ingenio - Battenfeld Sverige AB

SUITABLE FOR
UNIVERSAL APPLICATIONS
INGENIOUS DESIGN
Thermoplastics ...
3 working steps in one
Virtually all thermoplastics, including
PE, PP, PA, PS, PC, PET, ABS,
EVA, PPS, bio-tech and materials
with problematic structures (technical plastics) can be gently recycled
into granulate. In this regard, the
control system of the A:GRAN offers
mastery of difficult material recipes
and processing parameters.
NGR invented and patented* the
“cutter-feeder-extruder combination”,
which allows three working processes
to be completed in one:
C
D
4
5
Printed LDPE film
2
Operating terminal
4
Switchgear cubicle
5
Melt filter
RECYCLING MACHINE
Hot die granulation
*) Yield values for LDPE pursuant to NGR plant standard,
depending on the material and its characteristics
**) Standard value for transport, depending on version
Basic ... short screw design without venting
Infinitely adjustable screw speed with frequency
inverter in the standard version
Additional versions on request:
Speed version with increased screw speed
Torque version with increased scew torque
3
B
Cutter
Hopper volumes
m3
0,1
Cutting width
mm
390
Diameter
mm
Screw length
L/D
3
5
6
2
On average, the industrial manufacture of plastic products results in
2 - 20 % rejects. These can include
start-up rejects, which are produced
until the required product data such
as thickness, colour, shape and
characteristics is attained, and
waste emanating from production
changes or the process itself
(stamping waste, sprue or edge
strips from blown film).
Dimensions
Weight **)
65
19
kW
Torque
rpm
175
Standard
rpm
197
Speed
rpm
220
A
mm
4.085 5.000
B
mm
2.550 3.460
C
mm
1.840
D
mm
2.190
E
mm
In the case of the A:GRAN, the invention
has been so adapted that all three of the
main components, i.e. the cutter shaft,
feeder screw and extruder are mounted
on a single shaft. The ingenious details
of this design have been patented.
...in any form
33
Motor standard
...granulate output
of 20 - 100 kg/h (44 - 220 lbs/h)
2.230
2,8
UNIVERSALLY SUITABLE FOR …
...thermoplastics
55
t
65
3,2
WE TAKE CARE
OF YOUR PLASTIC WASTE
A:GRAN 65 V
Next Generation Recyclingmaschinen GmbH
Gewerbepark 22, 4101 Feldkirchen, Austria
Phone +43 (0) 7233 70 107-0, Fax -2
[email protected], www.ngr.at
The text and illustrations may contain requested and special features, which are only available at extra charge. The rights relating to technical changes and printing errors are retained.
12 I 08, E
Heavily printed LD film
kg/h
Extruder
1
V
up to 100
Pellet yield *)
E
Start-up lumps
Basic
Venting variation
4
1
2
3
This all occurs in a single operation,
without leaving the machine, which is
why the process bears the designation,
“NGR one-step technology”.
A:GRAN 65
Size
• Film edge trims
• All types of film waste
(on rolls, loose or bundled)
• Punching waste
• Injection moulded
parts and tubes
• Start-up lumps
• Fibres
• Tapes
• Fabrics, nonwovens
• Yarns
3. Extrusion and, if required,
degassing take place in the extruder.
A
PP synthetic grass
1. Slow-running cutting blades shred
any plastic waste.
The shredded material is transported to the extruder immediately by
means of a feeder screw.
1
... in any form
Nonwoven
Cutter/feeder/extruder combination
3
6
6
The A:GRAN has been designed for
the inline processing of film edge
trims and is equipped with a single
e-drive for the cutter/feeder/extruder.
The efficient cutter and fine control
for differing quantities of material
greatly expand the range of machine
applications. Control takes place by
means of two pneumatic pistons,
which press the material onto the
cutter. The A:GRAN is thus suitable
for universal use with plastics in a
diversity of forms, irrespective of
whether these are simple or difficult
to shred.
Roller intake
2
www.marketing-tools.at
PP fabric net
1
* S:GRAN series
Two pneumatic pistons press the material
against the cutter.
SUITABLE FOR
UNIVERSAL APPLICATIONS
INGENIOUS DESIGN
Thermoplastics ...
3 working steps in one
Virtually all thermoplastics, including
PE, PP, PA, PS, PC, PET, ABS,
EVA, PPS, bio-tech and materials
with problematic structures (technical plastics) can be gently recycled
into granulate. In this regard, the
control system of the A:GRAN offers
mastery of difficult material recipes
and processing parameters.
