Plastic production equipment. registration certificates of main unitsFunction of agglomerators, arrangement and operation principle
Agglomerator is used for recycling film wastes (washing, drying, milling and agglomeration of PE wastes)
There are simple and washing agglomerators used, depending on model, for milling, washing, agglomeration, preliminary drying of secondary film wastes of polymeric materials. Sometimes they are used as dryers for drying and heating of wet raw materials.
The resultant product called agglomerate (balls of various size (3-10 mm) and color) is a semi-finished product used as a secondary raw material
Agglomerator is a batch operation device, it may be used both for complete recycling, including all the above mentioned stages and in combination with other machines for performance of one or several stages following by recycling other machines and in secondary materials recycling lines.
Agglomerator consists of body and bed, on which all units and drive electric engine are mounted. Inside the body, on the shaft of bearing mount assembly, located below, there guides with blades of various shape. There is a water feeding devices fastened on the body
Control cabinet can be located on the body or is assembled as a single unit (depends on model).
It is desirable to fasten the beds using anchor bolts. All agglomerators works from 380 V -50 HZ.
Earthing is compulsory for all models of agglomerators.
Principle of operation of agglomerator is very simple. An operator just feeds the film wastes into working chamber
(the machine must be turned on 1-2 minutes prior to the beginning of operation to make the lubricant distribute in the bearing unit
Then the material is cut following by washing (if required) (Film washing reduces the productivity of agglomerate formation but allows to receive raw materials from foul and cheap film) then it is dried by friction, heated ( more thn 100 C) and turns into homogenous paste. It is important to timely feed shocking water to the chamber for abrupt cooling of the paste. The water cools, the blade cuts, the resultant agglomerate is dried for 1 -2 min to make a ready prodcutt
AM30 Rotor washing agglomerator
The finished product called agglomerate is used in industry as a ready fraction.
The agglomerate has irregular granular shape of 3-10 mm.
This product can be ready for processing on foundry machines (any type of foundry) extrusion equipment (production of film). You can see the above at out factory and see our machines in opera-tion. Our production line operates 24 hours/days ;
Mounting
The machine must be installed on level surface.
Then it is necessary to set the belt drive from the main engine and adjust the tension of belts.
Then the cooling bath is mounted. It is mounted below butt outlet of the main unit with holes of 2-3 cm for dragging plastic paste
After that cutting device is mounted
Then the devices are connected to feeding net.
After mounting of electric equipment it is necessary to check the insulation resistance and make sure that thres no power leakage.
If theres no power leakage, than the mounting is finished successfully
It is necessary to pay special attention to earthing of the machine .
The bath is made by the User, the control panel place and operators place are determined in accordance with the layout for the specific place. Near the machine the place for grid cleaning should be stipulated.
Electric equipment is mounted by the specialists.
It is necessary to set the operation temperature required using regulators on the control panel. After setting the required operation temperature it is necessary to manually turn rotating parts of the main unit and auxiliary machines shafts.
It is necessary to make sure that the rotation of shafts and details takes place in normal mode
Then it is necessary to to unscrew the body in the end part of the machines.
To fill completely the bunker with raw materials.
Turn the main unit on
watch the movement of liquated plastic paste from the outlet. The fibers must go to the bath for cooling.fill completely the bunker with raw materials
Then turn off the main engine and mount a latticed filter on the outlet part of the machine. For each type of plastic 2-5 latticed filters should be mounted. Over the lattice the stopper is mounted and butt device body is with fiber dragging holes is attached.
Then it is necessary to use the handle of the control panel to turn the main unit. .
Then turn the machine on
Wait, till fibers of plastic paste will go out of main unit The fibers go along the cooling bath and enter the cutting device. It is necessary to guide the fibers along the bath by hand to the inlet of the cutting device.
Then the machine operates well.
The fibers should go not too slow but not too fast. If fibers are of different thickness, this means that the temperature is too low, so it is necessary to use controller on the control panel to raise it by 10-120C.
Slow movement of materials or thin fibers indicates and the lattices are crammed, so it is necessary to replace the latticed filters.
