20-unit Injection Workshop Renovated withTL46100 Economical Centralized Crusher , 70% Labor Reduction in Scrap Processing

Decentralized single-machine crushing in small and medium-sized clustered injection factories generally suffers from five major pain points: redundant labor, high energy consumption, excessive consumables, noise exceeding standards and recycled material contamination. Eliminating multiple small independent crushers and building a single-host TL Economical Centralized Crusher  has become a mainstream standardized cost-reduction renovation solution for medium-sized injection factories. A daily plastic product injection factory in Zhejiang completed centralized crushing upgrading, achieving all-round reduction in labor, power and consumable costs while realizing full environmental and safety compliance, providing a replicable renovation model for peer factories of the same scale.

1. Project Background

This professional daily plastic product injection factory in Zhejiang operates 20 horizontal injection molding machines, mainly producing PP and ABS washing product shells and sealing caps, involving materials with metal gaskets and high-transparency PP raw materials. Before renovation, the workshop adopted a one-machine-one-crusher mode with 20 independent small crushers, restricting profitability and compliant production due to long-term drawbacks:

1. Wasted Labor Cost: Each crusher required dedicated monitoring and material handling, causing serious labor redundancy with 3 workers working in shifts for scrap processing and high monthly labor expenses;
2. High Overall Energy Consumption: The total installed power of 20 small crushers exceeded 60kW with large decentralized operation loss and high monthly electricity bills;
3. Tedious Maintenance & Consumables: Ordinary carbon steel blades had poor wear resistance, requiring weekly machine disassembly and blade polishing for all units, resulting in heavy workload and high consumable costs;
4. Non-compliant Safety & Environmental Protection: Superimposed noise from multiple machines exceeded workshop standards; lacking complete cover-opening interlock protection, hidden safety hazards existed due to accidental startup during cleaning;
5. Low Recycled Material Utilization: Rusty iron hoppers contaminated transparent PP materials, limiting the mixing ratio of recycled materials and requiring large new material procurement.

In 2026, the workshop completed full production line upgrading, eliminated 20 small single crushers, and purchased 1 set of TL46100 (37kW Economical Centralized Crusher) to build an integrated negative-pressure central scrap recycling system.

2. Customized Centralized Crushing Renovation Solution
3. Main Crushing Host: Adopted TL46100 Economical Centralized Crusher with 37kW rated power and 660×1000mm extended crushing cavity, achieving 800–1400kg/h output capacity to fully process the daily total 4 tons of sprues and defective scraps from 20 injection machines;
4. Impurity Protection Configuration: Equipped with original strong magnetic iron removal device at the feeding port to intercept metal gaskets and iron scraps from bottle caps, protecting the scissor cutter group from hard object damage;
5. Automatic Conveying Supporting System: Fully laid negative-pressure closed suction pipelines to automatically collect and transport waste materials from 20 injection machines to the host hopper without manual handling;
6. Closed-loop Recycling Matching: Standard 12mm screen ensures uniform particle size compatible with injection mixing processes. Discharged materials are delivered to closed storage barrels and directly sent to injection barrels via negative pressure, realizing full closed-loop waste recycling.
7. Verified Cost Reduction & Efficiency Improvement Data
8. 70% Reduction in Scrap Processing Labor Cost

The original 20 small crushers required 3 shift workers for monitoring and handling; after renovation, only 1 worker is needed for daily regular inspection and screen cleaning, greatly streamlining staffing and cutting monthly scrap labor expenses by 70%.

2. 35% Reduction in Water & Power Energy Consumption

The total power of decentralized small devices exceeded 60kW, while the TL46100 Economical Centralized Crusher only consumes 37kW. Combined with energy-saving scissor cutting structure with lower operating load, monthly electricity consumption decreased by 35%. Centralized fixed-point cleaning also reduced production water loss with remarkable energy-saving effects.

3. 75% Reduction in Blade Maintenance & Consumable Costs

The high-chromium re-grindable blades of the central grinder operate stably for more than 20 days per polishing with only one simple monthly maintenance, compared with weekly batch polishing of 20 small machines. Comprehensive expenses for blade procurement, disassembly, polishing and maintenance decreased by 75%. External dust-proof bearings operate failure-free all year round without replacement.

4. Greatly Improved Plastic Raw Material Utilization

The galvanized inner hopper completely eliminates rust contamination on transparent PP materials, increasing the recycled material mixing ratio from 20% to 40% and reducing new material procurement cost by 18%. The fully closed cavity prevents dust leakage and realizes 100% fine powder recycling with zero raw material waste.

5. Dual Compliance of Workshop Safety & Environmental Protection

The single fully enclosed body with thickened shock-absorbing base eliminates superimposed multi-machine noise and meets environmental inspection standards. Dual protection of motor overload and cover-opening mechanical interlock ensures zero safety accidents since operation. Standardized workshop equipment layout greatly improves on-site production management level.

4. On-site Feedback from Workshop Supervisor

The workshop supervisor commented: “Compared with various central crushing equipment on the market, the TL series Economical Centralized Crusher accurately solves the core pain points of medium-sized injection factories. The scissor cutter group is power-saving and durable, the split body enables easy disassembly and maintenance, and the dual safety protection is comprehensive. It offers higher cost performance than heavy-duty industrial models of the same specification. One single host replaces 20 small crushers, cutting three major hidden costs of labor, electricity and consumables. For medium-sized factories with 10–30 injection machines, the TL central grinder is a fast-return upgrading choice.”

5. Replicable Model Selection Reference

This centralized crushing renovation solution is applicable to clustered factories with more than 10 injection machines, toy manufacturing industrial parks, overmolding insert injection factories and transparent daily plastic product molding factories. Standard selection: TL36 series for 8–15 machines, TL46 series for 15–30 machines, and flagship TL56 ultra-wide cavity models for large industrial parks with over 30 machines.

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