Applied Machinery’s HDPE Bottle and Container Washing System

Applied Machinery’s range of plastic-washing systems are designed for high-performance recovery of rigid and flexible plastics derived from a variety of sources.

The modular systems tackle HDPE bottles, PE films, PP woven bags and PET bottles.

A standout of the range is Applied’s Genox modular HDPE Bottle and Container Washing System, which is designed for ridged plastics with a wall thickness ranging from 1-25 millimetres.

The HDPE Bottle and Container washer features a wear resistant shredding system that works to maximise operating time and throughput via consistent processing.

Next, a high-speed washing system, with corresponding speed according to material type, liberates contamination for plastic flakes.

The washing tank’s under-water force-washing paddles then work to amplify washing efficiency, while mechanical and thermal drying systems reduce end product moisture.

Label separation can be achieved with advanced wind separation, while shredding and washing are set at calculated intensities to avoid over friction and material loss.

Intelligent system automation ensures that all component actions are sequenced and monitored.

The HDPE Bottle and Container Washing System features an inclined friction washer, float-sink washing tank and vertical dewatering machine, before material passes through a zig-zag classifier.

For more information contact Applied Machinery at 03 9706 8066 or visit their website here.

Melting for the Yarra: Applied Machinery

With a recent report revealing polystyrene to be the most common waste material in Victoria’s Yarra River, Daniel Fisher of Applied Machinery outlines an efficient equipment solution.

Polystyrene, which can take centuries to degrade, is the most prevalent litter item in Melbourne’s Yarra River, according to a new state government report.

The plastic was found at 80 per cent of sites in the Yarra River catchment monitored in a Cleanwater Group and Yarra Riverkeepers study.

“Since 2018, polystyrene has consistently been found to be the highest littered item found on the river,” the report reads.

“Being both a light-weight and brittle material means that the ecological impacts of polystyrene, which can unfold gradually over time, can be widespread and devastating for the river and Port Phillip Bay.”

According to Expanded Polystyrene Australia, an estimated 71,000 tonnes of polystyrene is used annually, growing at a rate of five per cent each year.

Add to ubiquity the material’s notoriously difficult to recycle composition, and Australia’s natural environment has a problem.

While the situation may seem dire to some, according to Daniel Fisher of Applied Machinery, recycling solutions do exist.

First showcased in Australia at the 2019 Waste Expo Australia, Daniel says Applied’s new range of Greenmax EPS recycling machines represent a technological step forward for polystyrene recycling.

When it comes to polystyrene, Greenmax is an internationally renowned specialist. Committed to providing complete polystyrene recycling solutions, Greenmax’s densifiers have been sold in more than 70 countries across the world.

Greenmax Mars C200 hot melt machines operate via a hot melting system, with material initially crushed before heat is introduced. Following this, the liquified material is squeezed out of the machine, and once cooled, shaped into plastic ingots for resale.

“After the shredding, heating and extruding process is complete, the end product has a volume reduction ratio of up to 90:1. This has obvious storage and transport benefits, with a once difficult-to-manoeuvre product transformed into high-value, densified blocks ready for reprocessing,” Daniel says.

Greenmax Mars’ melters are suitable for all kinds of polystyrene material, Daniel says, with a competitive price point for a quality and reliable machine.

He adds that the machines can process most forms of foam plastic waste, including EPE, EPS and EPP.

Daniel explains that given polystyrene’s lightweight and low-density nature, it can be extremely difficult to transport it economically for recycling.

“With Greenmax’s relatively modest footprint, however, the machine is suitable for installation at smaller-scale, local operations,” he says.

The Greenmax series features screw melting technology that enables continuous outputs, with high-density ingot weights of up to 25 tonnes per 40-foot-high cube container load.

The machine enables three temperature control stages to keep output colour as white as possible, with easy operation and no additional adjustment required when in use.

Applied Machinery is proud to be an Australian sales and service partner for Greenmax Recycling, Daniel adds, with the added value of Greenmax’s parent company Intco Recycling’s buy-back offer.

“Intco Recycling can buy the densified polystyrene for their local manufacturing, which Applied can facilitate for local customers, creating a further efficiency and economic benefit,” he says.

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Washing billions of bottles: Applied Machinery

With onshore plastic processing set to grow, Daniel Fisher, Applied Machinery, details the streamlining ability of high-energy washing.

