Noise Reduction and Efficiency Improvement Transformation ofTL4060 Silent Central Crusher Replacing Old Crushers in Urban Injection Molding Factory

Urban and street-side industrial park injection molding factories generally face five major pain points: strict environmental noise control, excessive roaring noise of old crushers, rust pollution of transparent raw materials, high manual crushing costs, and frequent material sticking and blockage caused by high temperature. A compliant injection molding factory in Jiangsu urban industrial park eliminated multiple old open-type side crushers and upgraded to one silent central crusher TL4060  to build a central crushing system, successfully passing the park’s annual noise environmental protection inspection, while achieving multiple benefits of labor reduction, power saving and improved recycled material quality, which can be replicated and transformed for similar urban factories.

Project Background

A precision injection molding processing factory in Jiangsu urban industrial park is adjacent to park staff dormitories and municipal roads, with strict factory noise control standards (daytime workshop noise limit ≤78dB). The factory is equipped with 24 horizontal injection molding machines, mainly producing transparent PS shells, ABS home appliance parts and PP daily chemical accessories. Before transformation, the factory was equipped with 6 old open-type water-cooled crushers, with long-term production pain points:

1. Severe noise exceeding standard: Old open-type machines have no sound insulation structure, with single-machine crushing noise above 90dB. Superimposed multi-machine roaring caused noise disturbance complaints and multiple park rectification notices, failing annual environmental inspection;
2. Frequent high-temperature material sticking and shutdown: Old simple water cooling pipelines cause ABS hard plastic melting and cutter sticking every 3 hours in summer, requiring shutdown and cavity disassembly for cleaning. The daily effective crushing time was less than 7 hours with serious waste backlog;
3. Poor recycled material quality prone to scrap: Ordinary iron hoppers produce rust chips, causing discoloration of transparent plastics. The new material mixing ratio of recycled materials was only 15%, and inferior powder could only be sold at a low price;
4. High labor and energy consumption: 6 small crushers required 2 fixed workers for operation and transportation, with a total installed power of 52kW and high scattered power consumption. Blades needed weekly disassembly and polishing with cumbersome maintenance;
5. Prominent safety hazards: Old equipment has no cover opening interlock protection, leading to accidental startup risks during manual cleaning. Dust scattered in the workshop with poor operating environment.

In 2026, the factory carried out full-scale transformation, eliminated all 6 old crushers, and purchased 1 set of TL4060 (22kW water-cooled silent model) to build a negative pressure centralized crushing system, solving noise, production capacity, safety and raw material problems in one stop.

Customized Factory Crushing Transformation Solution

1. Main silent host: Adopt silent central crusher TL4060 with 22kW high power, 600×360mm extended crushing cavity, original closed water cooling and double-layer sound insulation body. The low-speed high-torque spindle supports direct feeding of small sprues and medium-thickness ABS shells, with stable hourly output of 650-1100kg, fully digesting the factory’s daily 3.8 tons of leftover materials;
2. Fully automatic material collection support: Connect to the factory’s fully enclosed negative pressure pipeline to automatically collect waste materials from 24 injection molding machines, equipped with a standard cyclone material collection device for full dust collection without overflow;
3. Customized protection configuration: A strong magnetic iron removal device is installed at the feeding port to absorb mold iron scraps and metal inserts and protect alloy cutter groups; equipped with 12mm standard screen mesh, the discharge particle size meets injection molding recycling standards;
4. Clean recycling configuration: The whole machine is equipped with a stainless steel feeding bin to eliminate rust pollution of transparent plastics. Crushed materials are directly transported to storage tanks through negative pressure for closed-loop recycling production.

Measured Core Data of Noise Reduction and Efficiency Improvement After Commissioning

1. Noise compliance to eliminate rectification risks: With double-layer closed sound absorption body and shockproof foot pads, the load crushing noise is stably 72dB, far lower than the park’s 78dB control limit. It passed the environmental noise in-depth inspection at one time, no need for additional sound insulation rooms or noise reduction accessories, completely eliminating noise disturbance rectification and shutdown penalty risks;
2. Doubled stable production capacity without high-temperature shutdown loss: The integrated back plate water cooling realizes 24-hour uninterrupted continuous crushing, completely eliminating plastic melting, cutter sticking and cavity blockage. The daily crushing capacity increased from 3 tons to 3.8 tons, realizing daily waste digestion and zero backlog;
3. Comprehensive cost reduction in labor, energy and consumables: 6 small devices are replaced by 1 host, crushing post personnel are reduced from 2 fixed workers to 1 inspector, cutting labor costs by 50%; The 22kW host power is far lower than the original 52kW total power, and the inclined energy-saving cutter group reduces monthly electricity bills by 42%; Imported alloy blades can be used for 21 days per polishing, reducing polishing frequency by 70% and greatly cutting monthly operation and maintenance costs;
4. Improved raw material utilization and finished product quality: The stainless steel bin ensures clean and colorless transparent PS and ABS recycled materials, increasing the new material mixing ratio from 15% to 38% and reducing new plastic procurement costs by 16%; The cyclone system collects 100% fine powder for full recycling without raw material loss caused by dust leakage;
5. Standardized safe operation and improved workshop environment: Dual protection of motor overload and cover opening interlock ensures zero safety accidents during cleaning and operation since commissioning; Closed pipelines and cyclone dust collection realize dust-free workshop operation with standardized and tidy environment; The modular quick-disassembly body design allows single-person cavity cleaning and screen replacement, simplifying daily maintenance.

User Feedback from Factory Production Supervisor

Factory Supervisor Comment: Noise compliance is the top priority for crushing operations in urban injection molding factories, followed by production capacity and cost control. The silent central crusherTL4060  has far better sound insulation effect than ordinary crushers. The water cooling structure ensures non-stop operation in summer, and the stainless steel bin avoids transparent material pollution. One machine replaces six old devices, saving power and labor with zero environmental assessment risks. The TL silent series covers full power gradients from 7.5kW to 37kW, adapting to urban factories with 6-35 injection molding machines, with excellent adaptability and durability for long-term mass production.

Replicable Industry Selection Guidelines

The noise reduction and transformation solution of silent central crushers is applicable to urban industrial park injection molding factories, street-side processing factories, transparent light-colored plastic product factories, and blow molding & extrusion centralized recycling workshops. Standard selection: TL3036 for 6-10 machines, TL3542/TL4050 for 10-20 machines, TL4060/TL4080 for 20-35 large workshops, and TL5080 flagship model for cluster factories with more than 35 machines.

Contact Information

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