30,000-ton Annual Recycling Park Upgrades TL70200 160kW Heavy-powerful Crusher, Double Full-line Crushing Capacity

Mega integrated plastic recycling industrial parks mainly process whole thick chemical barrels, complete home appliance shells and integrated automobile bumpers. Traditional non-water-cooled high-power crushers suffer from common pain points including high-temperature blade sticking, cumbersome pre-treatment procedures, limited capacity and excessive dust emission. A 30,000-ton annual plastic recycling park in East China upgraded to Tenlong Powerful  crusher TL70200 160kW water-cooled , matched with TL70120 auxiliary machine to reconstruct the automatic production line, doubling the full-line crushing capacity and achieving full compliance in cost, environmental protection and safety, providing replicable renovation solutions for large-scale industrial parks.

 Project Background

This large-scale integrated plastic recycling park in East China has a planned annual processing capacity of 30,000 tons of waste HDPE, ABS and PP plastics, focusing on recycling and granulating large thick hollow chemical barrels, waste automobile bumpers and complete waste washing machine shells, with super-large thick and hard materials accounting for over 70% of total raw materials. In the initial operation stage, the park was equipped with 2 sets of traditional 90kW non-water-cooled large crushers, restricted by four core production bottlenecks:

1. Frequent high-temperature shutdowns: In high-temperature summer workshops, plastic melting and blade sticking occur every 1.5 hours, requiring shutdown and cavity cleaning, resulting in an effective operation rate below 55% and a daily crushing capacity of only 22 tons, far failing to meet the annual 30,000-ton output target and causing long-term raw material backlog;
2. High consumable and labor costs: Traditional ordinary alloy blades have poor wear resistance, requiring shutdown, disassembly and polishing replacement every 5 days, leading to high monthly expenditure on blade procurement, maintenance and grinding labor;
3. Redundant pre-processes: Super-large chemical barrels and complete home appliance shells require two manual cutting procedures before feeding, occupying massive front-line labor and reducing production efficiency;
4. Dual flaws in environmental protection and raw material utilization: No negative pressure dust recovery system causes fine plastic powder loss and low raw material utilization rate, while excessive workshop dust leads to risks of environmental rectification and penalties.

In 2026, the park completed core host iteration, purchasing 1 set of TL70200 160kW water-cooled claw blade top-configured crusher as the main crushing host, matched with 1 set of TL70120 water-cooled crusher to divert and process small gate and thin-shell waste materials.

Customized Production Line Renovation Solution

Based on the park’s working conditions dominated by large hard materials, mixed materials, annual non-stop production and fully automatic granulation, we customized a closed-loop crushing solution exclusively:

1. Main Line Large Material Crushing Host: TL70200 160kW water-cooled claw blade crusherwith 2040mm super-long & wide crushing cavity, 370rpm high-torque heavy-duty main shaft and original high-power closed-loop water cooling system. Complete large chemical barrels and automobile bumpers can be directly fed without cutting;
2. Small Material Diversion Balancing Unit: TL70120 75kW water-cooled modelspecially processes disassembled home appliance thin shells and injection gate fine waste to balance feeding speed and avoid overload of the top main host;
3. Full-range Environmental Protection & Protection Configuration: Both machines are equipped with feeding magnetic iron removal and negative pressure dust separation & recovery systems to intercept metal impurities and collect all plastic fine powder;
4. Closed-loop Line Connection: Uniformly fitted with 14mm standard screen mesh, the discharging particle size adapts to downstream two-stage granulation technology. The discharging port connects with heavy-duty belt elevators, directly linked with friction cleaning tanks and rinsing tanks to realize full automatic conveying from crushing to cleaning.

Measured Core Operation Benefits

1. Double Full-line Crushing Capacity

The original factory water-cooled constant temperature system completely eliminates high-temperature melting, blade sticking and shutdown failures. The equipment realizes stable 7×24-hour non-stop continuous operation. The park’s daily crushing capacity increased from 22 tons to 44 tons, fully matching the 30,000-ton annual output plan, eliminating outsourced crushing processing and saving huge external processing costs.

2. 72% Reduction in Comprehensive Consumable & Labor Costs

TL700 series SKD11 heavy-duty alloy steel blades feature high temperature and wear resistance, supporting stable continuous operation for over 25 days per polishing, with the blade replacement cycle extended 8 times compared with traditional alloy blades. The two manual pre-cutting procedures for large materials are cancelled, reducing 4 full-time operators in the crushing line. The comprehensive monthly cost of blade procurement, maintenance and labor is reduced by 72%.

3. Improved Raw Material Utilization & Stable Premium Product Quality

The negative pressure dust separation system recycles 100% of fine plastic powder for granulation with main materials, increasing the park’s comprehensive raw material utilization rate by 9%. The high-pressure oil seal structure eliminates oil pollution of crushed materials, delivering clean and uniform particles with stable finished granule quality, no market discount and improved product premium capability.

4. Minimal Maintenance & Dual Compliance in Safety and Environmental Protection

The 11.5-ton super-heavy steel body operates continuously under full load for a long time without deformation or weld cracking. Daily maintenance only requires regular bearing lubrication and screen replacement. The triple safety lock system passes first-level safety supervision standardization audit. Complete sound insulation, shock absorption and dust recovery configurations ensure smooth passing of in-depth environmental inspections with no rectification or shutdown penalties.

On-site Feedback from Park Management

The park director commented truly: “The TL70200 is currently the flagship top-spec Powerful crusher in our park, with three core advantages of super-large cavity, high torque and high-power water cooling, accurately solving the crushing pain points of super-large thick and hard plastics. Tenlong TL full series covers all power ranges from 4KW station crushers to 160kW park flagship hosts, with optional flat blades and claw blades adapting to soft and hard plastics. It supports accurate model selection for small workshops with hundreds of tons output to large parks with hundreds of thousands of tons output. The machine adopts solid materials and stable electric control, with excellent durability for high-intensity annual mass production.”

Replicable Solutions for Peer Enterprises

This automatic renovation solution is applicable to mega plastic recycling parks with an annual output of over 20,000 tons, centralized automobile plastic recycling bases, large-scale HDPE hollow barrel recycling and granulation factories, and integrated recycling enterprises for batch scrapped large home appliances. Standard selection reference: parks with daily crushing capacity of 15–25 tons choose TL70100/TL70120; large-scale fully automatic lines with daily capacity over 30 tons prefer TL70150/TL70200 high-power water-cooled flagship models.

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