Grund scrap access dr Variable speed drive system Grund scrap inlet Cnsistency Is The Key T Successful Thin-Gauge Scrap Recycling Inner grund scrap cmpartment Gravity-fed virgin material fllws an unbstructed path t the extruder Auger/bridgebreaker assembly prevents bridging and meters scrap t the extruder Scrap high level switch interlcks rll feeder and prevents verfilling Cnsistent Scrap-t-Virgin Rati Grund scrap and the much denser virgin material are held in separate cmpartments t prevent stratificatin. Highly cnsistent scrapt-virgin rati is maintained by metering the grund scrap and allwing the virgin material t feed by gravity. If the scrap feed is interrupted fr any reasn, the virgin material cntinues t feed, supplying the entire need f the extruder. N Extruder Surge r Starvatin As the grund scrap is metered frm the inner hpper, the weight f the surrunding virgin material and the frce f the auger cmpacts the scrap int a cnsistent clumn f densified scrap, which is then fed t the extruder screw rt. The scrap never permeates the base material, s the extruder screw bites ff a cnsistent cmbinatin f scrap and virgin with each turn. This cnsistent feed eliminates extruder surge r starvatin. Maximum Scrap Refeed Rates With this system, scrap refeed capability is limited nly by the extruder s screw design and the prduct s scrap tlerance. Due t the highly cnsistent rati and the densificatin f the scrap, the highest pssible scrap levels can be achieved. Virgin material drain Scrap Cmpactin Zne: The frce f the surrunding virgin material plus the actin f the auger cmpacts the grund scrap and maintains this cmpactin dwn t the extruder screw rt. High percentage f thrat area is available fr virgin material flw which facilitates unifrm feeding Virgin Material (base and additives) Cmpacted inner cre f grund scrap
6 GF SERIES Film Grinder High Perfrmance Grinders Prvide Maximum Refeed Rates AEN Air Eliminatr (Optinal) Prcess Cntrl grinders are specifically designed t grind thin-gauge scrap, unlike the traditinal applicatins f parts grinders fr these applicatins. This task-specific design prduces grund scrap with the highest bulk density and the best flwability - imprtant factrs fr successfully recycling thin-gauge scrap. Increase Prfits by Recycling Rlls Rll scrap generated during startups r prduct changevers can be intrduced int the grinder thrugh the additin f a Rll Feeder. The rll feeder has knurled rlls t prvide a strng pull n the film, withut wrapping. A large feed chute prvides ample space t intrduce the film while bunching it fr best pull. Adjustable rll gap and pressure allw peratin ver a wide range f thicknesses. RFN Rll Feeder (Optinal) Grinder Bdy Manual Feed Chute Cutting Chamber Cutting Chamber Design A clean, slicing actin has been prven t prduce the mst cnsistent, highest bulk density grund scrap. Fr this reasn, GF series film grinders use duble-angled knives and a steep knife apprach angle t prvide a clean, scissrs-cut slicing actin. This actin, cupled with the clse tlerance alng the entire knife length assures superir grund scrap. T maintain the grunds crap quality and prlng the life f the knives, Prcess Cntrl utilizes adjustable bed knives. This allws precise adjustment f knife clearance, even after several knife sharpenings. Fluff Blwer Cutting Chamber Interir
7 IN SERIES Trim Remval Inducer AIR FROM BLOWER Trim Remval System INLET TUBE Trim remval systems are designed t pick up and cnvey edge and/r bleed trims generated during the prductin f prducts like film, tape and fam. These cntinuus trims are remved frm the line by suctin created in the inducer s venturi sectin. The Prcess Cntrl inducer design is particularly effective fr handling tacky film. AIRFLOW VENTURI GAP INLET SETSCREW VACUUM Greater Operating Efficiency Prcess Cntrl s patented venturi design uses the same principle used t create lift with an aircraft wing. The venturi design is far mre efficient than the mre cmmnly used cyclnic design, resulting in mre suctin and far greater air flw per fan CFM. This efficiency reduces the required hrsepwer, which results in lwer energy csts, reduced nise and easier separatin f the trim frm the cnveying air at the grinder. Trim Pickup Manifld
8 Fr detailed prduct infrmatin, including specs and dimensins, please request a PCC cut sheet: PROCESS CONTROL CORPORATION HEADQUARTERS 6875 Mimms Drive Atlanta, GA 30340, USA P: F: sales@prcess-cntrl.cm Fr mre infrmatin abut the cmpany and ther PCC prducts, please visit ur website: PCC GmbH Industriestrasse Birstein, Deutschland P: (+49) F: (+49) prcess-cntrl@t-nline.de
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