Shredder Technologies for Improving Resin Reclamation Processes

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Shredder Technologies for Improving Resin
Reclamation Processes Economics
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Resin Reclamation

• Important because
• Responsible
• Ethical
• Healthy
• Creates jobs
• Saves Natural Resources
• Makes profits

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Resin 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

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Industry 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

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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

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Additional Technologies for Optimization

• Shears
• Guillotines
• Screeners
• Compactors
• Saws
• Shredders

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Shredders-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

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Shredders

• 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

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Typical 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.

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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.

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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.

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Shredders

• 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

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Multi-Shaft Shredders

• Basic, pierce-tear technique
• Controlled breakdown of large, bulky scrap
• Well suited for certain applications

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Multi-Shaft Shredders

• Principle is same as your home/office paper
  shredder, but beefed up for industrial duty
• Final form is material sensitive

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Two Shaft Shredder counter-rotating cutters rip
materials into strips, with strip length
controlled by hook placement

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Two 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

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Quad 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.

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Options for Multi-Shaft Shredders

• Ram feeding assist
• Screens for classification / control

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Single Shaft Shredders

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Single Shaft Shredders

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Single 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

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Single Shaft Rotor

• Cutter action breaks large masses to smaller,
  more manageable pieces

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Single Shaft Design

• Many different rotor diameters and cutter
  quantities
• Special configurations for special applications

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Single Shaft Design

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Integrated 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

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Sequential 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

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Sequential System

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Stacked 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

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Single Shaft Granulator Stack

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Integrated 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

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Specialty Shredders

• Mini units small patties / purgings
• Pipe Shredder reclamation of bulk length
  products
• IBC Shredder reclaim of IBC (Industrial Bulk
  Containers)

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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).

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Mini 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

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Pipe Shredder
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Pipe 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

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Pipe Shredder
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Pipe Shredder
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Pipe Shredder
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Tire / Contaminated Material Shredder

• Robust and reinforced for tire applications
• Specialized process multi stage reduction

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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

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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.

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Shredder 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

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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

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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

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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