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Plastic pellet granulator- choose its use and advantages

Release time:2023-08-16 Browse:18Second-rate

New pelletizing machine improves polyethylene granule quality

With the growth of demand for plastic products, the quality requirements of polyethylene particles are also increasing. Traditional granulators have problems such as uneven particle distribution and poor surface finish, which cannot fully meet the needs of high-end applications for granule quality. To this end, we have developed a new type of polyethylene particle granulator, through optimized design and precise control of process parameters, the uniformity and surface quality of the particles have been greatly improved.

The new granulator adopts a unique twin-screw quantitative feeding structure, which can accurately measure and transport the melt, ensure the uniform distribution of raw materials in the screw hole and die hole, and effectively reduce the fluctuation of particle weight and size. At the same time, we have developed an advanced mold temperature control system to achieve precise control and quick response to the mold temperature, so that each mold hole can be kept at the best granulation temperature, which greatly improves the surface finish of the granules and reduces the defect rate.

In addition, the new granulator adopts a high-precision electronic proportional drug removal device, which can accurately measure and add various additives to meet the requirements of different formulas for the ratio of additives. With the advanced automatic control system and human-machine interface, the operator can easily monitor and adjust every key process parameter to ensure long-term stable operation.

Through a series of performance tests and comparative experiments on the new granulator, the results show that: compared with the traditional granulator, the particle size distribution range of the new model is reduced by 30%, and the weight fluctuation is reduced by 25%. The smoothness has been improved by 40%, and the defect particle rate has been reduced by 20%. This will greatly improve the processing and use performance of the pellets.

The high-quality granules produced by the new polyethylene granulator have better fluidity and more uniform dispersion in subsequent processing processes such as injection molding, extrusion and blow molding, which can reduce mechanical damage and burrs, and improve the surface quality of plastic products . Especially in high-end applications such as multi-layer co-extrusion and thin-walled articles, uniform and stable particle size and smooth surface are crucial to ensure product quality.

In addition, high-quality particles will also directly improve the quality of recycled materials, reduce heat loss and pollution during the regeneration process, and achieve more efficient recycling. Generally speaking, the application of the new polyethylene particle granulator will promote the further development of plastic processing technology, meet the needs of users for high-performance plastic products, and create greater environmental and economic benefits for enterprises.

Looking forward to the future, with the upgrading of consumption and the popularization of the concept of green environmental protection, the market's demand for customization and individualization of plastic products will become stronger. This requires the development of plastic granule production equipment in a more precise and intelligent direction to achieve precise control and rapid switching of parameters such as particle size, shape, and formula. We will also continue to research and develop new technologies, and develop multi-functional and modular pellet production lines to achieve rapid response to changing market demands.

At the same time, combined with digitalization and automation technology, intelligent perception and optimization of each production link will become a development trend, further improving output, quality, and flexibility. We will actively cooperate with experts inside and outside the industry to establish efficient data collection and analysis systems, researching and developing even more advanced pelletizing solutions to meet the needs of tomorrow’s circular plastic economy.

Artificial intelligence and machine learning technologies will also play a greater role in granulation process control and quality prediction. We look forward to contributing to the sustainable development of the plastics industry through technological innovation and jointly creating a greener and more environmentally friendly world.

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Working principles and applications of plastic pellet granulators

Plastic pellet granulators are important equipment in the plastics processing industry. They can continuously produce plastic pellets with uniform size and smooth surface from plastic raw materials. The pellets can be easily transported and fed into various processing machines for making plastic products. This article will introduce the working principles, structural features, operational parameters, and applications of different types of plastic pellet granulators.

The pelletizing process consists of three main steps - melting, extruding, and cutting. The plastic raw materials are first fed into the barrel and melted by the heaters. The molten plastic is then conveyed forward by the rotating screw and forced through the die face under pressure. The extrudate is finally cut into pellets of equal length by the rotating knives mounted on the die face.

According to the number of screws, pelletizers can be divided into single-screw and twin-screw types. Single-screw granulators are simple in structure and suitable for most thermoplastics. Twin-screw granulators provide more positive feeding and mixing and are used for processing PVC and other shear-sensitive materials. The screw/barrel design, screw speed, die temperature are key factors affecting pellet quality.

Based on the cutting manner, there are two types of pelletizers - strand and hot-face pelletizers. For strand pelletizers, the extrudate is cut after leaving the die face. Cooling water is applied to solidify the strands before cutting. The cut length depends on the rotating speed of blades. For hot-face pelletizers, cutting is done at the die face while the melt is still hot. No cooling water is needed and cut length depends on die hole dimensions.

