How much does a high pressure film agglomerator cost. Agglomerators. The complete line contains
Polyethylene recycling is one of the few recycling technologies that provides a solution to the environmental problem of waste, and is able to bring good profits.
The problem of pollution of the planet with polyethylene is becoming more serious every year. The use of this material is so widespread that it is found in almost every area of human life. Difficulties in disposal and a long period of decomposition threaten our planet. To solve the problem, technologies for processing and recycling the substance are being developed. This is a great way to get rid of the huge amount of garbage in landfills around major cities and build a profitable production on this basis. The introduction of this method on a global scale is a chance to defeat an ecological catastrophe.
Relevance of polyethylene processing
It is not easy to dispose of this material - the structure and composition of polyethylene provide resistance to various chemical factors, which makes it so popular. In terms of use, these qualities are exactly what you need. However, it is these same properties that lead to the impact of waste on the environment.
The decomposition of polyethylene takes about 300 years. A dangerous factor is also the fact that, when decomposed, polyethylene objects are capable of releasing hazardous chemical elements into the biosphere that pollute the air, soil, and groundwater. In sum, this action affects the environment and public health.
If this material has such amazing properties and is stored for several hundred years, the question arises, why not take advantage of these qualities of waste. Modern technology allows the recycling of polyethylene waste at such a level that the material becomes usable again. This is both a way to save on new materials and a solution to the problem of environmental pollution.
For the smooth and continuous functioning of the processing system, the condition for collecting raw materials and the availability of the necessary equipment is necessary. Subsequent recycling will give waste a new life in the role of everyday household items.
The number of enterprises involved in the processing of polyethylene waste naturally increases every year - this is facilitated by the relevance and demand for this service. The low cost of the source material and the wide possibilities for the production of goods for which demand does not fall are the key advantages of such a business.
An important point. The use of products made from recycled polyethylene should be included on the packaging of the product, while the quality of the recycled product is inferior to virgin polyethylene. This fact should be taken into account.
How is the processing of raw materials?
Waste is processed in several successive steps:
- collection of raw materials;
- sorting;
- primary processing;
- grinding;
- processing in a centrifuge;
- the effect of temperature;
- the use of material for the production of products.
The collection of raw materials and their sorting is the beginning of the process. At this stage, the waste is divided into categories that correspond to the type of raw material. Sorting can be done manually or using mechanized devices.
Sorted waste must be cleaned of dirt, parts from foreign material. Raw materials are cleaned in special washing machines. Some collectors of raw materials themselves carry out this procedure, increasing the price of it.
Grinding of purified and prepared raw materials is carried out in special machines, using crushing. The next processing step is centrifugation. This relieves the material of moisture, impurities. After grinding, heat treatment of the material follows.
The raw material is ready for recycling and the production of items from it.
Necessary equipment for polyethylene processing
For a complete and high-quality recycling process, the following equipment is used:
- washing machine;
- waste shredder;
- centrifuge;
- heat treatment plant;
- agglomerator - to reduce the volume of raw materials;
- granulator;
- extruder - to form a homogeneous raw material, using temperature.
Automation of the process is carried out by using a pipeline - this speeds up the process and allows you to control it in stages.
The use of an agglomerator is one of the ways to increase the efficiency and economy of processing. The output is a commercial product - an agglomerate.
The principle of operation of the agglomerator for polyethylene processing, see the video:
The use of an extruder makes it possible to obtain low-pressure polyethylene, which is resistant to physical and chemical factors.
Extruders are also used for processing raw materials (agglomerate) into a homogeneous melt with giving it a certain shape.
In order for the material to be conveniently transported and used for the production of products, flakes must be processed into denser forms, such as agglomerate or granulate.
For this, the simplest equipment can be used - an agglomerator, which is a metal barrel, in the lower part of which a rotating knife is installed. If you type the word Agglomerator in Yandex, then in 100% of the answers there will be links to just such simple designs, which differ in the number and power of drives and barrel sizes.
it works like this: the material is manually loaded into the barrel. The rotating knife cuts the film, while it heats up both due to friction and due to the release of energy during cutting. The operator, observing the state of the material, selects the moment when the temperature is close to the melting point and splashes a small amount of water. A thermal shock occurs, as a result of which the mass in the agglomerator breaks into more or less even lumps, which are unloaded through an opening in the lower part of the barrel. The advantage of an agglomerator of this design is that it is available even to novice entrepreneurs. Prices from 120 thousand rubles. Actually, this is where the benefits begin and end.
The production process may look like this photo.
Manufacturers of polymer products are reluctant to buy agglomerate of such welding and only at the lowest prices, no more than 20 rubles per kg. The reason is that it is unstable in quality. Much depends on how the operator has estimated the right moment for splashing water, often there is a lot of fine dust or, conversely, large lumps of material.