NGR invented and patented* the
“cutter-feeder-extruder combination”,
which allows three working processes
to be completed in one:
C
D
4
5
Printed LDPE film
2
Operating terminal
4
Switchgear cubicle
5
Melt filter
RECYCLING MACHINE
Hot die granulation
*) Yield values for LDPE pursuant to NGR plant standard,
depending on the material and its characteristics
**) Standard value for transport, depending on version
Basic ... short screw design without venting
Infinitely adjustable screw speed with frequency
inverter in the standard version
Additional versions on request:
Speed version with increased screw speed
Torque version with increased scew torque
3
B
Cutter
Hopper volumes
m3
0,1
Cutting width
mm
390
Diameter
mm
Screw length
L/D
3
5
6
2
On average, the industrial manufacture of plastic products results in
2 - 20 % rejects. These can include
start-up rejects, which are produced
until the required product data such
as thickness, colour, shape and
characteristics is attained, and
waste emanating from production
changes or the process itself
(stamping waste, sprue or edge
strips from blown film).
Dimensions
Weight **)
65
19
kW
Torque
rpm
175
Standard
rpm
197
Speed
rpm
220
A
mm
4.085 5.000
B
mm
2.550 3.460
C
mm
1.840
D
mm
2.190
E
mm
In the case of the A:GRAN, the invention
has been so adapted that all three of the
main components, i.e. the cutter shaft,
feeder screw and extruder are mounted
on a single shaft. The ingenious details
of this design have been patented.
...in any form
33
Motor standard
...granulate output
of 20 - 100 kg/h (44 - 220 lbs/h)
2.230
2,8
UNIVERSALLY SUITABLE FOR …
...thermoplastics
55
t
65
3,2
WE TAKE CARE
OF YOUR PLASTIC WASTE
A:GRAN 65 V
Next Generation Recyclingmaschinen GmbH
Gewerbepark 22, 4101 Feldkirchen, Austria
Phone +43 (0) 7233 70 107-0, Fax -2
[email protected], www.ngr.at
The text and illustrations may contain requested and special features, which are only available at extra charge. The rights relating to technical changes and printing errors are retained.
12 I 08, E
Heavily printed LD film
kg/h
Extruder
1
V
up to 100
Pellet yield *)
E
Start-up lumps
Basic
Venting variation
4
1
2
3
This all occurs in a single operation,
without leaving the machine, which is
why the process bears the designation,
“NGR one-step technology”.
A:GRAN 65
Size
• Film edge trims
• All types of film waste
(on rolls, loose or bundled)
• Punching waste
• Injection moulded
parts and tubes
• Start-up lumps
• Fibres
• Tapes
• Fabrics, nonwovens
• Yarns
3. Extrusion and, if required,
degassing take place in the extruder.
A
PP synthetic grass
1. Slow-running cutting blades shred
any plastic waste.
The shredded material is transported to the extruder immediately by
means of a feeder screw.
1
... in any form
Nonwoven
Cutter/feeder/extruder combination
3
6
6
The A:GRAN has been designed for
the inline processing of film edge
trims and is equipped with a single
e-drive for the cutter/feeder/extruder.
The efficient cutter and fine control
for differing quantities of material
greatly expand the range of machine
applications. Control takes place by
means of two pneumatic pistons,
which press the material onto the
cutter. The A:GRAN is thus suitable
for universal use with plastics in a
diversity of forms, irrespective of
whether these are simple or difficult
to shred.
Roller intake
2
www.marketing-tools.at
PP fabric net
1
* S:GRAN series
Two pneumatic pistons press the material
against the cutter.
SUITABLE FOR
UNIVERSAL APPLICATIONS
INGENIOUS DESIGN
Thermoplastics ...
3 working steps in one
Virtually all thermoplastics, including
PE, PP, PA, PS, PC, PET, ABS,
EVA, PPS, bio-tech and materials
with problematic structures (technical plastics) can be gently recycled
into granulate. In this regard, the
control system of the A:GRAN offers
mastery of difficult material recipes
and processing parameters.
NGR invented and patented* the
“cutter-feeder-extruder combination”,
which allows three working processes
to be completed in one:
C
D
4
5
Printed LDPE film
2
Operating terminal
4
Switchgear cubicle
5
Melt filter
RECYCLING MACHINE
Hot die granulation
*) Yield values for LDPE pursuant to NGR plant standard,
depending on the material and its characteristics
**) Standard value for transport, depending on version
Basic ... short screw design without venting
Infinitely adjustable screw speed with frequency
inverter in the standard version
Additional versions on request:
Speed version with increased screw speed
Torque version with increased scew torque
3
B
Cutter
Hopper volumes
m3
0,1
Cutting width
mm
390
Diameter
mm
Screw length
L/D
3
5
6
2
On average, the industrial manufacture of plastic products results in
2 - 20 % rejects. These can include
start-up rejects, which are produced
until the required product data such
as thickness, colour, shape and
characteristics is attained, and
waste emanating from production
changes or the process itself
(stamping waste, sprue or edge
strips from blown film).
