Shredding and Granulation

The method of reducing the size of materials by shredding and granulation comprises the following steps:

  • Sorting

    The initial step is sorting the materials set to be shredded and granulated, which may contain contaminants like metals and other plastic materials. This is a key part of the process, as this stage has to be correctly adhered to for no unwanted materials to enter the process.

  • Shredding

    Once the materials have been sorted, they will then be fed into the shredder, this process completes the initial size reduction of the material.

  • Granulation

    After the material has been screened, it is then processed through a granulator, thereby reducing the size further to customer-specific requirements or for processing through extrusion.

Overall, the process of size reduction through shredding and granulation involves a combination of cutting and screening to create granules of a desired size. This process is commonly used in the recycling industry to reduce plastic components.

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Extrusion / Compounding

Below is the step by step guide on how extrusions and compounding is conducted:

Extrusion

  • Preparing materials

    The first step when it comes to extrusion is preparing and selecting the materials. The raw materials which generally come in the form of granulated material are placed into the hopper of the extruder. Any additives, colourants or fillers can be either premixed or added through dosing and feeding systems into the extruder.

  • Melting and mixing

    After the materials are placed into the extruder, they will then be heated and melted whilst being conveyed through the extruder barrel. This is a process of melting and filtering the material as well as allowing the introduction additives, fillers and colourants.

  • Shaping

    The heated molten materials then travel through a die, which will mould it into the final shape. The die is able to customise the shapes needed, so that it can create a number of different products such as granules for injection moulding/extrusion and finished goods in the form of pipes and profiles.

  • Cooling

    After extrusion the materials are then cooled typically using a water bath or air dependant on the materials end application.

  • Cutting

    In the case of granules the material after being cooled is cut in a pelletiser. If the product is an extruded part this is cut to the desired length before QC testing.

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Raw materials

Below are the general steps involved in the process of raw material selection and development which can vary from industry to industry:

  • Research and Development

    The initial step involved in the raw material selection process is research and development. This process involves selecting the correct properties and characteristics for the material to be used. This will be defined by the end product required specification.

  • Prototype Development

    Once potential sources and methods have been identified, prototypes are developed to test and refine the material and process. This can involve creating small batches of the material and testing for the physical, chemical and mechanical properties.

  • Scale-up

    Once a promising prototype has been developed, the next step is to scale up to production. This involves developing a manufacturing process that can produce the material in larger quantities while maintaining consistency and quality. This is typically done on a pilot plant prior to scale up onto full scale production.

  • Quality Control

    Quality control measures are put in place to ensure that the material meets the desired specifications and performance criteria. This involves testing the material at various stages of production and implementing corrective actions as needed. Then once the product is manufactured various agreed parameters are tested to confirm the specification has been met.

  • Regulatory Compliance

    Depending on the industry and application, the material may need to meet certain regulatory requirements, such as safety or environmental standards. Compliance with these is an important consideration throughout the development process.

  • Market Launch

    Once the material has been developed and tested, it is ready for market launch. This can involve marketing and promotion efforts, as well as ongoing quality control measures to ensure that the material continues to meet the desired specifications and performance criteria. Consistency of product is vital and must be monitored for conformance at all stages of the process before launch.

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