Any inclusions that could be in the material go into the agglomerate, since there is no filtration here. In addition, excessive felling of the material sometimes contributes to its degradation, cross-linking. (In simple words, crosslinking is when you cut a polyethylene molecule, two active ends were formed, radicals that closed on neighboring molecules, thus forming bonds between them, this is not good, but I think to write more about this in a separate post about the degradation of polyethylene during processing)
A better quality agglomerate can be obtained using agglomerators or permanent plast compactors, such as, for example, a German company's agglomerator. 
The German agglomerator has a completely different principle of flake compaction.
Schematically, it is shown in the figure below.
The main working element is the rotor 3 with knives 2, which rotates inside the cylindrical matrix 1. The material is fed into the matrix and heated due to friction against the rotor and knives. Holes are made in the matrix, into which the material is squeezed out, just as meat is squeezed out of a meat grinder with sausages. In this case, the rotating knives 1 constantly cut off these sausages, which are fed to an additional crusher after that. Dust is captured and sent to the beginning of the process so that the finished product is obtained more or less the same size, which is important for its subsequent processing. 
Since only what passes through the holes of the matrix passes into the finished product, there is a certain filtration element in this case, that is, stones and pieces of wood will not pass into the finished product, although their appearance will not be useful for the agglomerator, so they, in any case must be removed before.
The advantage of such agglomerates is that the costs of their purchase and operation are lower than those of granulators of comparable capacity, while the agglomeration problems that I wrote about above are almost solved.
True, as soon as you use the word "agglomerate", then your potential buyer is skeptical about the quality and is waiting for an offer at a low price.
A cardinal way to expand the sales market and increase the profitability of polyethylene processing is the use of advanced granulators, which I will write about next time.
Send your question regarding the choice of agglomerators to e-mail [email protected] and get an answer within twelve hours or write a question in the comments.
Obtaining agglomerate is the first production step in the processing of recycled plastic. Of course, in order to bring large wastes to a fraction acceptable for grinding in an agglomerator, preliminary crushing in industrial shredders or crushers is necessary. However, many enterprises are focusing on the processing of more accessible materials that do not require prior preparation.
Agglomerator Application
The agglomerator is the equipment of the first line for the processing of plastic waste - stretch film, polypropylene, polystyrene, as well as low and high pressure polyethylene and other types of polymers. The machine allows you to get a product ready for further use or sale - an agglomerate.
In addition to grinding raw materials, the technological process allows additional drying of the material during the sintering process, however, the use of raw material reduces the productivity of the equipment. For this reason, for pre-washing, it is recommended to use more efficient solutions.
Production of plastic agglomerate
The crushing of plastic in the agglomerator occurs due to the rapid rotation of the movable knives. The shape and angle of sharpening knives can be essential to the efficiency of working with various types of waste. Since due to the friction of the crushed mass on the body of the agglomerator and the surface of the movable and fixed knives, the material is heated. Homogeneous heated mass cools sharply and under the action of chopping knives rolls into separate uneven balls of various shapes, ranging in size from 0.5 to 5 mm, depending on the feedstock. The resulting agglomerate can be used directly in injection molding machines or sent for granulation.
AGL series agglomerators
We produce agglomerators of various modifications for use as machines for the first line of plastic waste processing and sinter production. At your request, we will select the necessary equipment modification or we will custom-make any agglomerator according to the technical specifications.
Technical characteristics of the AGL-02 agglomerator
| Overall dimensions, LxWxH, mm | 1200 x 550 x 1250 |
| Weight, kg, no more | 600 |
| Recyclable material | PVD, HDPE, PET, stretch film, polypropylene, polystyrene and other types of polymers |
| Number of rotor knives, pcs | 6 |
|
Productivity, kg/h: |
120 |
| Case volume, l | 200 |
| Type of shell | removable |
| Sinter unloading window size, mm | 100x100 |
| Electric motor power, kW | 30 |
plastic agglomerator price
The current price for the basic agglomerator AGL-02 for plastic processing in the price list.
FILM RECYCLING - PROFITABLE, PROMISING AND ENVIRONMENTALLY FRIENDLY!
Demand for the processing of polymer waste and, at the same time, for the production of new film materials is increasing from year to year. In addition to large factories, quite a lot of small manufacturing enterprises have recently opened that need timely processing of used film. Huge volumes of film waste are also provided by shopping centers and shops of various profiles. The segment of potential consumers of the product obtained after processing (agglomerate) is the companies, one way or another engaged in the manufacture of films, as well as various products from polymers for non-food purposes. If you build your business on the processing of film waste, you will be able to work with both their suppliers and agglomerate consumers.
What is needed?