Dimensions
Weight **)
65
19
kW
Torque
rpm
175
Standard
rpm
197
Speed
rpm
220
A
mm
4.085 5.000
B
mm
2.550 3.460
C
mm
1.840
D
mm
2.190
E
mm
In the case of the A:GRAN, the invention
has been so adapted that all three of the
main components, i.e. the cutter shaft,
feeder screw and extruder are mounted
on a single shaft. The ingenious details
of this design have been patented.
...in any form
33
Motor standard
...granulate output
of 20 - 100 kg/h (44 - 220 lbs/h)
2.230
2,8
UNIVERSALLY SUITABLE FOR …
...thermoplastics
55
t
65
3,2
WE TAKE CARE
OF YOUR PLASTIC WASTE
A:GRAN 65 V
Next Generation Recyclingmaschinen GmbH
Gewerbepark 22, 4101 Feldkirchen, Austria
Phone +43 (0) 7233 70 107-0, Fax -2
[email protected], www.ngr.at
The text and illustrations may contain requested and special features, which are only available at extra charge. The rights relating to technical changes and printing errors are retained.
12 I 08, E
Heavily printed LD film
kg/h
Extruder
1
V
up to 100
Pellet yield *)
E
Start-up lumps
Basic
Venting variation
4
1
2
3
This all occurs in a single operation,
without leaving the machine, which is
why the process bears the designation,
“NGR one-step technology”.
A:GRAN 65
Size
• Film edge trims
• All types of film waste
(on rolls, loose or bundled)
• Punching waste
• Injection moulded
parts and tubes
• Start-up lumps
• Fibres
• Tapes
• Fabrics, nonwovens
• Yarns
3. Extrusion and, if required,
degassing take place in the extruder.
A
PP synthetic grass
1. Slow-running cutting blades shred
any plastic waste.
The shredded material is transported to the extruder immediately by
means of a feeder screw.
1
... in any form
Nonwoven
Cutter/feeder/extruder combination
3
6
6
The A:GRAN has been designed for
the inline processing of film edge
trims and is equipped with a single
e-drive for the cutter/feeder/extruder.
The efficient cutter and fine control
for differing quantities of material
greatly expand the range of machine
applications. Control takes place by
means of two pneumatic pistons,
which press the material onto the
cutter. The A:GRAN is thus suitable
for universal use with plastics in a
diversity of forms, irrespective of
whether these are simple or difficult
to shred.
Roller intake
2
www.marketing-tools.at
PP fabric net
1
* S:GRAN series
Two pneumatic pistons press the material
against the cutter.
QUALITY
Longevity through
robustness
The A:GRAN has an especially
compact and stable design, which
in its simplicity saves both space
and drive power. The A:GRAN is
characterised by long service life
even at full performance and with
the processing of problematic
materials such as PA fibres. In
addition, slow cutter shaft speeds
secure long knife life.
MACHINE HANDLING
Automation
The A:GRAN machine can be fully
integrated into the process used in
a film production plant. This
ensures safe and cost-effective
inline operation. Basically, the
A:GRAN is designed for continuous
feeding in inline operation, but is
also able to react automatically to
any changes in material quantity
and can therefore deliver granulate
of uniform high quality. To this end,
the pneumatic pistons on the cutter
and the screw and granulation
speeds are regulated automatically.
Simple maintenance and
long operating periods
Simultaneous processing
of material in diverse forms
A high degree of process stability
marginalises the influence of the
operating personnel. Moreover,
simple access to wear parts reduces any downtimes to a minimum.
The size and quantity of the
charged material is only restricted
by the funnel opening and not the
process. Therefore, several
differing material feeding systems
can be employed simultaneously.
Glass inspection window/
maintenance opening on the feeder
Stationary knife
Designed and built for
long-term profitability
Robust design, high-grade materials and top quality manufacturing in
combination with the finest possible
controls and proven electronics
guarantee a service life that
extends far beyond the short
amortisation period. It is then that
NGR machines really pay off, as
hundreds of operators on every
continent can confirm.
• Solids such as start-up
lumps and stamping waste can
be fed through an opening. The
A:GRAN funnel cross-section
also permits the feeding of
bulky items. As an option, this
material feed flap can be fitted
with a transport belt,
in order to allow continuous
feeding. A detector provides
a warning of metallic foreign
objects.
Operator-free running
The NGR recycling process merely
requires a sufficient inflow of
material. Hence the fact, that in
order to operate, NGR machines
need just one person to handle
feeding. During inline operation this
material feed is preset through the
production process and automated,
which creates enormous personnel
savings and turns interim material
handling into a thing of the past.
AMORTISATION
Problem-free restarts after
emergency stops
Following sudden plant halts (e.g.
emergency stops), the system can
be immediately restarted without
any problem with filled funnel and
extruder screw.
OPTIONS
Uniform high granulate
quality brings first class
end products
Amortisation in 6-12 months!