The onshore consequences of the upcoming waste export ban could see the domestic resource recovery industry swamped by mountains of plastic.

To fully capitalise on this, Daniel Fisher, Applied Machinery Project Manager, says plastic recycling operators need to invest in efficient and high-capacity washing systems.

“The significance of washing is often understated, with importance placed on seemingly more complex processes such as sorting and granulating,” Daniel says.

“But, given the nature of most plastic waste, and the fact it often takes the form of packaging, removing contaminants and impurities efficiently is critical to sustained operations.”

According to Daniel, Applied Machinery’s range of plastic-washing systems are designed for high-performance recovery of rigid and flexible plastics derived from a variety of sources.

“We’re able to facilitate modular systems to tackle HDPE and PET bottles, and depending on application requirements, can provide bale breakers, infeed conveyor belts, pre-shredders for wet or dry size reductions, pre-washers and screw washers,” he says.

In particular, Daniel says Applied Machinery’s HDPE Bottle/Container Washing System is well suited to operators hoping to take advantage of the upcoming domestic plastic processing boom.

Developed by Guangzhou-based equipment manufacturer Genox, the HDPE washing line is designed for rigid plastics.

Daniel says the washing system’s wear-resistant design works to maximise operating time and throughput via consistent processing.

“The high-speed washing system works to liberate plastic flakes from contaminants,” Daniel says.

“The washing tank’s under-water force-washing paddles then work to amplify washing efficiency, while mechanical and thermal drying systems reduce end product moisture.”

Shredding and washing are set at calculated intensities, Daniel says, to avoid over friction and material loss.

“Label separation can also be achieved through advanced wind separation,” he adds.

The system features an inclined friction washer, float-sink washing tank and vertical dewatering machine, before material passes through a zig-zag classifier.

In the current economic and political waste climate, Daniel says investing in a Genox HDPE Bottle/Container Washing System can deliver significant returns on investment.

“The Australian resource recovery industry will see major opportunities over the next few years, so the time is right for facilities to upscale their operations and capitalise on the next generation of plastic processing.”

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Genox PE Film Washing Lines: Applied Machinery

Applied Machinery’s PE/PP plastic washing system facilitates high-performance recovery of difficult-to-recycle plastic films.

The PE/PP Film system is designed for washing plastic films with contamination levels exceeding 80 per cent. The process works to minimise the recycling waste flow rate and evaporation losses.

The process begins with pre-shredding and pre-washing, which removes a large portion of abrasive material, such as sand and grit to protect the rest of the system. Underwater force-washing paddles in the washing tanks then work to maximise washing efficiency.

Next, a high-speed washing system optimised according to specific material type liberates and separates contamination from film flakes. This is followed by mechanical (centrifugal and squeezing) systems that control the moisture content of the finished product. At less than five per cent moisture, the material output is suitable for high-quality pelletising.

The system features a film press, float-sink washing tank, centrifugal dryer, inclined friction washer and pre-washer. Intelligent system automation ensures all component actions are sequenced and monitored.

The correct combination, sizing and equipment configuration of the equipment results in a reliable, efficient plastic recycling system producing high-quality materials ideal for sale.

The system is suitable for agricultural films, films recovered from MSW or MRFs, films recovered from landfills, post-industrial or post-consumer films and large raffia bags.

Pelletising polypropylene: Applied Machinery

Daniel Fisher, Applied Machinery Project Manager, wants to revive domestic plastic recycling through sustainable Polystar pellets. 

The recycling conversation is becoming more layered and complex by the day, with notoriously problematic plastic often taking centre stage. While the problem of plastic waste is widely understood, manufacturing processes still heavily rely on the material.

Daniel Fisher, Applied Machinery Project Manager, says responsibly processing plastic while keeping up with demand requires straightforward remanufacturing options. He adds that one such option is recycled plastic pellet production.

Daniel says to implement a wider uptake of recycled pellets in the manufacturing industry, resource recovery operators need simple-to-use equipment.

“When dealing with a difficult waste stream such as plastic, it’s common for operators to think that a more complex system will perform better,” Daniel says.

“But as the exclusive Australian distributor of Polystar Machinery, Applied Machinery is committed to supplying customers with straight forward and cost-effective solutions.”

Applied Machinery has worked with the Taiwan-based recycling equipment manufacturer for four years.

