Complete granulation solution for converting shredded plastic bottles into uniform plastic regrind
PROSINO provides customized shredded plastic bottles granulating systems for recyclers that need to further reduce pre-shredded plastic into a more uniform particle size for downstream processing.
The complete system integrates feeding, ferrous-metal separation, metal detection, granulation, air extraction and dust collection into one continuous recycling process.
Complete System
Rubber Conveyor → Magnetic Metal Separator → Metal Detector → Granulator → Air Extraction System → Dust Collector
The system configuration can be customized according to the plastic material, input size, required output size, processing capacity and downstream application.
Send us your material photos/video and processing requirements for a recommended configuration.
How the Shredded Plastic Bottle Granulating System Works
The system is designed to provide controlled material feeding, metal protection and efficient size reduction in a continuous process.
1. Infeed Rubber Conveyor
The shredded plastic bottles are loaded onto the rubber conveyor and transported continuously toward the granulation section.
The conveyor provides a controlled material flow and helps connect the upstream feeding operation with the separation and granulation equipment.
Suitable for:
- Pre-shredded plastic bottles
- Plastic bottle flakes
- Mixed shredded plastic, subject to testing
- Other pre-processed plastic materials
The conveyor dimensions and conveying speed can be selected according to the required throughput and site layout.
2. Magnetic Metal Separator
Before the material enters the granulator, a magnetic metal separator removes ferrous metal contaminants from the plastic stream.
This step helps reduce the amount of ferrous metal entering the granulator and provides an additional level of protection for the cutting system.
Main function:
- Remove ferrous metal contaminants
- Protect downstream equipment
- Reduce the risk of metal entering the granulator
- Improve material cleanliness before granulation
3. Metal Detector
A metal detector is installed after the magnetic separator to detect remaining metal contamination that may not be captured by the magnetic separation stage.
This provides an additional protection step before the material enters the granulator.
Why Use Both?
The magnetic separator and metal detector perform different functions:
Equipment | Main Function |
|---|---|
Removes ferrous metal from the material flow | |
Detects remaining metal contamination |
Using both stages can provide more comprehensive metal protection for the granulator, particularly when the incoming shredded material may contain unknown contaminants.
4. Plastic Granulator
The plastic granulator is the core size-reduction machine in the system.
Pre-shredded plastic bottles enter the granulator, where rotating and stationary knives cut the material into smaller particles. The final particle size is controlled by the screen opening installed in the granulator.
Granulator Functions
- Further reduce pre-shredded plastic
- Produce more uniform plastic regrind
- Control output particle size through the screen
- Prepare plastic for downstream recycling or processing
The granulator should be selected according to:
- Plastic type
- Input material size
- Required output particle size
- Processing capacity
- Material bulk density
- Contamination level
- Downstream application
Important: The appropriate granulator model should be determined from actual material and production requirements rather than capacity alone.
5. Air Extraction System
During plastic granulation, lightweight plastic particles and dust can become suspended in the air.
The air extraction system draws air and fine particles away from the granulation and collection area.
This helps create a more controlled material-handling environment and transfers extracted air and fines toward the dust collection stage.
Main Functions
- Extract airborne dust and fines
- Improve material conveying
- Help control dust around the granulator
- Connect the granulation system with the dust collector
The air extraction configuration can be adjusted according to the granulator, material characteristics and plant layout.
6. Dust Collector
The extracted air is directed to a bag-type dust collector, where dust and fine particles are separated from the airflow.
The dust collector provides centralized dust collection for the system.
Main Functions
- Collect fine plastic dust
- Separate dust from extracted air
- Centralize dust collection
- Help maintain a cleaner working environment
Dust-control requirements vary depending on the plastic material, moisture, particle size and operating conditions. The final air extraction and dust collection configuration should therefore be confirmed during system engineering.
Complete Process Flow
Shredded Plastic Bottles
↓
↓
↓
↓
Plastic Granulator
↓
Air Extraction System
↓
↓
Plastic Regrind Collection
This configuration provides a continuous plastic size-reduction process with upstream metal protection and centralized dust extraction.
What Materials Can Be Processed?
The system can be engineered for different types of pre-shredded plastic, depending on the material characteristics and required output.
Potential materials include:
- PET plastic bottles
- HDPE plastic bottles
- PP plastic containers
- Other rigid plastic bottle materials
- Pre-shredded plastic recycling materials
Because different plastics have different cutting characteristics, bulk densities and melting behavior, material testing is recommended before finalizing the granulator configuration.
If you are processing a specific type of plastic bottle, send us:
Material photos + current shredded particle size + required output size + capacity
and we can evaluate the appropriate granulation configuration.
Key Benefits of the Complete System
Integrated Material Feeding
The rubber conveyor provides a continuous and controlled material flow from feeding to granulation.
Two-Stage Metal Protection
The magnetic separator and metal detector provide two different levels of protection against metal contamination.
Controlled Particle Size
The granulator screen determines the approximate final particle-size range according to the selected configuration.