Low labour, energy and
maintenance costs
The unique design of the A:GRAN
feed guarantees especially uniform
processing and gentle material
melting. This results in high material
quality without any tangible loss of
physical characteristics.
Due to their high process stability,
throughput performance and low
operating costs, NGR machines offer
extremely short amortisation periods.
grated into the recycling process.
4
Recycling systems can have
a major, negative effect on
polymer quality. Undesirable
deviations such as changes in
viscosity or granulate discolouring may reduce both the
possibilities for its utilisation and
its value.
Air separator
The roller intake allows
the processing of unwound film
rolls.
NGR’s one-step technology
provide energy cost savings of
up to 40 %*.
The shredded plastic is immediately
fed to the extrusion process and is
therefore “hot”. This reduces the
energy requirement for material
melting.
n
The investment, operating and
maintenance costs for a preshredding system are no longer
required.
n
The extremely short material process path facilitates quick cleaning
and material switches, as well as
shorter down time.
n
Low personnel, compressed air,
water and spare part costs.
n
5
Roller intake for film
Feed funnel with electrically powered intake rolls, process controlled.
Air separator feeding
Film edge trims can be carried to the A:GRAN using compressed air. The air
separator, which is mounted above the feed opening, separates the transport air
from the edge trims.
n
In addition to high quality, the
consistency of the regranulate
allows it to be mixed homogenously with original material.
Therefore, NGR is an indirect
guarantor for uniform end
product standards and the
prevention of production rejects.
1 Start-up rejects are simply reinte-
The fact that interim material
storage is no longer required and
the small machine dimensions mean
that valuable space can be saved in
the production hall.
Conveyor belt
Stable design with high sidewalls and metal detector, e-drive, process controlled.
Additive dosing device
In the section between the shredder and the extruder intake, additives equal to
up to 20 % of the material flow can be fed in (e.g. for the improvement of flow
characteristics or material colouring), process controlled.
Simple degassing with two maintenance covers
6
Simple degassing (V)
Vacuum degassing consists of two openings, where melt degassing takes place
using a water ring vacuum pumps (drying).
Manual screen changer
A lever is used to allow the alternate cleaning of two screens, which are swung
out of the plastic melt.
Melt filter
7
Automatic melt filter
A high-quality, two-piston melt filter represents an intelligent solution for automatic melt cleaning. Therefore, a piston screen change is possible without shutting
down the process. Process controlled.
Backflush melt filters
are recommended for badly soiled material.
GRANULATION SYSTEMS – process controlled
In the case of the A:GRAN, various process granulation systems can be utilised
in line with the plastic to be processed.
Hot die granulation (HD) is generally used for the majority of polyolefins.
The air separator serves
the continuous recycling of film
edge trims as production backup. This inline operation makes
material handling superfluous
and fully automates the NGR
recycling machine. Furthermore, no material storage is
required.
Strand granulation (SG) or
underwater granulation (UWG) are employed for PA, PET or other polymers
and PP with a high melt flow index.
Hot die granulation
In addition, NGR also supplies the entire granulate transport equipment such
as blowers, piping, cyclones, etc.
8
conveyor (transport belt),
e.g. for stamping waste
Operating terminal
Granulation systems
A:GRAN 65 V
*Depending on the material
Strand granulation
QUALITY
Longevity through
robustness
The A:GRAN has an especially
compact and stable design, which
in its simplicity saves both space
and drive power. The A:GRAN is
characterised by long service life
even at full performance and with
the processing of problematic
materials such as PA fibres. In
addition, slow cutter shaft speeds
secure long knife life.
MACHINE HANDLING
Automation
The A:GRAN machine can be fully
integrated into the process used in
a film production plant. This
ensures safe and cost-effective
inline operation. Basically, the
A:GRAN is designed for continuous
feeding in inline operation, but is
also able to react automatically to
any changes in material quantity
and can therefore deliver granulate
of uniform high quality. To this end,
the hydraulic pistons on the cutter
and the screw and granulation
speeds are regulated automatically.
Simple maintenance and
long operating periods
Simultaneous processing
of material in diverse forms
A high degree of process stability
marginalises the influence of the
operating personnel. Moreover,
simple access to wear parts reduces any downtimes to a minimum.
The size and quantity of the
charged material is only restricted
by the funnel opening and not the
process. Therefore, several
differing material feeding systems
can be employed simultaneously.
Glass inspection window/
maintenance opening on the feeder
Stationary knife
Designed and built for
long-term profitability
Robust design, high-grade materials and top quality manufacturing in
combination with the finest possible
controls and proven electronics
guarantee a service life that
extends far beyond the short
amortisation period. It is then that
NGR machines really pay off, as
hundreds of operators on every
continent can confirm.