It is necessary to turn the machine off, unscrew the butt device and take out the latt
It is necessary to clean the lattices 1 time/8hours. .
In the case of normal operation of the machine the raw materials goes continuously from upper part of the bunker inside the machine, so it is necessary to continuously supply the raw materials to upper part of the bunker. .
If the raw material doesnt go from upper part of the bunker inside the machine, it is necessary to stop the machine, dismount the case and timely eliminate defects. .
Maintenance of the machine
The lubrication points of the machine should be regularly filled with lubricant. Liquid lubricants fill the machine reducer, lubricant grease is filled into the machine bearings
The machine should not be operated at low temperature of the machine.
When the machine is not in operation it is necessary to remove the remains of the mold plastics.
The maintenance of the machine is performed regularly ad properly, the operators working place should be kept clean
The condition of the machine should be controlled in every shift, it is necessary to timely tighten the fastening of the details
It is necessary to check the fastening of the ground wire
Only plastic raw materials can be fed, not other materials can be fed, otherwise premature wear will occur.
Instruments
A set of spanners, adjustable wrench, screwdriverss set, scrubs to remove the remaining plas-tics, latticed filters
Selection of cutting device
Type of device : 400. Engine power 10,5 kW. Driving belt: 160 mm.
Type of device: 500.Engine power 13-15 kW. Driving belt: 180 mm.
Blowing machine
Blowing machines usually include engine, three feeding pipes, nozzle and cooling system, bun-ker, etc.
Production process.
The raw materials fill up the bunker that it is heated up and molded into tubular sheeting, the compressor boosts inside. The film cools down and turns into finished product, and then reels into rolls.
Make ready:
Make sure that the extruder and its parts are properly mounted and fixed..
If engine, bunker, nozzle are mounted in the wrong place, it is necessary to mount them as required by production conditions
Panel board:
Toggle: heating.
Toggle: temperature control. The temperature is adjusted as required
Toggle: switches on at max. Temperature .
Toggle D: Maintenance of permanent temperature.
Temperature indicators are mounted on the panel board
Specific indication may vary, depending on recycling process of specific plastic. If the raw mate-rials are melted it is necessary to adjust heating temperature.
Material high pressure PE
In device #1 temp is 1400. In device 2 temp. is 1500. In device #3 temperature is 1550. In tween elbow temperature is 1680. Nozzle: 15000. In tween elbow temperature is 1680. Nozzle: 1500 0.
Material low pressure PE
In device #1 temp is 17000.In device 2 temp. is 1800. 0. In device #3 temperature is 18500.In twin elbow temperature is 190 0.
Nozzle: 1850.
Material: polypropylene
In device #1 temp is 18000. In device 2 temp. is 2300.0. In device #3 temperature is 230-25000. In twin elbow temperature is 2200. 0. Nozzle: 2000.
If high pressure PE is used, heating plate is not compulsory, If low pressure PE is used, heating plate must be used practically in all cases
Sequence of operations:
1. Put the plastic crumbs into initial materials bunker
2. Start the engine.
The crumb goes into the device and melts there. Using pincher, take the tubular sheeting from the nozzle by catching its top. The tubular sheeting starts to stretch.
Using pincher, take the tubular sheeting from the nozzle by catching its top. The tubular sheeting starts to stretch.
3.Turn the compressor on. Open air pump valve. Feed some amount of compressed air to the nozzle. Excess of air may result in tearing of the hose.
4. The tubular sheeting goes through the feeding box, after that the compressed air pressure can be raised. When air pressure reaches the rated one, the air valve may be closed.
5. Wait till film blowing process becomes stable, and the films thickness and width becomes regular.
6. It is necessary to control the precision of specifications of the film being blown, its width and evenness.
7. If the specifications are at variance to those require, then troubleshooting should be performed.
Bag making machine
This machine is supplied with automatic control device. Automatic temperature control and program management Tubular film size adjustment device
Bag sealing adjustable device.
Bag sealing adjustable device.<
The devise seals the bags and prints logos on them automatically.
