Title: Shredder Technologies for Improving Resin Reclamation Processes
1Shredder Technologies for Improving Resin
Reclamation Processes Economics
2Resin Reclamation
- Important because
- Responsible
- Ethical
- Healthy
- Creates jobs
- Saves Natural Resources
- Makes profits
3Resin Reclamation
- Since circa 1939, the Historical process
involved granulation of collected post-use or
post-manufacturing scrap - The approach was all simple .
- Does it fit
- How much can fit
- How much output
- What size output
- From there choose the unit to match your output
and size
4Industry approach till early 90s
- For about 60 years, granulators ruled the
plastics market - There were all sorts of machines, various rotor
types and chamber geometries - Purgings Hog granulators
- Film lots of knives
- Bottles lots of screen area
- Bulk scrap match machine to goals
5 Clarification
- But were not here today to discuss granulators
- Integral to ANY/ALL reclaim operations, is the
task to integrate the best SOLUTION - Utilize available technologies to develop the
total solution package for YOUR needs - Remember The solution for one client, may not
succeed with ALL clients
6Additional Technologies for Optimization
- Shears
- Guillotines
- Screeners
- Compactors
- Saws
- Shredders
7Shredders-Granulators
- Primary differences
- - Shredders low or lower speed, higher
torque - Low approx 16 and 21 RPM
- Lower approx 120 150 RPM
- - Granulators higher speed, lower torque
- 1) Shredders do not replace granulators
- 2) Shredders are NOT the answer for all
operations or applications
8Shredders
- Existed for years metals, wood, etc
- 2 primary technologies
- Multi-Shaft and Single Shaft
- Multi shaft designs date back over 60 years
- Single Shaft designs date back over 40 years
- Principle Take large/bulky, make manageable
9Typical Shred-able Plastics
- PET (Polyethylene terephthalate)
- HDPE (High-Density Polyethylene)
- PVC (Polyvinyl Chloride)
- LDPE (Low-Density Polyethylene)
- PP (Polypropylene)
- PS (Polystyrene)
- Unsorted resins and plastics.
10 3 Ways to Shred
- Tearing material to reduce it to smaller
particles depends on three actions. - Shearing This action involves the actual
cutting of material. As in scissors, shearing
efficiency depends on the sharpness of the
cutting edges working against each other and the
tolerance of the space between them. SSI has
developed technology (such as ACLS and hardened
alloys) to maintain this tolerance and sharpness,
ensuring a clean cut even after long operation. - Tearing Tearing involves pulling the material
with such force that it comes apart. Some
materials like fabric, soft metals, plastics, and
tires, are more tearable than others.
Purpose-built tearing reducers (such as SSI's
Primary Waste Reducers) are good for reducing
mixed waste where small, uniform particle size is
not important. - Fracturing Some materials are brittle, such as
glass, hard plastics, and certain metals, and
tend to be broken or shattered in a shredder when
the cutters aren't sharp or are loose. Unlike
tearing, when something breaks it releases energy
explosively, sometimes propelling the shards
upwards into the faces of the fascinated
onlookers. Always wear eye protection. - Optimum Action All three actions, shearing,
tearing, and breaking are present when a shredder
is being used. However, when the cutters are kept
sharp and the tolerances tight, the dominant and
most efficient reduction action should be
shearing.
11 Material Types
- Each type of material is best reduced by a
certain type and configuration of shredder.
Different materials have their own physical
characteristics which determine how they will
react to the reduction process - Ductile Materials Ductile materials are not
easily fractured but tend to tear into long
strips. They are best reduced by shearing to
ensure small particle size. Examples are cloth,
rubber, soft plastics, paper, cardboard, or soft
metals. - Friable Materials These are materials that are
easily fractured (the opposite of ductile) or
broken into shards. Examples are stone, glass,
cast metals, hard plastics, or wood. Shredded
friable materials tend to come out as small
pieces rather than the long strips.
12Shredders
- Single Shaft hybrid of granulator shredder
technology retains use of screen for size
classification addition of ram functionality - Multiple Shaft pre-cutter to break materials
from their original form to more manageable,
steady feed forms has option for screen
classification - Special Shredders Hybrids, IBC, Pipe, Wood
- Tire
Shredders
13Multi-Shaft Shredders
- Basic, pierce-tear technique
- Controlled breakdown of large, bulky scrap
- Well suited for certain applications
14Multi-Shaft Shredders
- Principle is same as your home/office paper
shredder, but beefed up for industrial duty - Final form is material sensitive
15Two Shaft Shredder counter-rotating cutters rip
materials into strips, with strip length
controlled by hook placement
16Two Shaft Shredder
- Better suited for non-solid mass parts
- a) Tires
- b) Extruded sheet (not stacked)
- c) Gas Tanks
- d) Baled Film
- e) 55-gallon drums
-
17Quad Shaft Shredders
- Low-speed, high-torque, four-shaft shredder.
Especially suited for applications such as
electronic scrap, tire shredding,alternative fuel
production, and reduction of contaminated
materials where uniform, small to medium particle
size is desired.