• Solids such as start-up
lumps and stamping waste can
be fed through an opening. The
A:GRAN funnel cross-section
also permits the feeding of
bulky items. As an option, this
material feed flap can be fitted
with a transport belt,
in order to allow continuous
feeding. A detector provides
a warning of metallic foreign
objects.
Operator-free running
The NGR recycling process merely
requires a sufficient inflow of
material. Hence the fact, that in
order to operate, NGR machines
need just one person to handle
feeding. During inline operation this
material feed is preset through the
production process and automated,
which creates enormous personnel
savings and turns interim material
handling into a thing of the past.
AMORTISATION
Problem-free restarts after
emergency stops
Following sudden plant halts (e.g.
emergency stops), the system can
be immediately restarted without
any problem with filled funnel and
extruder screw.
OPTIONS
Uniform high granulate
quality brings first class
end products
Amortisation in 6-12 months!
Low labour, energy and
maintenance costs
The unique design of the A:GRAN
feed guarantees especially uniform
processing and gentle material
melting. This results in high material
quality without any tangible loss of
physical characteristics.
Due to their high process stability,
throughput performance and low
operating costs, NGR machines offer
extremely short amortisation periods.
grated into the recycling process.
4
Recycling systems can have
a major, negative effect on
polymer quality. Undesirable
deviations such as changes in
viscosity or granulate discolouring may reduce both the
possibilities for its utilisation and
its value.
Air separator
The roller intake allows
the processing of unwound film
rolls.
NGR’s one-step technology
provide energy cost savings of
up to 40 %*.
The shredded plastic is immediately
fed to the extrusion process and is
therefore “hot”. This reduces the
energy requirement for material
melting.
5
Roller intake for film
Feed funnel with electrically powered intake rolls, process controlled.
Air separator feeding
Film edge trims can be carried to the A:GRAN using compressed air. The air
separator, which is mounted above the feed opening, separates the transport air
from the edge trims.
n
In addition to high quality, the
consistency of the regranulate
allows it to be mixed homogenously with original material.
Therefore, NGR is an indirect
guarantor for uniform end
product standards and the
prevention of production rejects.
1 Start-up rejects are simply reinte-
The fact that interim material
storage is no longer required and
the small machine dimensions mean
that valuable space can be saved in
the production hall.
Conveyor belt
Stable design with high sidewalls and metal detector, e-drive, process controlled.
Additive dosing device
In the section between the shredder and the extruder intake, additives equal to
up to 20 % of the material flow can be fed in (e.g. for the improvement of flow
characteristics or material colouring), process controlled.
Simple degassing with two maintenance covers
6
n
The investment, operating and
maintenance costs for a preshredding system are no longer
required.
n
The extremely short material process path facilitates quick cleaning
and material switches, as well as
shorter down time.
Simple degassing (V)
Vacuum degassing consists of two openings, where melt degassing takes place
using a water ring vacuum pumps (drying).
Manual screen changer
A lever is used to allow the alternate cleaning of two screens, which are swung
out of the plastic melt.
Melt filter
7
Automatic melt filter
A high-quality, two-piston melt filter represents an intelligent solution for automatic melt cleaning. Therefore, a piston screen change is possible without shutting
down the process. Process controlled.
n
Low personnel, compressed air,
water and spare part costs.
n
Backflush melt filters
are recommended for badly soiled material.
GRANULATION SYSTEMS – process controlled
In the case of the A:GRAN, various process granulation systems can be utilised
in line with the plastic to be processed.
Hot die granulation (HD) is generally used for the majority of polyolefins.
The air separator serves
the continuous recycling of film
edge trims as production backup. This inline operation makes
material handling superfluous
and fully automates the NGR
recycling machine. Furthermore, no material storage is
required.
Strand granulation (SG) or
underwater granulation (UWG) are employed for PA, PET or other polymers
and PP with a high melt flow index.
Hot die granulation
In addition, NGR also supplies the entire granulate transport equipment such
as blowers, piping, cyclones, etc.
8
conveyor (transport belt),
e.g. for stamping waste
Operating terminal
Granulation systems
A:GRAN 65 V
*Depending on the material
Strand granulation
QUALITY
Longevity through
robustness
The A:GRAN has an especially
compact and stable design, which
in its simplicity saves both space
and drive power. The A:GRAN is
characterised by long service life
even at full performance and with
the processing of problematic
materials such as PA fibres. In
addition, slow cutter shaft speeds
secure long knife life.
MACHINE HANDLING
Automation
The A:GRAN machine can be fully
integrated into the process used in
a film production plant. This
ensures safe and cost-effective
inline operation. Basically, the
A:GRAN is designed for continuous
feeding in inline operation, but is
also able to react automatically to
any changes in material quantity
and can therefore deliver granulate
of uniform high quality. To this end,
the hydraulic pistons on the cutter
and the screw and granulation
speeds are regulated automatically.
