PLASMAC Ltd. Units 11&12 Aylesbury Business Centre Chamberlain Road Aylesbury Bucks. HP19 8DY. UK Phone +44 (0)1296 398 698 Fax +44 (0)1296 395 110 Web www.plasmac.co.uk E-Mail sales@plasmac.co.uk
Plasmac is an established, global business with a strong emphasis on service, design and quality providing a turn-key recycling solution to suit every customer's requirements. From design and manufacture through installation, training and after sales support, Plasmac works closely with you, the customer. Plasmac recognises that each series has its own performance window but each technology alone cannot meet all of the market's recycling needs. Plasmac does not believe its customer should have to compromise. Being the only recycling manufacture to offer three different recognised reprocessing methods gives Plasmac the unique advantage of being able to offer the best recycling solution possible.
Being the only recycling manufacture to offer three different recognised reprocessing methods gives Plasmac the unique advantage of being able to offer the best recycling solution possible.
The Alpha series all use dual diameter low L/D ratio screws, manufactured from En41A, nitride hardened, ground and polished. Barrels are manufactured from En40B, honed finish and nitride hardened. Colmonoy screw/bi-metallic barrels are also available. Zambello extruder gearboxes are used, close coupled with AC motors. All models regardless of pelletizing system are fitted with auto pellet length control, cold start protect and other safety features.
The smaller sizes (40/50/60) are generally for trim recycling, sometimes in conjunction with a Rollfeed. On these applications it is possible to feed both trim and reels simultaneously into the machine. All Plasmac can be equipped with either B&R or Siemens HMI/PLC control.
The larger sizes are generally used for large inline trim or off-line recycling applications. The Alpha range of A40-A70 is available with either air (Aircool) or water cooling (Hydrocool). Machines after the A80 are available with water-cooling only.
Trim basket For air conveyed trim, available in 2 sizes and can be used simultaneously with the Rollfeed Manufactured in 2 sections. The top section is circular and made from perforated metal. The trims and air enter from the side which creates an air curtain. Trims spiral into the conical lower section and into the screw, excess air is exhausted through the perforations. The lower section is fitted with an access door/viewing window.
Rollfeed. Automatic feed unit for scrap reels of film. Available in sizes to suit the extruder. The same size unit is fitted to the A40-60, larger units are fitted to the A70-105. Generally mounted to either a dual feed adapter (trim/reel) or directly to the extruder feed entry. The unit comprises of 2 rollers, one driven by an AC motor/gearbox the other via gears. The top roller is fitted with pneumatic cylinders to maintain pressure to give a constant feed and the material is guided into the unit with a feed chute. Controlled automatically by the extruder drive amperage. Best results are obtained using multiple reels on a slower feed than 1 reel at a fast speed.
Supatrim Feed unit for high speed sticky film (such as lamination or stretch film). The unit comprises of 2 gear cut rollers, one driven via an AC direct coupled motor, the other is spring loaded. The Supatrim is mounted vertically above the extruder feed and has a set of adjustable guide wheels. The Supatrim is fitted with a take up system that gives the option of feeding the material into the unit at full line speed. It can be synchronised to the main winder or run independently. Programmable control via the HMI. Can be used simultaneously with the Rollfeed system.
Flake feeder Feed unit for materials when in flake or chip form from a granulation system. The unit comprises of a hopper fitted with an auger screw at the bottom and 2 lateral stirrers to prevent bridging. The unit is mounted directly to the extruder feed entry and is available in either side or vertical feed depending on material. The main feed auger is driven via an AC motor/gearbox, the stirrers are fixed speed. Programmable feed control by the HMI to give a constant feed. The flake feeder is used as a main feed for dense bottle chip and similar products and is cheaper alternative unit to the ECO/Omega range.
Powerfeed Consists of a manifold with suction points/flexible hoses/suction cups, which is connected to a venture.
Powerfeed The Powerfeed system is available in standard size systems but complex systems are designed specifically to suit the application. Unlike other pneumatic systems, the Plasmac Powerfeed system is designed to diffuse the outlet air pressure which then gives minimum air at the discharge point, an advantage when using a reclaim machine or collection cage. Available in 4 standard sizes 306 (4Kw), 408 (5.5Kw), 510 (7.5Kw) and 612 (11Kw). A range of in-line anti-static rings are also available for each size.
The Omega series is a one-step recycling process, able to handle a wide variety of different forms of scrap. Uses a dual-diameter screw similar to the Alpha series but with enhanced geometry and compression zones. Loose pieces, slabbed-off reel, purgings etc are placed on the inclined conveyor. The conveyor feed is controlled by level sensors in the shredder feed hood. All material passes through an optional metal detector and is fed into the shredder stock box. Rolls can be fed into the stock box via a heavy duty rollfeed either separately or simultaneously, controlled also by the same level sensors.
Continuous high speed trims are also fed directly into the top of the shredder hood via a trim basket if required. The shredder is mounted adjacent to the feed zone of the ECO extruder. Material is fed into the shredder stock box and by the combined action of the programmable hydraulic pusher, low speed rotor and a patented screen arrangement it is size reduced and then fed directly into the OMEGA extruder screw via a variable speed auger screw that is synchronised to the extruder drive to ensure constant feeding of the extruder screw.
The size reduced material is then processed by the dual diameter screw during which it is heated, plasticised prior to being filtered by the Screenchanger, extruded through a multihole die face and pelletized. All feed methods/materials can be fed simultaneously. The Omega series starts at the Omega 60 rising to the Omega 160, with outputs from 120-1000 Kg/Hr. The Omega series is available only with the Hydrocool or Water slide pelletizer systems and can be with non-venting, Single venting or Double venting.