Centralized Dust Extraction
The air extraction system and bag-type dust collector work together to remove and collect airborne dust and fines.
Customized System Design
The complete line can be configured according to:
- Material type
- Capacity
- Input particle size
- Output particle size
- Factory layout
- Feeding method
- Collection method
- Electrical requirements
- Downstream process
Complete Line vs. Standalone Granulator
For some recycling applications, purchasing only a granulator may not address the complete material-processing requirement.
A complete system can integrate:
Feeding → Metal Separation → Metal Detection → Granulation → Air Extraction → Dust Collection
This is particularly useful when the incoming shredded plastic contains potential metal contaminants or when centralized dust extraction is required.
For a standalone application with clean and controlled material, a granulator may be sufficient. The appropriate configuration depends on the actual production conditions.
How to Select the Right Plastic Granulating System
To recommend a suitable system, we need more than the material name.
Please provide the following information:
1. Plastic Material
For example:
- PET bottles
- HDPE bottles
- PP bottles
- Mixed plastic
2. Current Material Size
What is the approximate size of the shredded plastic entering the granulator?
For example:
20-50 mm shredded plastic
3. Required Output Size
What particle size do you need after granulation?
For example:
6 mm / 8 mm / 10 mm / other
4. Required Capacity
Please specify:
kg/h or tons/h
If you have a daily production target, please also tell us the expected operating hours per day.
5. Material Condition
Please provide:
- Dry or wet
- Approximate moisture
- Clean or contaminated
- Percentage of labels/caps/other materials, if applicable
6. Downstream Application
What will you do with the granulated plastic?
For example:
- Plastic recycling
- Extrusion
- Injection molding
- Pelletizing
- Washing line
- Sale as recycled plastic regrind
Customized Plastic Granulation Solution
There is no single granulator configuration suitable for every plastic bottle recycling project.
The final system should be selected based on the relationship between input material, capacity, output size and downstream requirements.
PROSINO can help configure the complete system from the infeed conveyor through metal separation, granulation and dust collection.
Send Us Your Requirements
For a preliminary solution, please send:
1. Material photos/videos
2. Current shredded material size
3. Required output size
4. Required capacity (kg/h or tons/h)
5. Plastic type
6. Downstream application
7. Factory power supply
We can then recommend a suitable plastic bottle granulating system, including the granulator model, conveyor, metal separation, metal detection, air extraction and dust collection configuration.
Get a Customized Plastic Granulation Solution →
Technical Configuration Table
System Section | Equipment | Main Function |
|---|---|---|
Feeding | Continuous material feeding | |
Metal Separation | Remove ferrous metal | |
Metal Protection | Detect remaining metal contamination | |
Size Reduction | Plastic Granulator | Further reduce shredded plastic |
Air Handling | Extract dust and fines | |
Dust Collection | Collect extracted dust | |
Output | Collection System | Collect finished plastic regrind |
Frequently Asked Questions
Can shredded plastic bottles be directly fed into a granulator?
Yes, a granulator can be used for further size reduction of pre-shredded plastic. The suitability of the selected model depends on the incoming particle size, plastic type, required output size and capacity.
Why is a magnetic separator installed before the granulator?
It is used to remove ferrous metal contaminants before the material reaches the granulator, helping reduce the risk of metal entering the cutting chamber.
Why is a metal detector also needed?
A magnetic separator primarily targets ferrous metal. A metal detector provides an additional detection stage for metal contamination that may remain in the material stream.
What output size can the granulator produce?
The output size depends on the granulator configuration and screen opening, as well as the plastic material and operating conditions. The required output size should be specified when selecting the machine.
Does the system include a plastic washing machine?
No. The configuration described above is a granulation and dust-extraction system. A washing, drying or pelletizing process can be considered separately if required by the recycling application.
Can the system process whole plastic bottles?
The proposed system is specifically described for shredded or pre-processed plastic bottles. If you have whole bottles, an upstream shredder or other size-reduction equipment should be required.
Can the system be customized?
Yes. Conveyor dimensions, granulator configuration, metal separation, dust extraction and other system parameters can be designed according to the material, capacity, factory layout and downstream requirements.
KEYWORD
All Shredders and Granulators
Categories by Number of Rotor
Categories by Function
Auxiliaries
Related Equipments
Successful Installations Pictures
Successful Operation Videos
Shredded PET Bottles Granulating System, Large Plastic Granulator
FAQ about this machine
No. The configuration described above is a granulation and dust-extraction system. A washing, drying or pelletizing process can be considered separately if required by the recycling application.
The output size depends on the granulator configuration and screen opening, as well as the plastic material and operating conditions. The required output size should be specified when selecting the machine.
A magnetic separator primarily targets ferrous metal. A metal detector provides an additional detection stage for metal contamination that may remain in the material stream.
It is used to remove ferrous metal contaminants before the material reaches the granulator, helping reduce the risk of metal entering the cutting chamber.
Yes, a granulator can be used for further size reduction of pre-shredded plastic. The suitability of the selected model depends on the incoming particle size, plastic type, required output size and capacity.
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