Simple maintenance and
long operating periods
Simultaneous processing
of material in diverse forms
A high degree of process stability
marginalises the influence of the
operating personnel. Moreover,
simple access to wear parts reduces any downtimes to a minimum.
The size and quantity of the
charged material is only restricted
by the funnel opening and not the
process. Therefore, several
differing material feeding systems
can be employed simultaneously.
Glass inspection window/
maintenance opening on the feeder
Stationary knife
Designed and built for
long-term profitability
Robust design, high-grade materials and top quality manufacturing in
combination with the finest possible
controls and proven electronics
guarantee a service life that
extends far beyond the short
amortisation period. It is then that
NGR machines really pay off, as
hundreds of operators on every
continent can confirm.
• Solids such as start-up
lumps and stamping waste can
be fed through an opening. The
A:GRAN funnel cross-section
also permits the feeding of
bulky items. As an option, this
material feed flap can be fitted
with a transport belt,
in order to allow continuous
feeding. A detector provides
a warning of metallic foreign
objects.
Operator-free running
The NGR recycling process merely
requires a sufficient inflow of
material. Hence the fact, that in
order to operate, NGR machines
need just one person to handle
feeding. During inline operation this
material feed is preset through the
production process and automated,
which creates enormous personnel
savings and turns interim material
handling into a thing of the past.
AMORTISATION
Problem-free restarts after
emergency stops
Following sudden plant halts (e.g.
emergency stops), the system can
be immediately restarted without
any problem with filled funnel and
extruder screw.
OPTIONS
Uniform high granulate
quality brings first class
end products
Amortisation in 6-12 months!
Low labour, energy and
maintenance costs
The unique design of the A:GRAN
feed guarantees especially uniform
processing and gentle material
melting. This results in high material
quality without any tangible loss of
physical characteristics.
Due to their high process stability,
throughput performance and low
operating costs, NGR machines offer
extremely short amortisation periods.
grated into the recycling process.
4
Recycling systems can have
a major, negative effect on
polymer quality. Undesirable
deviations such as changes in
viscosity or granulate discolouring may reduce both the
possibilities for its utilisation and
its value.
Air separator
The roller intake allows
the processing of unwound film
rolls.
NGR’s one-step technology
provide energy cost savings of
up to 40 %*.
The shredded plastic is immediately
fed to the extrusion process and is
therefore “hot”. This reduces the
energy requirement for material
melting.
5
Roller intake for film
Feed funnel with electrically powered intake rolls, process controlled.
Air separator feeding
Film edge trims can be carried to the A:GRAN using compressed air. The air
separator, which is mounted above the feed opening, separates the transport air
from the edge trims.
n
In addition to high quality, the
consistency of the regranulate
allows it to be mixed homogenously with original material.
Therefore, NGR is an indirect
guarantor for uniform end
product standards and the
prevention of production rejects.
1 Start-up rejects are simply reinte-
The fact that interim material
storage is no longer required and
the small machine dimensions mean
that valuable space can be saved in
the production hall.
Conveyor belt
Stable design with high sidewalls and metal detector, e-drive, process controlled.
Additive dosing device
In the section between the shredder and the extruder intake, additives equal to
up to 20 % of the material flow can be fed in (e.g. for the improvement of flow
characteristics or material colouring), process controlled.
Simple degassing with two maintenance covers
6
n
The investment, operating and
maintenance costs for a preshredding system are no longer
required.
n
The extremely short material process path facilitates quick cleaning
and material switches, as well as
shorter down time.
Simple degassing (V)
Vacuum degassing consists of two openings, where melt degassing takes place
using a water ring vacuum pumps (drying).
Manual screen changer
A lever is used to allow the alternate cleaning of two screens, which are swung
out of the plastic melt.
Melt filter
7
Automatic melt filter
A high-quality, two-piston melt filter represents an intelligent solution for automatic melt cleaning. Therefore, a piston screen change is possible without shutting
down the process. Process controlled.
n
Low personnel, compressed air,
water and spare part costs.
n
Backflush melt filters
are recommended for badly soiled material.
GRANULATION SYSTEMS – process controlled
In the case of the A:GRAN, various process granulation systems can be utilised
in line with the plastic to be processed.
Hot die granulation (HD) is generally used for the majority of polyolefins.
The air separator serves
the continuous recycling of film
edge trims as production backup. This inline operation makes
material handling superfluous
and fully automates the NGR
recycling machine. Furthermore, no material storage is
required.
Strand granulation (SG) or
underwater granulation (UWG) are employed for PA, PET or other polymers
and PP with a high melt flow index.
Hot die granulation
In addition, NGR also supplies the entire granulate transport equipment such
as blowers, piping, cyclones, etc.
