Low-Cost Stable Mass Production Case of Small Recycling Plant with 125 Type Granulator
Most novices entering the plastic recycling industry prefer small granulation equipment for trial production. However, most low-cost and low-end equipment suffers from frequent operational problems after startup: rapid screw wear, uneven plasticization, excessive black spots on particles, frequent screen blockage and shutdown, and high energy consumption. These problems not only hinder stable order receiving, but also continuously consume labor and power costs, resulting in low factory profits. This real customer case shares the actual production effect, quality improvement and cost reduction achievements of a small start-up plastic recycling factory in Anhui after putting into operation the high-end 125 type granulator.
The customer is mainly engaged in the recycling and granulation of PP/PE plastic scraps, waste films and crushed flake materials from local factories, belonging to a typical small-scale refined recycling and processing model. Previously, the customer used ordinary low-end small granulators with prominent production pain points: ordinary carbon steel screws were extremely prone to wear when processing impurity-containing recycled materials and required disassembly, polishing and maintenance every month; the single heating coil caused large temperature control deviation and unstable material plasticization, resulting in uneven and low-value particles with many black spots; manual screen changing led to frequent shutdowns, intermittent production, high labor costs and low productivity, with meager overall profits.
To stabilize product quality, reduce operation and maintenance costs and realize stable mass production, the customer compared multiple models and finally selected our full set of high-end 125 type granulator production line. Relying on the equipment’s advantages of wear resistance, constant temperature and high automation, it completely solves all production shortcomings of old equipment with remarkable improvement effects after startup.
In the core extrusion production link, the high-end advantages of the nitrided screw and barrel of the 125 type granulator are fully demonstrated. When processing daily recycled scraps with trace impurities and slight oil stains, the screw has no strain or rapid wear, and carbon deposition is greatly reduced. The equipment can operate continuously under heavy load for a long time with greatly improved effective operation rate, completely eliminating frequent shutdown maintenance problems. Matched with a 225 type hard-tooth reducer, it operates silently with stable power and uniform extrusion pressure, achieving significantly improved consistency of material plasticization.
The dual-group heating system completely solves the previous problems of uneven plasticization and excessive particle defects. The 60KW electromagnetic heating achieves fast temperature rise and power saving, and the auxiliary heating coil realizes precise voltage stabilization and temperature control, ensuring uniform and stable temperature of the whole barrel, sufficient plastic melting and smooth and transparent extruded strips without scorching or raw materials. Cooperated with the 360 type electric screen changing head, the 310mm large-diameter filter screen efficiently filters impurities without frequent shutdown screen replacement, greatly enhancing production continuity and increasing daily effective production time.
The rear-end cooling, pelletizing and storage supporting equipment operates cooperatively. The 4000mm extended stainless steel water tank ensures full cooling and shaping of plastic strips. The 180 type variable frequency alloy pelletizer produces uniform particles without broken materials or burrs with greatly improved appearance. The 201 stainless steel storage bin matched with a dust removal fan ensures clean and dry finished particles without floating dust or moisture agglomeration. The finished particle quality directly reaches the mid-range market sales standard with a significant premium per ton.
The customer’s production person in charge feedback: After upgrading to the 125 type granulator, the biggest change of the factory is stability. The equipment has an extremely low failure rate and no daily disassembly and maintenance, saving obvious labor costs. The uniform and high-quality particle appearance ensures stable repeat orders from old customers and successfully connects with new purchasers with high particle quality requirements. Featuring lower energy consumption and simple maintenance, it is very suitable for refined mass production of small factories with a short equipment investment payback period. The customer plans to stabilize production capacity and gradually expand the recycling and processing scale in the later stage.
It can be seen from this landing case that for small recycling plants, start-up entrepreneurship, scrap recycling and material sample testing scenarios, the high-end 125 type granulator can fully meet the core needs of stable mass production, high-quality output and low operation and maintenance costs, becoming one of the most cost-effective main models for small-scale plastic recycling processing.
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