18 Options for Multi-Shaft Shredders
- Ram feeding assist
- Screens for classification / control
19Single Shaft Shredders
20Single Shaft Shredders
21Single Shaft Shredder
- Ram fed (typically) to aid/speed in the feeding
of material volume - Best Suited for larger, solid mass products
- Baled film
- Large Purgings
- Carpet bales
- Bowling Balls
- Baled bottles
22Single Shaft Rotor
- Cutter action breaks large masses to smaller,
more manageable pieces
23 Single Shaft Design
- Many different rotor diameters and cutter
quantities - Special configurations for special applications
24Single Shaft Design
25Integrated Systems
- Integrated systems utilize several technologies
to achieve the final goal - Benefits
- a) Lower power consumption
- b) Breakdown exposes contaminants
- c) More versatility
- d) Less risk to total down-time
- (2) Types of Integrated Systems
- - Sequential
- - Stacked
26Sequential System
- By utilizing sequential size reduction, the
material is processed in first stage, extracted,
then transferred to second stage (or third as
needed) for final processing in this fashion,
no one device takes the full brunt/impact,
reducing strain, stress, heat generation, and
material degradation - Benefits Drawbacks
- Metal detection More area needed
- Added versatility More equip needed
27Sequential System
28Stacked System
- A stacked system places a granulator beneath the
shredder allowing material to pass from one stage
to the next via gravity - Benefits Drawback -
- a) space saving a) no metal
detection - after shredder
- b) allows sound suppression b) less
versatile
29Single Shaft Granulator Stack
30Integrated Solutions Summary
- Either Shredder Technology can be integrated into
final system based on needs - Either Shredder Technology can be sequential or
stacked based on needs - Both elements need not be utilized at same site
- The right shredder can compliment the operation,
but the wrong shredder can complicate the
operation
31Specialty Shredders
- Mini units small patties / purgings
- Pipe Shredder reclamation of bulk length
products - IBC Shredder reclaim of IBC (Industrial Bulk
Containers)
32 Drive Types Electric / Hydraulic
- Electric Drives Generally, electric shredders
require less space, are easier to operate and
maintain, and are more energy efficient than
their hydraulic counterparts. They also tend to
be less expensive. Electric shredders are
appropriate and sufficiently powered processing
many materials. - Hydraulic Drives Hydraulic drives are often
better for more heavy duty processing. They are
also better for processing materials that
experience frequent overloads from batch feeding.
Hydraulic drives also offer better shockload
protection from non-shreddables and work well
with SSI's Auto-Chop feature, allowing more
precise particle size control. - When would I need a hydraulic shredder? A
hydraulically powered shredder might be more
appropriate if you have any of the following
factors in your processing environment - Materials are batch fed.
- Feed include unsorted or unknown materials.
- Materials are exceptionally difficult to
shred. - Process requires tighter particle size
control. - System needs to meter shredded material to
downstream equipment. - System will require frequent starts and
stops. - Shredder will require reduced voltage start
(soft start).
33Mini Shredders
- Small units 2 models
- Hand / conveyor fed
- Discharge to multiple sources
- Simple, well priced, economical
- solutions for injection molders,
- E-Waste, etc
- Low price offering for small purge
- reclaim market good size and
- configuration for granulator
- interfacing
34Pipe Shredder
35Pipe Shredder
- Very unique product
- Excellent option for very difficult material
source - Versatile
- Suited for long product, baled, and other
applications - Good for HDPE and PVC Pipe
36Pipe Shredder
37Pipe Shredder
38Pipe Shredder
39 Tire / Contaminated Material Shredder
- Robust and reinforced for tire applications
- Specialized process multi stage reduction
40 Tire / Contaminated Material Shredder
- Special note systems for tires and contaminated
materials require multi step size reduction and
separation technologies - New operations for these sorts of applications
require more equipment, more area, and the
expenditure of larger investment dollars - Strongly suggest that an experienced size
reduction expert be brought in who has experience
in all size reduction technologies
41 CD Shredders
- Low-speed, high-torque, multi-material primary
reducer. A high-capacity solution ideal for
construction and demolition and for volume
reduction of bulky waste containing metal and
abrasives. Particle size is coarse.
42Shredder Economics
- No calculations are perfect or guaranteed
- Performance any utilized shredder can increase
down-stream equipment performance from 25 to
75, (material/application sensitive) - With addition of a 50HP shredder to provide
balanced loading, energy savings can range from
20 to 50 (KWH and performance sensitive) - Utilization reduces motor / HP size of secondary
- operation, while increasing output
- In many cases- allows reclamation of materials
that were before impossible / impractical to
reclaim
43 Economic Impact
- Ongoing studies indicate the following
- - Energy saving up to 15,000 per year per line
- - Yield increase can add up to 100,000 per
year, per line - - Material purity can add up to 50,000 per
year, per line - Each of these benefits add to your bottom line
- individual results may vary
44 Economic Impact cont
- Integrating a system can also
- Reduce maintenance costs
- Reduce maintenance frequency
- Add redundancy and versatility
- Protect operational up-time
- Reduce manual labor
- Reduce or eliminate manual processes that can
compromise safety and the economic impact of
worker injuries
45 Summation
- Shredders can add to / augment the performance of
most operations - Shredders are NOT to magic wand solution
- To correctly integrate a final system, consult
your size reduction expert to insure successful
implementation and proper solution succession - Take NOTHING for granted