Underwater pelletizing technology has become more popular recently. The main advantage is immediate water cooling and hardening after pellet cutting, which results in very smooth surface and tight tolerances of the pellets. It is ideal for processing PET, nylon and other polymers. But it requires higher initial capital investment.

In addition to screw extruder pelletizers, ram extruder pelletizing systems are also used for PVC and engineering plastics when precise temperature control and low-stress processing are needed. The ram reciprocatingly pushes the melt through the die holes without excessive shearing flow.

Besides conventional small pellet sizes around 3-5mm, micro-pelleting and nano-pelleting technologies have been developed to produce pellets in the size range of 0.5-2mm and 0.2-0.5mm respectively. The ultra-small pellets improve end product quality and appearance by increasing uniformity of polymer melting and mixing.

Pelletizers are widely used in various plastics processing fields. The produced uniform pellets can significantly increase the productivity and quality consistency of plastic products like films, pipes, profiles, sheets and injection molded articles. They are also ideal for plastic recycling industry to upgrade waste plastics into high-quality regenerated pellets.

Advanced intelligent control systems are now integrated with pelletizers to enable easy parametric control, real-time monitoring, diagnosis and quality prediction. IoT technologies are also implemented for remote monitoring and troubleshooting. These will become future development trends to further assist the plastics industry in producing consistent high-quality pellets and products efficiently and sustainably.


Analyzing pelletization behaviors of different raw materials in granulators

The pelletization behavior of different plastic raw materials can vary significantly in granulators due to their distinct rheological, thermal, and mechanical properties. A thorough analysis and understanding of the pelletization characteristics of various raw materials is crucial for determining the optimal processing parameters and granulator design. This article analyzes and compares the major factors affecting the pelletization behaviors of several common plastics.

Polyethylene (PE) is widely pelletized in single screw extruders. The high melt strength and low melt viscosity of PE enables a smooth and continuous extrusion strand suitable for air/water cooling. However, the low heat conductivity can result in uneven radial temperature profiles. Proper screw design and die temperature controls are essential for uniform melting and smooth pellet surface.

Polypropylene (PP) has high melt strength but low melt viscosity like PE, but has better heat transfer properties and faster crystallization rate. This allows higher output rates in pelletization but requires efficient cooling to ensure complete pellet solidification. The fast crystallization may also cause internal stresses and crack formations.

Polystyrene (PS) has much lower melt viscosity and melt elasticity compared to PE and PP. The extrusion of PS tends to be irregular. Strong shear thinning behavior also makes the melt viscosity highly variable under processing conditions. This makes PS more difficult to pelletize uniformly. Antioxidants and viscosity enhancers may be added to improve melt strength.

Polyvinyl chloride (PVC) requires specialized granulators due to its narrow processing window and susceptibility to thermal degradation. The unstable melt properties lead to extrusion surging and uneven pellet dimensions. Twin screw extruders provide gentler processing with less thermal damage. Pellet surface tackiness also needs to be controlled.

Engineering plastics like nylon, PET, POM have excellent melt strength but easily degrade when overheated. They also crystallize very fast. Precise temperature control of the barrel zones and die assembly is needed to maintain stable output while avoiding material degradation during pelletization.

Filled compounds like glass or mineral filled PP and PE tend to cause rapid abrasive wear on contact components like screws, barrels, and dies. Non-corrosive components and proper clearances are necessary to maximize service life. The high melt viscosity also requires higher processing temperatures and torque.

In summary, factors like melt rheology, thermal conductivity, crystallization kinetics, thermal stability, abrasiveness, must be considered in granulator design and operation for different raw materials. Adequate melt homogenization, temperature control, cooling and downstream handling are also critical to achieve consistent high quality pellets. Advanced process monitoring and control techniques will continue to be developed to further improve the pelletization efficiency, flexibility and pellet quality of various plastics.

Major factors in selecting plastic pellet granulators

Selecting the right plastic pellet granulator is crucial for plastics processors to achieve high productivity and pellet quality. This article summarizes the major factors to consider when choosing a suitable granulator.

Output rate is an essential factor. It determines the production capacity and should match the volume requirements. Both the targeted throughput range and space for future expansion should be taken into account. Over-sizing or under-sizing the capacity usually leads to efficiency or quality issues.

Type of raw materials is also important. Different plastics have distinct rheological, thermal and flow properties in the melt, requiring granulators with specific screw and die designs. Abrasion resistance and corrosion resistance of contact parts should also match the raw material characteristics.

Desired pellet size and shape must be considered. Granulators using different die face designs and cutter mechanisms produce pellets of various dimensions. Smaller pellets improve melt homogeneity but reduce flowability. Special shapes may also be required for some applications.

Level of automation and control is another key factor. Manual machines have low cost but less consistency. Automatic granulators with advanced computer controls provide enhanced monitoring, data logging, diagnostics and process optimization for stable quality output.