Recycling does not require large areas and a whole staff of specialists. You can organize this work on your own, even if there is a limited area. For these purposes, you will need to purchase a rotary agglomerator - special equipment for processing HDPE (low pressure polyethylene, LDPE (high pressure polyethylene) and stretch film. Using an agglomerator, you can also process polypropylene bags and big bags, but it all depends on the equipment modification.
How does an agglomerator work?
This equipment is used for grinding, washing, drying and agglomerating waste. Depending on the configuration, agglomerators are single- or double-rotor. Structurally, the agglomerator consists of a frame, an electric motor, a housing and a unit with knives fixed on the shaft. The principle of operation is simple: film waste is loaded into the working chamber, after which it is crushed and sintered. The addition of "shock" water allows this mass to cool and polymerize. At the output, irregularly shaped granules (pellets) 3-10 mm in size are obtained.
Depending on the capacity of the equipment, it may be necessary to pre-grind the film with crushers before filling into the chamber. This will make it possible to use small-capacity agglomerators for processing. Powerful agglomerators (more than 200-250 kg/hour), as a rule, give out large granules. However, the smaller the size of the agglomerate, the more suitable it is for use as a secondary raw material.
Where is agglomerate used?
The resulting product can be used both as a secondary raw material for the production of films and for granulation, which also expands business opportunities. Film materials are in great demand today in almost all areas, so there will be no shortage of agglomerate customers.
How much can you earn?
The cost of a budget-class industrial agglomerator ranges from 195,000-370,000 rubles. According to average calculations, the difference in price between the film and the agglomerate is from 10,000 rubles per ton. Let us take as a basis that the profit per kilogram of raw materials is 5 rubles (this figure can be twice as much).
In an hour, a two-rotor agglomerator processes 200 kg of raw materials without any problems - in total this is 1000 rubles. (200 kg x 5 rubles = 1000 rubles / hour). For an 8-hour shift, it turns out 8000 rubles. (1000 x 8).
If you work in two shifts, then this is already 16,000 rubles per day (1000 x 16).
For a month (22 working days), the profit will be 352,000 rubles. (16000 x 22).
Thus, in one month you can fully recoup the purchase of equipment and start making a profit from the next.
spin off
- Large areas are not required for the organization of work and equipment placement, therefore, this is a significant savings on rent. You can organize the processing of the film in a warehouse or in another suitable room.
- One or two specialists can work with the agglomerator (depending on the scale of processing and equipment model). Special qualifications and special knowledge are also not required. Consequently, the cost of employee salaries will also be negligible.
- When buying a high-performance, but at the same time energy-efficient agglomerator, the cost of paying for electricity is also reduced.
- Other operating costs, such as maintenance and replacement parts, also depend on the quality and reliability of the equipment. Based on this, it is advisable to buy agglomerators from leading manufacturers. Even if the payback period in this case increases, this will be compensated by the absence of regular repair costs.
Outcome.
The organization of processing of film materials to obtain agglomerate is a stable business that does not depend on seasonality or fluctuations in demand. The demand for film recycling and the purchase of agglomerate for its production will only grow. Buying an agglomerator is a win-win investment with a quick payback and the possibility of further expansion of activities. Subsequently, it will be possible to purchase equipment of a different modification for processing a wider range of materials.
Film Recycling Agglomerator- this is a knife or disk machine for mechanical and processing of thin-walled elastic polymer waste, which can have a different shape.
What is polymer agglomeration?
Film processing by polymer agglomeration- a process in which thin-walled polymer raw materials are crushed, melted and naturally sintered.
Materials that can be processed on the agglomerator
- stretch film;
- PVD film;
- polygon film;
- HDPE film;
- PP film;
- PP bag;
- other film waste.
Agglomerator design
Agglomerator for polyethylene is a tank with an elliptical or round section, which is equipped with movable and stationary knives, a system for supplying water and discharging finished raw materials. There are knife agglomerators (with a rotor equipped with knives) and disk agglomerators (with a movable disk - with knives on the bottom). The price of such machines for processing is determined by their type, the presence of additional functions and performance.
The principle of operation of the agglomerator
P Film processing using an agglomerator is carried out according to the following principle: polymer waste enters the processing zone, is crushed and heated. After that, the molten raw material is cooled with water, while the polymer particles are compressed and take the form of granules. After drying the equipment, the finished raw material is removed to the storage bin and the cycle is resumed.
Do you want to buy an agglomerator? Evaluate the offers of the Company ASTAT
You can buy an agglomerator for polyethylene processing from us at an affordable price by choosing the model that suits you in terms of size and performance. The models of agglomerators made in China presented by us are manufactured in accordance with strict quality requirements and have certificates of conformity.
Such equipment is characterized by simplicity and convenience in operation, has a large working resource, is economical and has high productivity. The ASTAT company provides comprehensive services for the installation and debugging of agglomerators purchased from us.