Turn key installations for plastics recycling

Third Generation Washing and Regeneration Plant

Video shows a typical plant in operation

General description of process

The process is designed according to the following criteria:

Optimal quality of the intermediate product (densified material) in order to assure a first class regranulate
Maximum productivity and minimum energy consumption
Automation where ever possible or useful

The designation of components follows the layout*)
* ) For viewing of the layout and planning samples the Plug-in WHIP!-Plug-in is needed. You can download the program free-of-charge from Autodesk under http://www.autodesk.com/whip. After the downloading WINDOWS must be restarted.

The loading conveyor (1.) is designed to allow, if required e.g. for stretch film, for the simultaneous feeding of 2 bales in order to achieve a good mix of different material-qualities already at this stage. The shredder (2.) with a grid-size of 30-35 mm provides the appropriate quantity and size of flakes for the subsequent washing process. Before entering into the Turbowash (5.) the material passes under a Fe-metal separator (3.a) and through a precleaning vessel with a high water flow (200 l/sec), which protects the Turbowash form solid objects and sand.

The Turbowash is basically a horizontal centrifuge with a closed cleaning drum. It thoroughly wets the material and separates it from paper and other impurities. It also opens the flakes which have become crisp in the shredder and thus might enclose impurities.
From the discharge of the Turbowash the material via a drained cyclone is transported to a large loading cyclone on top of the Sink-Float Tank.
There again it is spayed with water and then by a distributing tray brought carefully onto the surface of the water of the Sink-Float Tank. This way the separation process of the material is enhanced.
The photo shows also the discharge system for the sinking fraction, which consists of 2 bottom scraper conveyors.
Horizontal drums equipped with vanes convey the material along the 13 m length of Sink-Float Tank (9.) and allow for a separation of the light material (PE,PP) from the heavier material (PET,PS,PVC).
The floating material (PE, PP) is discharged into an auger at the downstream end of the Sink-Float Tank.

The Sink-Float Tank is made of high quality stainless steel. The rotating drums can be controlled individually for different throughput capacities.
Each of the washing components has its own water circuit.

From the discharge of the Sink-Float Tank the material is conveyed by a drained auger to the Dynamic Centrifuge (12.), where it is dried for the subsequent densification process. The densifier (17.) increases, due to thermal and friction action, the density of the material to about 0,4, thus making it perfectly suitable for the subsequent production of finished products such as regranulate or tubes or other.

An energy-saving alternative to the densifier is the plant VULCANO, which melts the material and feeds it in hot-viscous condition into the Extruder. The Extruder is fed either from the Densifier or the VULCANO. It processes the material to high-quality granulate. The granulate can be sold directly or worked to valuable final products.

Additional information contained in the following links:

Material input and pre-cutting

Post Selection

Wet-Granulating and Separation Sink Float Tank

Floating Fraction : Washing and Drying in Centrifuges

Sinking Fraction : Washing, Drying, Densifying or Granulating

Floating Fraction: Densifying

Floating Fraction : Extruding

Final Products of Floating or Sinking Fraction

Other planning samples for washing plants:
Washing Plant with Grinding-and Washing Plant ML1400

Click on components for detailed information

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The loading conveyor (1.) is designed to allow, if required e.g. for stretch film, for the simultaneous feeding of 2 bales in order to achieve a good mix of different material-qualities already at this stage.	The shredder (2.) with a grid-size of 30-35 mm provides the appropriate quantity and size of flakes for the subsequent washing process.	Before entering into the Turbowash (5.) the material passes under a Fe-metal separator (3.a) and through a precleaning vessel with a high water flow (200 l/sec), which protects the Turbowash form solid objects and sand.


The Turbowash is basically a horizontal centrifuge with a closed cleaning drum. It thoroughly wets the material and separates it from paper and other impurities. It also opens the flakes which have become crisp in the shredder and thus might enclose impurities. From the discharge of the Turbowash the material via a drained cyclone is transported to a large loading cyclone on top of the Sink-Float Tank.	There again it is spayed with water and then by a distributing tray brought carefully onto the surface of the water of the Sink-Float Tank. This way the separation process of the material is enhanced. The photo shows also the discharge system for the sinking fraction, which consists of 2 bottom scraper conveyors.	Horizontal drums equipped with vanes convey the material along the 13 m length of Sink-Float Tank (9.) and allow for a separation of the light material (PE,PP) from the heavier material (PET,PS,PVC). The floating material (PE, PP) is discharged into an auger at the downstream end of the Sink-Float Tank.


An energy-saving alternative to the densifier is the plant VULCANO, which melts the material and feeds it in hot-viscous condition into the Extruder.	The Extruder is fed either from the Densifier or the VULCANO. It processes the material to high-quality granulate.	The granulate can be sold directly or worked to valuable final products.