Energy consumption should be evaluated especially for large systems. More efficient motor, insulation, friction reduction methods and heat recovery systems help minimize energy usage and cost.

Quick access for cleaning and maintenance also affects selection. Modular components and layouts that provide easy access to key areas like screws, dies, filters etc. reduce downtime and improve efficiency.

Versatility to handle a wider range of materials and specifications allows convenient switching between production needs. Quick die change capability enables fast product changeovers.

Reliable after-sales support for spare parts supply, maintenance and service is essential to ensure minimal unplanned downtime, especially for continuous high-volume production lines.

For underwater pelletizing, additional factors like water filtration and recirculation systems, drainage and material handling systems need consideration.

Safety is another critical aspect, including overload protection, emergency stops, safeguards from heat, electrical and mechanical hazards. Noise and potential dust generation should be minimized.

Initial investment cost, expected operating costs, and availability of expertise for operation and maintenance also affect selection.

In summary, a comprehensive analysis of both production needs and capabilities of different granulator models and suppliers is necessary. Prioritizing the key requirements and focusing on long-term benefits can lead to the optimal solution for quality, efficiency and sustainability. Pilot trials to simulate actual production conditions are highly recommended during the evaluation process.

Energy-saving and emission reduction technological innovations for plastic pellet granulators

plastic pellet granulators are integral equipment in the plastics processing industry. However, they also account for a significant portion of energy consumption and emissions in plastics manufacturing. With rising energy costs, stricter environmental regulations, and increased sustainability awareness, developing energy-efficient and low-emission granulators has become an imperative for the industry. This article provides an in-depth overview of the latest technological innovations that can help reduce the energy usage and emissions of plastic pellet granulators.

Advanced Screw and Barrel Designs

Novel screw geometries and advanced mixing elements can enhance the plastication and homogenization efficiency while reducing shear heating and energy consumption. Optimized barrel designs improve the resistive heating efficiency and minimize heat losses. Computational modeling and simulation tools enable further optimization of screw and barrel designs for specific polymers. These improvements help cut down energy usage by 15-30%.

Efficient Heating and Cooling Systems

Optimizing the barrel and die heating systems such as multi-zone and cascade controls precisely match the heat supply to the process needs, avoiding overheating. Integrated cooling water circulation and air systems speed up cooling while reclaiming heat for reuse. Condensed water vapor recovery minimizes water and energy loss. Such optimizations can result in 10-20% energy savings.

Insulation and Sealing

Use of low thermal conductivity materials and multi-layer insulation minimizes heat losses from barrels, dies, piping and tanks. Improved door sealing and positive pressure nitrogen blanketing further reduce heat losses. This maintains optimal process temperatures with lower energy input.

Friction and Wear Reduction

Applying low-friction coatings on screws and barrels reduces torque requirements and energy consumption while also minimizing wear. Special corrosion-resistant bearing materials also have lower friction. These innovations provide 5-15% energy savings especially for large or high-speed granulators.

Efficient Motors and Drives

Using energy efficient servo motors, variable speed drives, and vector controls that precisely match speed and torque to the process load requirements avoids over-sizing and throttling. This results in up to 10% lower energy usage.

Advanced Automation and Control

Smart processing control algorithms and sensors enable real-time optimization of processing parameters for improving energy efficiency. Data collection systems identify areas for more savings. These technologies can bring about 5-12% energy reductions.

Energy Recovery and Reuse

Innovations like hydraulic oil heat exchangers, electrical and mechanical regenerative braking, and organic Rankine cycles recover various forms of wasted heat and mechanical energy for electricity generation or reuse in auxiliary systems. This can reduce overall energy usage by 10-20%.

Renewable Energy Integration

Partially replacing conventional electric power with renewable energy sources such as solar, wind, biomass/biogas helps lower the carbon footprint. Depending on availability and storage capabilities, 10-30% of total energy can potentially come from renewable sources.

Remote Monitoring and Diagnostics

Smart IoT-enabled systems collect granulator operating data remotely and apply big data analytics to detect efficiency losses, predict failures, and identify optimization opportunities to minimize energy waste and emissions.

Emissions Reduction Technologies

Specialized exhaust gas treatment systems, filters, adsorbents, catalytic/thermal oxidizers help control and destroy harmful VOCs, fumes, and dust generated. Pellet drying and cooling innovations also minimize emissions.

In summary, implementing a combination of these emerging technologies can potentially reduce the overall energy consumption of plastic pellet granulators by 30-50%. But a holistic approach examining the entire production system and life cycle impacts is needed to maximize their sustainability benefits. Continued research and cross-industry collaboration will be key to developing next-generation high-efficiency, low-emission granulators.

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