The equipment, performing the above functions (tubular film size adjustment, bag sealing, print-ing of logos) is completely automatic. It is a single unit.
Film specification automatic control breaker serves to regulate the specifications of raw materi-als feeding to the machines inlet.
Film specification automatic control device is off, red signal lamp lights. Film rolling process can be adjusted manually by lifting of guide roller..
The guide rollers goes down, red light is on, the guide roller goes up, red light is off.
Bag production
The machine is mounted on even surface and connected to domestic power supply 220V 50Hz
From this moment the production process may begin.
First check that electric supply is connected properly. Turn of automatic switches inside distri-bution board of the machine. Raise and drop the guide film folding roller, switch the red lamp on and off.
Press start button, make sure the process goes in design mode. Make sure that all the mecha-nisms are ready for the operation
Turn on the heating device. Adjust the temperature and set it to the value required
Temp for PE is 150000. Temperature for PP is 170 0.
Put the tubular sheet under the bar of the sealing device and make control sealing
Adjust the film size as required (on the tension roll)
Adjust clearances, distance between sealing seams and strength of seams. .
If seams are not strong enough, it is necessary to adjust the temperature using controller on the con-trol panel. Control step is 5-10o . Then check the quality of bags and seams
1. The evenness of welding seams is controlled
2. The quality of logo printing is controlled
If the quality meets the requirements, all automatic devices are properly adjusted, then the bag pro-duction process can be starte
The specifications of film is entered into the system of the machine
Since that automatic feeding of the material and bag sealing begin
Maintenance
To extend the service time of the machine, it is necessary to tighten the fastenings regularly, timely lubricate the machine and control its units.
All friction parts are lubricated by oil from the grease box. Details fastening and conditions of bearing are checked every day.
Worn details should timely replaced
After work it is necessary to clean the details of the paint remains, and wipes all rolls and shafts
The printing matrices are wiped using petrol or white spirit.
If machine is idle for a long time, it is necessary to dismantle the printing rolls and replace them y the new ones.
Printing
As a rule rubber matrices are used.
Matrices can be made by hand or using press formation
Matrices are attached to the roller using adhesive fabric
First separate protective fabric from the gluing layer..
Then adhesive fabric is glued to the drum, and the matrix is stuck on it. The matrix is ready for work.After paint filling the operation may begin
Special typographic dyers for printing on bags are used. .
When new tubular film is fed into the machine, it is usually necessary to re-adjust the matrix posi-tion on the roll by reattaching it.
When printing is not required the matrix can be covered by one or several layer plaster.
To make the optimal viscosity of the paint it may be thickened or diluted.
After preparation, you may begin printing logos on the bags
It is necessary to energize from domestic power supply system and start working.
A wood board is laid under holing blade. The bag is put on the board. After holing the finished bag is put into the packing bag.
If no holes are made, it is necessary to adjust the press and normalize corresponding clearances or replace the wooden board
EPS and plastics milling device
Technique of recycling of various plastics differs mainly in operation temperature.
There various types and sizes of bathes. The bathes can be made by the Customer. The bath depth 30- 40 cm. The bath should not be too, otherwise the fibers become fragile and can break
Assembly
Main engine: 10,5 kW
Auxiliary engine: 7,5 kW.
Main engine: 10,5 kW.
Belt drive: 180 mm. 3 units.
Auxiliary engine: 7,5 kW.
Belt drive: 130 mm. 3 units.
Miller: 0,5 kW
Belt drive: 140 mm. 1 unit.
