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7 Solutions to Common Plastic Recycling Operation Problems
Plastic recycling is one of the vital processes for reducing the environmental impact of plastic waste. However, due to the different characteristics of each type of plastic, plastic recycling operations might face problems from time to time. In most cases, many common plastic recycling problems can be solved with minimum effort when you have user-friendly and flexible plastic recycling machines, that can adapt to the changes in the operation. Here we have listed the possible solutions to 7 common plastic recycling operation problems.
7 Common Plastic Recycling Operation Problems
1. Material Feeding Instability
One of the common plastic recycling problems is materials feeding instability. Feeding waste materials into plastic recycling machines must be stable to achieve maximum productivity while preventing machine downtime. Excess feeding or insufficient feeding often results in poor production efficiency.
Solution:
Automatic material feeding systems with a belt conveyor, screw conveyor, or nip roller feeders that work synchronously with the plastic pelletizer can provide stable material feeding and solve this plastic recycling problem. These POLYSTAR feeding systems pause or run based on the load of the pelletizer, resulting in maximum feeding efficiency.
2. Contamination of the Plastic Material
Food residue, dirt, oil, and other impurities as well as mixing different types of plastics can contaminate the recycled pellets and cause a decrease in their quality and reusability. Contamination also makes the recycling process less effective, producing more waste while raising costs.
Solution:
The easiest solution to this common plastic recycling problem is to ensure that the waste plastics are clean and sorted according to their types before they are fed into the recycling machines. Dirty post-consumer plastic waste must be washed and dried before the recycling process.
3. Blockages and Hopper Bridging
Material blockage is generally caused by improperly prepared materials or poor maintenance of the machine components. In hopper-feeding recycling machines, the material might cause bridging because of interlocking with each other or due to moisture (for tiny particles).
Solution:
Proper preparation based on the type, shape, and condition of the waste material for your specific recycling machine, and using auto-feeding systems can help solve many of these plastic recycling problems related to blockage. Periodic maintenance on the machine components, regularly changing filter meshes, and unclogging the die head are also easy and common preventive. Using force feeders for hopper-feeding recycling machines can help prevent the plastic recycling problem of material bridging.4. Overheating
Overheating the plastic waste in the integrated pre-conditioning equipment (such as the cutter compactor and shredder) or overcooking the plastic melt in the extruder often causes the degradation of the recycled pellets. which is a significant plastic recycling problem.This reduces their reusability and weakens the quality of final plastic products.
Solution:
Setting the right temperature on the particular sections of the recycling machines based on the materials, calibrating heating, and cooling elements efficiently, and using reliable components that do not cause temperature imbalance can significantly prevent material overheating problems. Prevention of material blockages also reduces local clogging and overheating problems related to plastic recycling, addressing another plastic recycling problem.
5. Sticky Plastic Pellets
There might be several reasons that make recycled pellets stick to each other such as higher extruder temperature, poor pellet cooling, and material characteristics.
Solution:
To address these plastic recycling problems related to sticky pellets, setting the right extruder temperature parameters based on your material, and ensuring the cooling water temperature (air temperature on air-cooled recycling machines) is at a suitable level can solve most issues.
Using a centrifuge dryer can also prevent pellets from sticking to each other while also further drying them. tacking another of the plastic recycling problems.
Using a chiller, especially for hot climates, is also suggested.
Using a centrifuge dryer can also prevent pellets from sticking to each other while also further drying them. tacking another of the plastic recycling problems.
Using a chiller, especially for hot climates, is also suggested.
6. Hollow Plastic Pellets
One of the plastic recycling problems manufacturers face is the formation of hollow plastic pellets, which are not preferred for plastic production. Hollow pellets often cause inefficient production and poor final product quality because of their low density, reduced strength, inconsistent size, and shape. Poor degassing, poor plasticization, improper temperature, and incorrect cooling water circulation speed can be the common reasons behind this plastic recycling problem of hollow plastic pellets.
Solution:
Vacuum degassing system options based on the condition of the material is an effective solution to remove gas from the materials which causes hollow pellets.Adjusting the right and stable temperature on particular zones of the recycling extruder and die head provides smooth plasticization.
Adjusting the right cooling water temperature and speed (not too cold and not too fast) prevents recycled pellets from forming a hollow shape, tackling yet another issue among the various plastic recycling problems.
7. Non-uniform Pellets or Chunks
One of the significant plastic recycling problems is the lack of uniformity in the final recycled pellet shape and size, which is crucial for determining the quality of recycled plastic. Many factors, including instability in feeding, material flow, and especially a poor pellet cutting system, are common reasons behind this recycling problem of non-uniform pellet output. Pelletizing inefficiency is the most common reason for plastic recycling problem of chunk creation.
Solution:
Stabilizing material feeding, ensuring smooth melt flow with the right temperature adjustment and preventing clogging, and using an auto speed and pressure-controlled pellet cutting system will solve most of the non-uniform pellet output problems related to plastic recycling.
Such as the POLYSTAR water ring pelletizer automatically adjusts pellet cutting speed based on the speed of the melt coming out from the die head. The system also ensures the pelletizing knives are always positioned on the die head synchronously with the die head pressure.
This results in cutting uniform size and shaped pellets all the time. Dull pelletizing knives or their improper disposition might cause plastic recycling problems of chunk creation. Replacing the knives with original spare parts and maintaining the right position can solve this problem associated with plastic recycling.
How to Choose a Stable Plastic Recycling Machine?
While investing in a plastic recycling machine, recyclers, and plastic producers are suggested to consider the machine's performance, user-friendliness, and ease of maintenance all together to avoid potential plastic recycling problems. A stable plastic recycling machine must work in harmony with its all sections and equipment to prevent plastic recycling problems arising from machinery issues.
Moreover, responsive after-sales service with quick spare parts support provides a big advantage and helps you stay competitive in the market in the long run by minimizing downtime due to plastic recycling problems.
Conclusion
Thanks to continuous re-engineering and using world-class components, POLYSTAR is proud to provide stable machine operation performance along with high-quality outputs, minimizing plastic recycling problems. This is one of the important keys to our customers’ fast ROI by reducing issues from plastic recycling problems.
About the Author
Resul Gökpınar
International SalesResul creates up-to-date content based on his experience, gained by solving customers' problems in Turkey and the EMEA market.