Film Granulation Plant Capacity Upgrade Case: Replaced with TL40120 Double Roller Shredder, Tangling Shutdowns Reduced by 90%

The waste PE film granulation industry faces widespread problems: ordinary single‑shaft shredders suffer severe long‑film shaft tangling, general dual‑shaft models have poor adaptability for soft materials, flat screens easily clog with film dust, bearings are damaged by fine dust, and manual cleaning costs remain high. These issues interrupt continuous granulation line operation, causing raw material accumulation and high operation costs. A large‑scale certified PE film granulation plant in Henan eliminated outdated single‑shaft shredders and upgraded to the TL40120 professional film double roller shredder, solving full‑process soft material pain points, reducing shutdown frequency, increasing capacity, cutting operation costs and improving granulation quality. The solution is fully replicable for small and medium film and ton bag granulation & washing factories nationwide.

1. Project Background

The Henan local compliant PE film granulation plant holds complete environmental assessment qualifications for waste plastic recycling, washing and granulation. It mainly recycles and granulates greenhouse agricultural film, industrial packaging film and bundled stretch film, with a daily incoming material volume of 12 tons of mixed soft film. The backend is equipped with an integrated closed production line of crushing – rinsing – dewatering – granulation. Before renovation, the plant adopted an old 45kW ordinary single‑shaft shredder as the front coarse crushing host, with poor structural adaptability and prominent full‑process production defects restricting output and raising operating costs:

1. Frequent tangling shutdowns: Single‑shaft unidirectional rotation causes long agricultural film and woven bags to wrap tightly around the shaft, requiring 3–4 manual disassembly and cleaning sessions per shift, each lasting 30 minutes. The effective operation rate was below 65%, leading to intermittent production.
2. High blade consumption cost: Ordinary single‑sided carbon steel blades wear and dull quickly when shredding sediment‑containing waste film, requiring frequent shutdowns for grinding and replacement, disrupting continuous granulation production rhythm.
3. Severe screen clogging: Traditional flat screens are easily covered by soft film, causing uneven particle size and unstable granulator feeding load, resulting in granule bubbles, poor appearance and low sales prices.
4. High bearing failure rate: Built‑in bearings lack dustproof protection, with fine film dust penetrating continuously, causing abrasion and jamming. Bearings need full replacement every 2 months, resulting in high maintenance time and parts costs.
5. High manual labor cost: Two workers were required for shift duty to clean tangling film, inspect equipment and unclog screens, with fixed monthly labor expenses unable to be reduced.
6. Poor line linkage: Old electric systems lack linkage signal ports, making synchronous start/stop between shredder, rinser and granulator impossible and requiring separate manual operation, reducing overall efficiency.

In September 2026, the plant upgraded its coarse crushing section, eliminating the old single‑shaft shredder and adopting the 55kW TL40120 professional film double roller shredder as the exclusive front coarse crushing host for the granulation line, optimizing the entire soft material recycling production line.

2. Customized One‑stop Production Line Renovation Solution
3. Core Shredding Host: Adopt TL40120 professional film double roller shredder, standardly equipped with DC53 four‑edge anti‑tangling cutter group, integrated Z‑type anti‑blocking screen, external independent sealed oil‑filling bearing seat and Siemens linked PLC control system. 55kW power perfectly matches the daily 12‑ton material load.
4. Front Automatic Feeding Upgrade: Install variable‑speed closed belt conveyor at the feeding end to realize automatic uniform feeding for bundled film and ton bag stacks, eliminating manual feeding and safety risks.
5. Backend Line Docking: Custom connect the discharge port to the special feeding belt of the rinsing tank, delivering qualified shredded film directly to the rinsing section for sediment removal with fully closed conveying to reduce workshop dust.
6. Particle Size Matching: Retain the original 240mm standard screen aperture, perfectly matching the optimal feeding size of the granulator without secondary screening.
7. Electric Linkage Upgrade: The PLC control cabinet reserves full‑range linkage signal ports to realize synchronous one‑key start/stop and fault linkage shutdown for shredder, rinser and granulator, avoiding idle running loss of backend equipment.
8. Measured Multi‑dimensional Efficiency Improvement & Cost Reduction Benefits
9. Tangling shutdowns reduced by 90%, capacity fully met: The dual‑roller reverse interleaved meshing structure almost eliminates large‑area film wrapping. Only minor residual soft material adheres per shift without full machine disassembly. The equipment runs continuously 24 hours with an effective operation rate above 96%, stably processing 12 tons of film daily, completely matching backend granulation capacity and eliminating raw material accumulation.
10. Sharp drop in blade and bearing maintenance costs: DC53 reversible four‑edge alloy steel blades operate stably for 22 days per side, with four‑side recycling achieving a total service life of nearly 3 months, reducing comprehensive blade costs by 72%. External multi‑layer sealed bearings completely isolate dust penetration, with no abrasion or locking failures after months of operation, eliminating frequent bearing replacement costs and cutting maintenance time by 80%.
11. No screen clogging, improved granule quality and premium profits: The Z‑type three‑dimensional screen ensures smooth material passing without film adhesion or clogging, producing uniform shredded film particles. Stable granulator feeding load eliminates granule bubbles and hollow defects, improving finished product appearance and sales premium capability.
12. Labor cost halved, fully continuous production: The new double roller shredderfeatures automatic reverse anti‑blocking and independent feeding, requiring only one worker for daily inspection and regular bearing lubrication, eliminating full‑time cleaning posts and cutting monthly labor costs by 50%. Automatic blockage removal and idle sleep modes realize unattended continuous line production.
13. Dual environmental & safety compliance, hassle‑free annual audit: Fully closed shredding cavity plus auxiliary dust removal ensures workshop dust concentration meets environmental standards. Triple safety interlock protection (door‑opening power off, overload reverse, dual motor overload protection) passes industrial safety audits, ensuring smooth annual environmental and safety production certification reviews.
14. Short payback period, expandable for future capacity increase: The new machine occupies the same floor area as old single‑shaft equipment without foundation renovation. Relying on monthly savings in labor, blade and bearing costs, the renovation investment is recovered in 8 months. The expandable electric control system supports future 18‑ton daily film processing expansion without host replacement.

    

15. Real Feedback from Factory Director

Factory director comment: «Film and ton bag granulation has long suffered three major headaches: blade tangling, screen clogging and frequent bearing replacement. Ordinary single‑shaft and general dual‑shaft machines only solve superficial problems. Upgrading to the TL professional double roller shredder completely solves industry pain points with three exclusive designs: dual‑roller anti‑tangling meshing structure, DC53 four‑side reversible cutters and Z‑type anti‑blocking screens. The full gradient power range covers small workshops (30kW) to high‑capacity production (75kW). Plug‑and‑play line connection requires no repeated debugging, delivering stable and durable long‑term mass production.»

5. Professional Model Selection Guide

Applicable Scenarios: PE/PP film recycling plants, ton bag washing & crushing lines, waste paper baling stations, paper‑plastic separation workshops, packaging waste treatment workshops.

Model Selection: 3–6 tons/day small workshops → TL3280 (30kW); 6–10 tons/day mainstream film/ton bag recycling → TL40100 (45kW); 10–15 tons/day large‑scale washing & granulation lines → TL40120 (55kW); above 15 tons/day bulk film & ton bag processing bases → TL40150 (75kW).

Contact: WhatsApp/Phone: +86 15092868822 ｜ Email: [email protected]