8
conveyor (transport belt),
e.g. for stamping waste
Operating terminal
Granulation systems
A:GRAN 65 V
*Depending on the material
Strand granulation
QUALITY
Longevity through
robustness
The A:GRAN has an especially
compact and stable design, which
in its simplicity saves both space
and drive power. The A:GRAN is
characterised by long service life
even at full performance and with
the processing of problematic
materials such as PA fibres. In
addition, slow cutter shaft speeds
secure long knife life.
MACHINE HANDLING
Automation
The A:GRAN machine can be fully
integrated into the process used in
a film production plant. This
ensures safe and cost-effective
inline operation. Basically, the
A:GRAN is designed for continuous
feeding in inline operation, but is
also able to react automatically to
any changes in material quantity
and can therefore deliver granulate
of uniform high quality. To this end,
the hydraulic pistons on the cutter
and the screw and granulation
speeds are regulated automatically.
Simple maintenance and
long operating periods
Simultaneous processing
of material in diverse forms
A high degree of process stability
marginalises the influence of the
operating personnel. Moreover,
simple access to wear parts reduces any downtimes to a minimum.
The size and quantity of the
charged material is only restricted
by the funnel opening and not the
process. Therefore, several
differing material feeding systems
can be employed simultaneously.
Glass inspection window/
maintenance opening on the feeder
Stationary knife
Designed and built for
long-term profitability
Robust design, high-grade materials and top quality manufacturing in
combination with the finest possible
controls and proven electronics
guarantee a service life that
extends far beyond the short
amortisation period. It is then that
NGR machines really pay off, as
hundreds of operators on every
continent can confirm.
• Solids such as start-up
lumps and stamping waste can
be fed through an opening. The
A:GRAN funnel cross-section
also permits the feeding of
bulky items. As an option, this
material feed flap can be fitted
with a transport belt,
in order to allow continuous
feeding. A detector provides
a warning of metallic foreign
objects.
Operator-free running
The NGR recycling process merely
requires a sufficient inflow of
material. Hence the fact, that in
order to operate, NGR machines
need just one person to handle
feeding. During inline operation this
material feed is preset through the
production process and automated,
which creates enormous personnel
savings and turns interim material
handling into a thing of the past.
AMORTISATION
Problem-free restarts after
emergency stops
Following sudden plant halts (e.g.
emergency stops), the system can
be immediately restarted without
any problem with filled funnel and
extruder screw.
OPTIONS
Uniform high granulate
quality brings first class
end products
Amortisation in 6-12 months!
Low labour, energy and
maintenance costs
The unique design of the A:GRAN
feed guarantees especially uniform
processing and gentle material
melting. This results in high material
quality without any tangible loss of
physical characteristics.
Due to their high process stability,
throughput performance and low
operating costs, NGR machines offer
extremely short amortisation periods.
grated into the recycling process.
4
Recycling systems can have
a major, negative effect on
polymer quality. Undesirable
deviations such as changes in
viscosity or granulate discolouring may reduce both the
possibilities for its utilisation and
its value.
Air separator
The roller intake allows
the processing of unwound film
rolls.
NGR’s one-step technology
provide energy cost savings of
up to 40 %*.
The shredded plastic is immediately
fed to the extrusion process and is
therefore “hot”. This reduces the
energy requirement for material
melting.
5
Roller intake for film
Feed funnel with electrically powered intake rolls, process controlled.
Air separator feeding
Film edge trims can be carried to the A:GRAN using compressed air. The air
separator, which is mounted above the feed opening, separates the transport air
from the edge trims.
n
In addition to high quality, the
consistency of the regranulate
allows it to be mixed homogenously with original material.
Therefore, NGR is an indirect
guarantor for uniform end
product standards and the
prevention of production rejects.
1 Start-up rejects are simply reinte-
The fact that interim material
storage is no longer required and
the small machine dimensions mean
that valuable space can be saved in
the production hall.
Conveyor belt
Stable design with high sidewalls and metal detector, e-drive, process controlled.
Additive dosing device
In the section between the shredder and the extruder intake, additives equal to
up to 20 % of the material flow can be fed in (e.g. for the improvement of flow
characteristics or material colouring), process controlled.
Simple degassing with two maintenance covers
6
n
The investment, operating and
maintenance costs for a preshredding system are no longer
required.
n
The extremely short material process path facilitates quick cleaning
and material switches, as well as
shorter down time.
Simple degassing (V)
Vacuum degassing consists of two openings, where melt degassing takes place
using a water ring vacuum pumps (drying).
Manual screen changer
A lever is used to allow the alternate cleaning of two screens, which are swung
out of the plastic melt.
Melt filter
7
Automatic melt filter
A high-quality, two-piston melt filter represents an intelligent solution for automatic melt cleaning. Therefore, a piston screen change is possible without shutting
down the process. Process controlled.
n
Low personnel, compressed air,
water and spare part costs.
n
Backflush melt filters
are recommended for badly soiled material.