Polystar manufactures a range of one-step machines designed to reprocess multiple waste streams, notably polyethylene and polypropylene flexible packaging material.

Polystar technology is designed to be simple to operate and easy to maintain.

“The recycled output result is high-quality plastic pellets that can be repurposed back into manufacturing straight away,” Daniel explains.

“The pellets save waste disposal costs by producing a saleable product, while also offering an alternative to raw material extraction.”

Applied Machinery can offer customers the full suite of Polystar products, including the Polystar HNT and the Polystar Repro-Flex.

“HNT machines are typically suited for flexible, post-industrial film and have the added benefit of being able to produce quality pellets from even the most heavily printed packaging material.”

Daniel says the Polystar Repro-Flex is suited to multiple recycling applications including plastic bags, film scraps, bubble wrap, shrink film and laminated film.

“Repro-Flex machines also work well for post-industrial film waste, as the system can process washed flakes, scraps and pre-crushed rigid plastic waste from injection and extrusion,” he adds.   

Both the HNT and Repro-Flex feature an integrated cutter compactor, which removes the need for pre-cutting.

“The cutter compactor, which generates frictional heat during the compacting process, also helps remove moisture from the material.”

According to Daniel, eliminating moisture is a particularly significant feature when generating recycled plastic pellets, as even minimal water can render a whole batch unusable.

Daniel says the integrated Polystar system also eliminates the need for separate crushers and the common problem of inconsistent feeding.

“The integration of the cutter compactor and extruder ensures extremely fast and stable feeding, as the tangentially connected extruder is continuously filled with pre-compacted material.”

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The behemoth single-shaft shredder

Applied Machinery’s BH Series heavy-duty single shaft shredder can be considered a “behemoth.”

The heavy-duty size reduction machine is designed for shredding a wide variety of materials with the powerful, wear resistant machine structure well suited to demanding recycling applications.

Applications include municipal solid, industrial and demolition waste, wood waste, plastics, alternative fuels and a range of other items.

Its v-cutting rotor design allows for staggered cutter positioning alongside heat treated and adjustable counter knives ensuring cutter clearance can be maintained.

A classifier screen enables accurate particle size control while a force feeding ram supports a precision machined chamber base with adjustable/replaceable brass guides.

The machine’s powerful electric drive motors, heavy duty oversized gearboxes and shock absorption system ensure smooth processing with improved performance. Its bearings, hydraulic opening design and electrical control panel mean the machine is robust and intuitive.

Other equally capable machines include GC Series Granulators, ideal for a range of materials such as plastics, rubber and fibres and K Series high performance single shaft shredders suitable for processing a wide range of materials.

Applied Machinery works with its customers to find the right machine for them, with a number of Genox shredders and granulators also available for niche applications.

Applied Machinery’s plastic washing systems

Applied Machinery’s plastic washing systems are designed for high performance recovery of rigid or flexible plastics derived from a variety of sources.

The modular systems tackle HDPE bottles, PE films, PP woven bags and PET bottles.

Depending on the application, the plants may comprise a bale breaker, infeed conveyor belt, pre-shredder for wet or dry size reduction, pre-washer to remove sands and dirt and screw washer.

Other features may include a hot washing tank with alkaline (caustic) soda to remove glues and oils, a sink float separation tank to remove non-contaminants and granulator for wet granulation and washing. For high speed washing or material scrubbing, a horizontal friction washer can be applied. In addition, centrifugal dryers, screw presses, thermal drying systems, zig zag classifiers and bag stations are also plant features.

The correct combination, sizing and equipment configuration of the equipment results in a reliable, efficient plastic recycling system producing high-quality materials ideal for sale.

Typical designs cover a PE washing system for recycling materials to high purity and low moisture, such as post-consumer HDPE bottles (with labels), drums and containers and LDPE and LLDPE products.

A PP woven bag recycling line offers a system that minimises the quantities of fines created and keeps material loss to a minimum.

The PET bottle washing system recovers labels and caps from soft drinks and water bottles and produces a clean, uniform-sized PET flake with low moisture levels.

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Pure and simple: Applied Machinery partners with FIMIC

With China’s National Sword putting pressure on plastic recyclers, Applied Machinery has partnered with an Italian company to help recyclers hit contamination targets.

Read morePure and simple: Applied Machinery partners with FIMIC

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