Industrial Plastics Shredding for Mechanical Recycling and Energy Recovery
Brazil generates 11.3 million tons of plastic waste per year (Abiplast), of which 23% is mechanically recycled. The PNRS (National Solid Waste Policy) requires reverse logistics for packaging and shared responsibility for the product life cycle. Recycled resin (PET, HDPE, PP) is worth 60-80% of virgin price.
The challenge lies in diversity: large injection-molded parts (bumpers, drums, pallets), PET bottle bales, contaminated films, extrusion purges. Two complementary lines: D Line (dual-shaft) for bulky and contaminated items, and RAPTOR (single-shaft) for dense purges with controlled particle size.
D Line vs. RAPTOR
| Criteria | D Line (dual-shaft) | RAPTOR (single-shaft) |
|---|---|---|
| Ideal material | Injection-molded parts, pressed bales, contaminated mixed plastics | Extrusion/injection purges, fused blocks, purges |
| Output | 25-75 mm strips (per blade width) | 20-120 mm (controlled by screen) |
| Advantage | High throughput for bulky items, contaminant resistance | Final particle size in a single pass |
| Capacity | 0.5-5 ton/h (per model) | Up to 30 ton/h |
Process: Mechanical Recycling
- Sorting and resin separation — Separation by type (PET, HDPE, PP, LDPE, PS, PVC) — manual or automated (optical, densimetric).
- Shredding — D Line or RAPTOR — D Line processes large parts and bales with automatic reverse and slip clutch. RAPTOR processes purges with integrated screen.
- Magnetic separation — Ferrous removal (staples, clips, baling wires). Protects extruders.
- Washing and drying — Removal of dirt, labels and contamination. Centrifugation and drying.
- Extrusion and pelletizing — Clean chips melted, filtered and transformed into recycled pellets.
End Uses by Material
| Application | Particle Size | Typical Resins |
|---|---|---|
| Recycled pellets (mechanical recycling) | 10-30 mm | PET, HDPE, PP, LDPE |
| Plastic lumber | 5-20 mm | Mixed HDPE, PP, LDPE |
| RDF (energy recovery) | 20-80 mm | Contaminated plastics, multilayer |
| Asphalt additive | 2-10 mm | LDPE, HDPE, PP |
Equipment — D Line
| Model | Power | Cutting chamber | Estimated capacity |
|---|---|---|---|
| D290 | 40 hp | 580 x 900 mm | Up to 500 kg/h |
| D365 | 75 hp | 710 x 1,025 mm | Up to 1 ton/h |
| D460 | 125 hp | 890 x 1,372 mm | Up to 2 ton/h |
| D535 | 200 hp | 1,068 x 1,610 mm | Up to 3 ton/h |
| D610 | 250 hp | 1,250 x 1,400 mm | Up to 5 ton/h |
Capacities for mixed rigid plastics. Actual capacity depends on type, density and particle size.
Equipment — RAPTOR
| Model | Power | Opening | Output size | Capacity |
|---|---|---|---|---|
| RAPTOR 2000 | 200-400 hp | 2,000 mm | 20-120 mm | Up to 20 ton/h |
| RAPTOR 3000 | 200-400 hp | 3,000 mm | 20-120 mm | Up to 30 ton/h |
Interchangeable screens. Hydraulic unit for maintenance access.