Material separation device: 10,5 kW
UP>> 135 series secondary soft plastics and PET raw materials recycling equipment Registration Certificate number _____________
Warranty no before export ____________
The equipment was manufactured in the ___th quarter of 200_____ Registration certificate « of» 135 series secondary soft plastics and PET raw materials recycling granulator -
1. DEscription
MSJ-135 secondary plastics granulator
It consists of four units
1. Preliminary raw materials shredding machine
2. ZS 65 agglomerator
3. Flakes and granules production machine
4. ZR 1000 washing separator
The set is completed by three engines, designed for 380 volts, 5 am, second grade of electric safety, 3 phases
Engine #1, 1,5 kW should be mounted in flakes and granules production machines
Engine #2, 7.5 kW should be mounted on raw materials shredder
Engine #3, 11 kW should be mounted on agglomerator plastic recycling machine
1.1. Raw materials preliminary shredding machine
The shredder is used for shredding waste and old plastic products, such as barrels, bottles, tubes, bags, films, The equipment has a lot of advantages such as good design, high productivity, long service life. Shredded films and silk balls do not wind on the rotating shaft. Sifter allows to receive crumbled plastic secondary materials of various size and shape. During shredding of the used film, bags and balls, it is possible, if mount a mixer in lower part of the machine to make simultaneous shredding and purification of the materials. This shows versatility of the machine and its suitability for further operations with raw materials (patent L98 203051.7)
Main specification :
1.2.Machine 2 ZS 65 Agglomerator Agglomerator is the machine screw drive of diameter of 135 mm
Engine power vary from 3 kW to 6 kW depending on Customer order, standard power is 5 kW, mounting of engine up to 7.5 kW is acceptable. With the engine power of 7,5 kW productivity in-creases by 15% as compared to the standard one. Engine are mounted on site. The machine is equipped by 4 heating zones by power of 11 kW. Screw is adjusted by rotation speed depending on type of recycled plastics and loading of raw materials
Temperature of various plastics in various heating zones
Functional type means that in the process of heating the 4th zone can close
Specifications:
ZS 65 agglomerator serves for soft plastics and PET recycling. If necessary, in case of usage of inhomogeneous raw materials, some heating zones can be closed. Shredded and washed plastics is loaded into the machine. The size of loaded raw materials doesnt exceed 505020 mm, prelimi-nary drying of shredded materials is desirable. The machine may be connected to degassing system, in this case recycling of raw materials with moisture content of 15% is possible.
Agglomerator yields 6-12 threads of diameter of 10 mm of the recycled materials, the length of the thred can reach 79 meters. The machine makes sterile product, available for usage in food industry, guarantees complete sterilization of the product. Avoid ingress of metal or stone to the raw materi-als
1.3. Machine #3 Flakes and granules production machine
The machine serves to produce granules and flakes of thickness of 10 mm from secondary plastics after their recycling on agglomerator
Specifications:
1.4. machine 4 ZR 1000 separator
This machine separates labels from crumbled PET flakes by vibration depending on materials in in-ner part of the compressor.
Main specifications
Compressor:#5
Productivity:1000 kg/hr.
Compressor's engine power: 550Kw.
Voltage:220V
Productivity: 1000kg/hr
2. Test report for main units and machines
Test report
No.___________________
Letter: No._______________________
Letter: Quality control, Beijing, #: ______________ Mesurements and inspection Letter: Beijing #: __________ Name: Secondary plastics granulator
Organization to be inspected: Mega Power Hong Kong Group limited
Inspection category: By Proxy inspection
Inspection and machinery quality control station, Beijing
Seal of Inspection and machinery quality control station, Beijing
Reports code number: _________________
Name of specimen Secondary granulator of plastics
Name and type ______________
Trade markMega Power
INspection categoryBy proxy inspection
Number of specimen1 pc.
Quality The product meets the requirments
Name of the company under examination Mega Power Hong Kong Group Limited
Code of specimen __________________
Registered name of the enterprise Mega Power Hong Kong Group Limited
Date of production ________________.
The specimen's condition Standard
Date of the test ____________.
Date of finishing _______________
Confirmed: _______________ Controller:_______________ Chief Inspector:_____________________
Inspection and machinery quality control station, Beijing
3.Operation instruction
3.1 Examination of equipment
.First use controllers on the control panel to set the required operation temperature. When the opera-tion temperature is set to the required value, it is necessary to turn rotating parts of the main units and shafts of the auxiliary units by hand Make sure, that rotation of shafts and details takes place in normal mode
Then unscrew the body of the holed device in the end part of the machine. Fill the bunker with raw materials completely.