The Integra series uses different technology to both the Alpha and Omega but shares the same screw design. Scrap material is fed via an elevator or rollfeed into an integral compactor cutter. Control of the elevator/rollfeed is controlled by the current of the compactor cutter motor. At the bottom of the compactor drum is a rotating plate fitted with cutters that, along with cutters mounted in the sides of the compactor body, tear/shred the scrap material.
The heat generated by this process is stabilised by cooling fans and any overheating is avoided by using a small water jet system that sprays water into the drum. The frictional heat generated in the shredding/tearing process results in a pre-heated, size reduced mass that is then fed by centrifugal force directly into the Integra screw during which it is heated, plasticised prior to being filtered by the Screenchanger, extruded through a multi-hole die face and pelletized. The advantage of feeding preheated, size reduced material is enhanced output per screw diameter against the other series.
This series starts at the Integra 55 which, with the Integra60 are the only Integra s that can be fitted with either the Aircool or Hydrocool pelletizer, all sizes above these are only available with the Hydrocool or Water slide pelletizer systems. Outputs range from 130 kg/hr on the Integra 55 up to 1200Kg/Hr on the Integra 160.
Single Venting or De-gassing system Some polymers require a vent section in the screw/barrel to de-gas the polymer before it is pelletized. Likewise damp and heavily printed materials also require venting to take away any steam or volatiles from the print process. Vented machines have of a longer screw, the middle of which has a compression, weir, and decompression area. The barrel section at this point has a vent hole and suction point. As the material enters the screw it is compressed and transferred to the compression section and over the weir point.
Single Venting or De-gassing system The weir space is severely restricted and any trapped gas/steam/ volatiles are squeezed out of the polymer mass. Due to the fact that just past the weir the screw has a large decompression area, the steam and volatiles are forced to escape out of the vent. A slight negative vacuum is applied to the vent hole by a vacuum pump and can be either vented to atmosphere or into a water ring system. After the decompression zone the material is then recompressed and transferred into the screenchanger and dieface. Venting or degassing requires additional motor power due to the longer screw and venting process. Due to the higher temperatures used to force the de-gassing process, all machines having this function need the Hydrocool pelletizer system.
Screenchanger A range of screenchangers are available for the Alpha series dependent on the output or contamination level. Generally, the smaller trim-only machines do not need one but if a Rollfeed is fitted then a screenchanger is advisable.
Screenchanger For standard applications a manual dual filter option is used but also other systems are available ranging from manual backflush (AP series), discontinuous/continuous piston type to a fully automatic backflushing system.
Air cool Used generally on lower output, LD/HD applications. The unit comprises of a granule collector, knife cassette (.37Kw AC variable speed, conveying fan(s), ducting and cyclone(s). The smaller Alpha extruders are fitted with a single cyclone system, larger output applications can be fitted with a dual cyclonic systems where you have the 2 fans, 2 sets of pipework and 2 cyclones. The Aircool system knife cassette is available with various blade combinations for different applications/materials. Cannot be used on vented/double vented machines regardless of output.
Hydrocool Used for high output and materials with sharp melt points such as PP/ ABS/Polycarbonates/Nylons etc Robust design, all components manufactured from stainless steel. Various sizes are available to suit the output. All models comprise of a hot die face, water collector ring, water chutes, centrifuge and water tank/pumps/heat exchanger. The water ring is fitted with multiple internal water jets to give good water dispersion and granule cooling, the whole unit is hinged for easy access and cleaning. The collector unit is fitted with a fully adjustable knife cassette with multi-blade option and driven by direct drive from the motor. Polymer exits the dieface where it is cut by the rotating knives. The granules are thrown from the knives into the water flow and exit the collector into a water chute which transfers them to a high performance centrifugal drier. The centrifuge is manufactured from stainless steel with direct drive to the rotor. Access doors are fitted for easy cleaning and maintenance
The centrifuge casing is fitted with an exhaust fan (larger models only) and the complete unit is sound-proofed. The water tank is fitted with two pumps, one feeds the water collector ring, the other circulates water through a heat exchanger to maintain water temperature. A range of alternative heat exchangers are available, brazed plate, demountable easy clean plate and pipe/shell type. Both pumps are fitted with demountable, easy clean filters. All water is recirculating, the only losses being by natural evaporation. Granules are then conveyed via a fan to a cyclone for secondary cooling and transfer to day bins. A range of diefaces are available to suit different polymers and outputs.
Screw size & Output Screw size Cooling Material Output Kg/h 35 Air LD/HD 25 40 Air LD/HD 32 45 Air LD/HD 45 45 Water LD/HD 45 45 Water PP 40 50 Air LD/HD 55 50 Water LD/HD 60 50 Water PP 50 60 Air LD/HD 80 60 Water LD/HD 80 60 Water PP 65 70 Air LD/HD 130 70 Water LD/HD 145 70 Water PP 130 80 Water LD/HD 175-190 90 Water LD/HD 200-250
Screw size & Output Screw size Cooling Material Output Kg/h 60 Air LD/HD 100 60 Water LD/HD 125 60 Water PP 110 60 Water LD/HD 140 70 Water LD/HD 190 80 Water LD/HD 225 90 Water LD/HD 300 105 Water LD/HD 450 120 Water LD/HD 600 140 Water LD/HD 800
Screw size & Output Screw size Cooling Material Output Kg/h 55 Air LD/HD 130 55 Water LD/HD 150 60 Air LD/HD 150 60 Water LD/HD 180 80 Water LD/HD 250 90 Air LD/HD 325 105 Water LD/HD 500 120 Water LD/HD 650