GRANULATION SYSTEMS – process controlled
In the case of the A:GRAN, various process granulation systems can be utilised
in line with the plastic to be processed.
Hot die granulation (HD) is generally used for the majority of polyolefins.
The air separator serves
the continuous recycling of film
edge trims as production backup. This inline operation makes
material handling superfluous
and fully automates the NGR
recycling machine. Furthermore, no material storage is
required.
Strand granulation (SG) or
underwater granulation (UWG) are employed for PA, PET or other polymers
and PP with a high melt flow index.
Hot die granulation
In addition, NGR also supplies the entire granulate transport equipment such
as blowers, piping, cyclones, etc.
8
conveyor (transport belt),
e.g. for stamping waste
Operating terminal
Granulation systems
A:GRAN 65 V
*Depending on the material
Strand granulation
SUITABLE FOR
UNIVERSAL APPLICATIONS
INGENIOUS DESIGN
Thermoplastics ...
3 working steps in one
Virtually all thermoplastics, including
PE, PP, PA, PS, PC, PET, ABS,
EVA, PPS, bio-tech and materials
with problematic structures (technical plastics) can be gently recycled
into granulate. In this regard, the
control system of the A:GRAN offers
mastery of difficult material recipes
and processing parameters.
NGR invented and patented* the
“cutter-feeder-extruder combination”,
which allows three working processes
to be completed in one:
C
D
4
PP fabric net
5
Printed LDPE film
6
2
1
Roller intake
2
Cutter/feeder/extruder combination
3
Operating terminal
4
Switchgear cubicle
5
Melt filter
6
Hot die granulation
RECYCLING MACHINE
The shredded material is transported to the extruder immediately by
means of a feeder screw.
1
... in any form
3. Extrusion and, if required,
degassing take place in the extruder.
3
B
A
PP synthetic grass
A:GRAN 65
type
Heavily printed LD film
Basic
venting option
kg/h
cutter
hopper volume
m3
0,1
cutting width
mm
390
screw diameter
mm
screw length
L/D
extruder
1
3
5
6
2
On average, the industrial manufacture of plastic products results in
2 - 20 % rejects. These can include
start-up rejects, which are produced
until the required product data such
as thickness, colour, shape and
characteristics is attained, and
waste emanating from production
changes or the process itself
(stamping waste, sprue or edge
strips from blown film).
dimensions
weight **)
V
65
19
...in any form
33
motor
kW
torque
rpm
175
standard
rpm
197
speed
rpm
220
A
mm
4.085 5.000
B
mm
2.550 3.460
C
mm
1.840
D
mm
2.190
E
mm
...granulate output
of 20 - 100 kg/h (44 - 220 lbs/h)
2.230
2,8
UNIVERSALLY SUITABLE FOR …
...thermoplastics
55
t
65
up to 100
output of pellets *)
3,2
*) output for LDPE according to NGR standards, material and form
**) approx. value for transport; depending on chosen executions
standard execution:
Basic … short screw without venting
variable screw speed with frequency converter
optional execution:
• V … simple degassing
• execution ‚speed‘ for increased output
• execution ‚torque‘ for increased screw torque
WE TAKE CARE
OF YOUR PLASTIC WASTE
A:GRAN 65 V
Next Generation Recyclingmaschinen GmbH
Gewerbepark 22, 4101 Feldkirchen, Austria
Phone +43 (0) 7233 70 107-0, Fax -2
[email protected], www.ngr.at
The text and illustrations may contain requested and special features, which are only available at extra charge. The rights relating to technical changes and printing errors are retained.
12 I 08, E
Start-up lumps
• Film edge trims
• All types of film waste
(on rolls, loose or bundled)
• Punching waste
• Injection moulded
parts and tubes
• Start-up lumps
• Fibres
• Tapes
• Fabrics, nonwovens
• Yarns
In the case of the A:GRAN, the invention
has been so adapted that all three of the
main components, i.e. the cutter shaft,
feeder screw and extruder are mounted
on a single shaft. The ingenious details
of this design have been patented.
www.marketing-tools.at
Nonwoven
4
1
2
3
This all occurs in a single operation,
without leaving the machine, which is
why the process bears the designation,
“NGR one-step technology”.
E
The A:GRAN has been designed for
the inline processing of film edge
trims and is equipped with a single
e-drive for the cutter/feeder/extruder.
The efficient cutter and fine control
for differing quantities of material
greatly expand the range of machine
applications. Control takes place by
means of two pneumatic pistons,
which press the material onto the
cutter. The A:GRAN is thus suitable
for universal use with plastics in a
diversity of forms, irrespective of
whether these are simple or difficult
to shred.
1. Slow-running cutting blades shred
any plastic waste.
* S:GRAN series
Two pneumatic pistons press the material
against the cutter.