Turn the main unit on
Watch the movement of melted plastic paste through the outlet holes of the device. The fibers should go to the bath to cool. Switch on the Main engine set latticed filters on outlet part of the machine. There 2-5 latticed filters for each type of plastic. The stopper is mounted over the lattices and the body of end device with fiber dragging holes is screwed up
Then it is necessary to slightly turn the main unit by turning the handle on the control panel. Then energize the machine
Wait, till fibers of plastic paste will go out of main unit The fibers go along the cooling bath and enter the cutting device. It is necessary to guide the fibers along the bath by hand to the inlet of the cutting device.
The machine operates well.
The fibers should go not too slow but not too fast. If fibers are of different thickness, this means that the temperature is too low, so it is necessary to use controller on the control panel to raise it by 10-12 C. Slow movement of materials or thin fibers indicates and the lattices are crammed, so it is necessary to replace the latticed filters
It is necessary to turn the machine off, unscrew the butt device and take out the lattices. It is neces-sary to clean the lattices 1 time/8hours
In the case of normal operation of the machine the raw materials goes continuously from upper part of the bunker inside the machine, so it is necessary to continuously supply the raw materials to up-per part of the bunker. If the raw material doesnt go from upper part of the bunker inside the machine, it is necessary to stop the machine, dismount the case and timely eliminate defects.
3.2Mounting of equipment
The machine must be installed on level surface. Then it is necessary to set the belt drive from the main engine and adjust the tension of belts. Then the cooling bath is mounted. It is mounted below butt outlet of the main unit with holes of 2-3 cm for dragging plastic paste
After that cutting device is mounted Then the devices are connected to feeding net..< /div>
.After mounting of electric equipment it is necessary to check the insulation resistance and make sure that theres no power leakage.
If theres no power leakage, than the mounting is finished successfully .
It is necessary to pay special attention to earthing of the machine
The bath is made by the User, the control panel place and operators place are determined in ac-cordance with the layout for the specific place. Near the machine the place for grid cleaning should be stipulated.
Electric equipment is mounted by the specialists.
3.3 Maintenance of the machine
.The lubrication points of the machine should be regularly filled with lubricant. Liquid lubricants fill the machine reducer, lubricant grease is filled into the machine bearings
The machine should not be operated at low temperature of the machine..
When the machine is not in operation it is necessary to remove the remains of the mold plastics.
The maintenance of the machine is performed regularly ad properly, the operators working place should be kept clean.The condition of the machine should be controlled in every shift, it is necessary to timely tighten the fastening of the details
It is necessary to check the fastening of the ground wire
Only plastic raw materials can be fed, not other materials can be fed, otherwise premature wear will occur.
3.4 Tools
A set of spanners, adjustable wrench, screwdriverss set, scrubs to remove the remaining plastics, latticed filters.
Selection of cutting devices.
.Type of device : 400. Engine power 10,5 kW. Driving belt: 160 mm.
Type of device: 500.Engine power 13-15 kW. Driving belt: 180 mm.
4. Safety
1. All the machines should be earthed
2. in operation with threads the operator must wear thermal isolation gloves
3. In operation with raw materials the operator must wear thermal isolation.
4. When working with agglomerator it is recommended to use respiratory tracts protection devices
5. It is recommended to install compulsory ventilation under agglomerators heating zone
5. Warranty
Warranty time – year since crossing the border of PR China. The warranty means as follows
1. Warranty repair a complex of operations on restoring good operation conditions and restoration of resource or workability of the whole equipment or its parts.
and restoration of resource or workability of the whole equipment or its parts.
2. Warranty maintenance provision of conformity of quality of the sold equipment to the require-ments of documents, specifications, contractual terms etc during the warranty time, non-repayable removal of faults, found by the Customer during the warranty time, replacement of the equipment in case of its breakdown, provided that Customer keeps to the operating instructions, storage and trans-portation conditions.
