PG1200 Plastic Crusher Machine | 90KW Industrial Shredder for Recycling Lines

What Is the PG1200 Plastic Crusher Machine?

When processing post-industrial plastic waste at scale, the performance of your crusher determines the efficiency of your entire recycling line. The PG1200 Plastic Crusher Machine from Machinery is engineered for continuous, heavy-duty operation — delivering a processing capacity of 1,500 to 3,000 kg/h in a single compact unit. Designed to address the challenges of high-volume plastic waste recycling, this industrial-grade crusher combines robust construction, advanced technical features, and seamless integration capabilities to optimize your recycling workflow, reduce operational costs, and enhance output quality.

Plastic Crusher Machine

The PG1200 is a large-format industrial plastic shredder designed to reduce bulky plastic waste — including film, woven bags, rigid containers, and industrial scrap — into uniform flakes suitable for downstream washing, drying, and granulating processes. Unlike light-duty granulators, the PG1200 is built for inline integration within complete recycling systems, operating continuously alongside conveyors, friction washers, dust separators, and pelletizing extruders. Its heavy-duty design ensures durability even in harsh industrial environments, making it an ideal choice for mid-to-large scale recycling facilities seeking reliable, high-performance size reduction equipment.

PG1200 Key Technical Specifications

Core Technical Features

90KW Motor: High-Torque Drive for Continuous Operation

A 90KW motor is the foundation of the PG1200 high throughput. Plastic waste, especially thick-walled containers, multi-layer film, and tangled woven bags, creates highly variable load conditions. The PG1200 90KW drive sustains consistent rotor speed under peak load, ensuring uniform flake size output even when feed material composition changes mid-run. The motor is equipped with overload protection to prevent damage from sudden spikes in load, extending the service life of the crusher and minimizing downtime. This high-torque design ensures that the PG1200 can handle even the most demanding plastic waste processing tasks without compromising efficiency.

1,200mm x 900mm Feed Opening: Oversized Intake for Bulk Material

The wide 1,200 mm x 900 mm feed throat eliminates the need for pre-size reduction on most input materials. Large HDPE drums, baled film, industrial sacks, and agricultural film rolls can be fed directly without additional shearing or cutting, reducing handling steps and labor costs. For automated lines, the PG1200 pairs directly with a variable-speed belt conveyor (belt width: 1,000 mm, motor: 3KW, adjustable feed height: 2 to 2.5 m) fitted with a metal detector. The oversized feed opening also reduces the risk of jamming, ensuring smooth, uninterrupted operation and maximizing productivity.

9CrSi Blade System: Wear Resistance and Regrindability

The PG1200 uses 9CrSi (9 chromium silicon) tool steel for both its moving and fixed blades, chosen for high hardness after heat treatment (HRC 58-62), excellent wear resistance against abrasive plastics, good toughness under impact loads, and regrindability that allows blades to be resharpened 3 to 5 times before replacement, significantly reducing operating costs. The blade system is designed for easy maintenance, with quick access to blades for sharpening or replacement, minimizing downtime and ensuring consistent performance. This wear-resistant blade design makes the PG1200 suitable for processing abrasive plastic materials, such as filled PP or PET containers.

• Moving (rotor) blades: 6 pieces, 630 mm x 110 mm x 20 mm
• Fixed (stator) blades: 4 sets, 600 mm x 110 mm x 20 mm

Complete Plastic Recycling Line: 8-Stage Process

The PG1200 is the shredding backbone of an integrated recycling system. A fully configured line built around the PG1200 includes the following stages:

• Feed and Metal Detection: Variable-speed belt conveyor (1,000 mm wide, 3KW, 5,500 mm long) with automatic metal detector shutoff to protect blades from contamination damage. This stage ensures that any metal impurities are removed before entering the crusher, preventing blade wear and equipment failure.
• Primary Size Reduction: PG1200 crusher reduces bulk plastic to uniform flakes at 1,500 to 3,000 kg/h. The consistent flake size produced by the PG1200 ensures optimal performance in downstream processing steps, such as washing and granulating.
• Delamination and Fiber Separation: Dispersing friction machine (housing: 475 x 2,000 mm, 18.5KW, 10 mm spiral blades) separates multi-layer laminated films and loosens fiber contamination from flake surfaces. This step improves the purity of the plastic flakes, enhancing the quality of the final recycled product.
• Gravity Sorting: Gravity separator (350 x 800 x 1,200 mm) removes heavy contaminants such as stones and metal fragments via air-flow density differentiation. This stage further purifies the plastic flakes, ensuring that only high-quality material proceeds to the next step.
• Dust and Fines Separation: Two material-dust separators (diameter: 1,200 mm, 18.5KW + 5.5KW motors, 5 mm mesh screen) remove fine dust and lightweight impurities through pneumatic cyclone separation. This not only improves the quality of the plastic flakes but also maintains a clean working environment.
• Friction Washing (4 Stages): Four high-speed friction washers (37KW each, capacity greater than or equal to 2,000 kg/h, SUS304 stainless steel 5 mm screens) remove surface contamination, adhesive residues, and water-soluble soiling. The multi-stage washing process ensures that the plastic flakes are free from impurities, making them suitable for granulation into high-quality recycled pellets.
• Dust Collection: Two pulse-jet bag dust collectors (300 filter bags each, diameter 133 mm bags, 200 m2 filter area per unit, 30KW blower plus 1.5KW discharge motor) maintain facility air quality compliance. This system captures dust generated during the recycling process, protecting the health of workers and meeting environmental regulations.
• Automated Control: Siemens PLC, ABB variable frequency drives, Schneider contactors and relays, Siemens circuit breakers, CE-standard electrical design for the complete line. The automated control system allows for easy operation, monitoring, and adjustment of the recycling line, reducing the need for manual intervention and improving overall efficiency.

Application Scenarios

The PG1200 is specified by plastic recycling plants, municipal solid waste processing facilities, agricultural film recycling operations, industrial scrap processors working with HDPE, LDPE, PP, and PET waste streams, and pellet producers running complete wash-dry-granulate lines. Typical installation scale: single shifts processing 8,000 to 20,000 tons per year of mixed plastic waste. Its versatility makes it suitable for a wide range of plastic waste types, including post-industrial scrap, agricultural film, municipal plastic waste, and packaging waste. Whether you are operating a small recycling facility or a large-scale industrial plant, the PG1200 can be tailored to meet your specific processing needs.

Frequently Asked Questions

What types of plastic can the PG1200 process?

The PG1200 handles HDPE, LDPE, LLDPE, PP, PET, and PS in forms including film, woven fabric, rigid containers, pipes, and profiles. Material with high contamination is managed by the upstream conveyor and metal detector system. The crusher’s robust design and adjustable blade gap allow it to process both soft and rigid plastics, making it a versatile solution for various recycling applications.

How long do the 9CrSi blades last before replacement?

Under typical conditions processing agricultural or industrial film, rotor blades operate 800 to 1,500 hours before requiring resharpening. Each blade can be reground 3 to 5 times before replacement, making 9CrSi blades significantly more economical than standard alloy alternatives. The actual service life of the blades may vary depending on the type of plastic being processed and the level of contamination, but the regrindability feature ensures that blade replacement costs are kept to a minimum.

Plastic Crusher Machine

Can the PG1200 be integrated with existing recycling equipment?

Yes. The PG1200 uses standard flange connections and is compatible with conveyor, separator, and washing equipment from other manufacturers. The PLC control system can be configured to interface with existing line controllers via Modbus or Profibus protocols. This flexibility allows you to upgrade your existing recycling line with the PG1200 without the need for a complete system overhaul, saving time and investment costs.

What spare parts and after-sales support are available?

Standard spare parts kits include rotor and fixed blades (9CrSi), rotor bearings (FC309 x 4, UK309 x 4 for friction washers), and consumable screen panels. Machinery provides installation supervision, operator training, and remote technical support. Our team of experienced engineers is available to assist with any technical issues, ensuring that your PG1200 operates at peak performance at all times. We also offer regular maintenance services to extend the service life of your equipment and minimize downtime.

Full Technical Specifications Summary

For technical inquiries, customized line configurations, or project quotations, contact Machinery engineering team directly.