SHREDDERS | TECHNOLOGY
that are set to the demands of the input materials. Zerma introduced the ZCS series in 2018 but
has expanded the line recently. The combination unit is offered in three models, the ZCS 600, 1000 and 1400. All the units feature a screen size on the shredder that results in fractions equal to or less than 6 mm, Paeslack said. The smallest model in the range, the ZCS 600 unit, has a 570 by 490 mm feed opening and uses a shredder with a 310 mm diameter, 570 mm long rotor with 26 concave knives and one row of stator knives. The granulator features a 300 mm diameter rotor with three rows of rotor knives and two
unit that integrates a single-shaft shredder with granulator technology. The ZCS series recycling system is suited for large volume or heavy parts and thicker materials such as in-house injection moulded reject parts, purgings or blow moulded scrap parts such as intermediate bulk containers, Paeslack said, but it can also downsize extruded and thermoformed parts. The combination unit offers users a closed system that reduces the risk of contamination by eliminating a traditional conveyor belt between the units in a two-stage recycling system as well as a compact footprint. The combined electrical power of the ZCS is less than 50 kW, which the company says makes the unit ideal for plastics converters. The shredder segment is equipped with an
E-type rotor that incorporates Zerma’s proven knife and knife holder design, the company said. The lower segment consists of a 3-blade granulator based on the company’s GSC series granulator. The two components are matched to work together ideally and in conjunction with its Smart Drive advanced control system to constantly monitor the load and adjust the current accordingly to reduce energy consumption while ensuring smooth and reliable operation, Paeslack said. The shredder and granulator are individually
driven, which Zerma says allows for better control of the overall process. The shredder is driven by a high-torque gear drive via a gearbox on the shaft end on one side of the rotor, while the granulator is driven by a separate belt drive system. The shredder features a hydraulically operated
pusher ram that uses load-related controls to automatically feed material into the cutting chamber. The hydraulic system is equipped with high pressure valves and volumetric flow controls
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rows of stator knives. The largest unit, the ZCS 1400 has a 1,880 by 1,000 mm feed opening, with a shredder equipped with a 400 mm diameter, 1,400 mm long rotor with 34 knives and one row of stator knives. The granulator for this model has a 350 mm diameter rotor with three rows of rotor knives and two rows of stator knives.
One shaft Hosokawa Polymer Systems, a US-based busi- ness that is part of the recycling division of Ho- sokawa Alpine, developed Polyplex PPC 50/120, a combination shredder and granulator system where both the shredder and granulator reside on one single shaft. The unit is ideally designed for in-house size
reduction of a range of parts from extruded profiles, pipes and trim, sheets, sprues, reject housing, chunks, or machine purgings weighing up to several hundred kilos, said David Vill, Manager of Polymer & Recycling Markets at the NPE 2024 show. Diverse types of parts can be mixed and fed to the unit. According to the company, “in practice, the simultaneous feed of different plastic waste constitutes a considerable advantage (in that) pre-sorting or dosed material feed are now things of the past.” The unit combines a vertically arranged shred-
der rotor with a granulator rotor, where the feed material “doses itself” when being charged to the shredder. Shredded material falls by gravity into the granulator section where it is typically commi- nuted to a consistent fineness of 4-5 mm, Vill said. The configuration of the shredder-granulator means that chunks that are pre-crushed in the shredder section can be comminuted in one step to granulator fineness at considerably lower drive power than a traditional shredder-conveyor-granu- lator system, said Vill.
May/June 2024 | PLASTICS RECYCLING WORLD 37
Left: Polyplex PPC 50/120, a combination shredder and granulator system where both the shredder and granulator reside on one single shaft
IMAGE: HOSOKAWA
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