Warranty obligations of the manufacturer of maintenance of 135 plastic recycling line are valid during one year since the equipment crossed the border of the Customers country During the year the Seller renders services as follows
The manufacturer takes the performance of operations, described in previous section of the Con-tract, in accordance with application from the Buyer
If the case of breakage of the production line during the Warranty time, the Customer sends a written notice to the Manufacturer, describing the problems and faults
During three working days the Manufacturer must give the conclusion whether the case is the war-ranty one. If the Manufacturer refuses to admit it the warranty case, his conclusion should be grounded
.The decision of the Manufacturer may be appealed to the managing body of the Manufacturing plant.
Decision of the manufacturing plant concerning grouping of warranty cases is final and compulsory for the Manufacturer.
The Contract is considered to be performed after one year of occurrence in the Customers country, unless the latter lays claims as stipulated in the Contract
The Manufacturer has rights to give permission to use units and details, made in the Customers country when performing repair works
If the equipment got of order not by the Manufacturers fault and the Customer want to purchase spare parts from the Executor, then they should be delivered by additional contract, price and terms should be subject of negotiations
.When the details, made in the Customers country or some other country are used during repair, the Performer solves all the issues concerning compensation of expenses for their purchase.
.The cost of delivery of spare parts and units to the Customer is paid by the manufacturing plant.
The manufacturer must render services of proper quality
&The Manufacturer bears responsibility for service maintenance of the equipment but is not responsi-ble for delivery, its time, assembly, quality of products and other issues that are withing the compe-tence of the manufacturing plant .
The Customer is responsible for exploitation of the equipment in accordance with rules and regulations. If breaking of these rules and regulations caused the breakage of the equipment, the Customer bears the responsibility for
Director of service center ______________
Registration Certificate for secondary plastics and PET recycling equipment,
including degassing and soft raw materials feeding device. Series 145
Registration certificate #_____________ Pre-export warranty obligations _________________ Date of production _______________quarter of 200_________ 1 Description
1.1. Preliminary raw materials shredding machine
1.2. Agglomerator
1.3. Flakes and granules production machine
2. Mounting. Adjusting. Operations and the most important points
2.1 Mounting and adjustment
2.2 Mounting and adjustment of the rinser.
2.3. Mounting and adjustment of main unit
2.4Mounting and adjustment of granule cutting device
2.5Production
3. Check of the equipment
4. Mounting of the equipment
5. Tools
6. The problems of the secondary PET plastics recycling
7. Safety rules
8. Warranty
1. Description
YH-145 MSJ Secondary plastics granulator
It consists of three machines:
1. Preliminary raw materials shredding machines
2. Agglomerator
3. Flakes and granules production machine
1. Washing machine for preliminary shredding
The shredder is used for shredding waste and old plastic products, such as barrels, bottles, tubes, bags, films, The equipment has a lot of advantages such as good design, high productivity, long service life. Shredded films and silk balls do not wind on the rotating shaft. Sifter allows to receive crumbled plastic secondary materials of various size and shape. During shredding of the used film, bags and balls, it is possible, if mount a mixer in lower part of the machine, to make simultaneous shredding and purification of the materials. This shows versatility of the machine and its suitability for further operations with raw materials (patent L98 203051.7)
Main specifications:
Automatic shredder with washer serves to isolate any metals, stones, other solid admixtures from plastic raw materials, for shredding plastics with the blades and for washing the raw materials in swirling water. After that the raw materials go to the extruder to produce plastic crumbs Automatic shredder with washer includes electric engine, blade holder, sieves and other details..
Main functions and specifications
Note: The sieves can be replaced depending on size of raw materials.
Machine 2. Agglomerator
Agglomerator is the machine screw drive of diameter of 145 mm Standard engine power is 5 kW, mounting of engine up to 7.5 kW is acceptable. The engines on the machines are mounted on site, pulleys and belts are purchased and mounted by the Customer. The machine is equipped by 6 heating zones by power of 20 kW. Screw is adjusted by rotation speed depending on type of recycled plastics and loading of raw materials
Temperature of various plastics in various heating zones are as follows;
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