The multi-talented, high performer
A:GRAN is the compact technology for scrap plastic products created in industrial processes of any type. The recycling machine combination focuses on high performance in a compact space.
Thanks to the system‘s minimal energy consumption and material-conserving shredder, A:GRAN can be used to achieve zero-waste production (all production waste fed back in). This means that high efficiency and implemented sustainability are the biggest strengths of this recycling solution.
Thanks to the high capacity of A:GRAN, start-up lumps are actually re-processed without any additional pre-grinding. Do you have production waste that is created intermittently? No problem! This versatile solution switches on and off quickly and easily, enabling you to work efficiently and meet the needs of the shop floor.
At a glance
- Processing industrial plastic waste of any kind
- Output rate up to 120 kg/h (270 lbs/h) depending on type
- Switching on and off by a single push button
- Quick and easy start-up and shut-down at any time
*) Output values for LDPE according to NGR company standard, depending on material and quality.
In addition, NGR provides all the equipment for conveying pellets such as blower, pipes, cyclones and much more.
The operation principle of A:GRAN
Plastic waste is processed by a heavy duty shredder operating at low speed for gentle size reduction and minimal loss of material properties. In this process, pneumatic rams push the material into the shredder drum. After shredding, the material is fed directly into the extruder.
In the extruder, the material is brought to a uniform melt temperature and degassed, if necessary. All the components are positioned in close proximity to prevent oxidation of the material and to make optimal use of heat from the shredding process.
Shredder, feeder and extruder lie along one axis and are driven by a single motor. This patented combination of shredder, feeder and extruder is a feature of all units in the A:GRAN line.
In a single process step, the slow-turning shredder blades grind up the plastic waste and the shredded material is then fed continuously to the extruder.
Process bulky plastic scrap
Large, thick or bulky waste can be processed without pre-shredding as long as pieces fit into the hopper opening.
One-button automatic ON/OFF control
The control system provides for smooth start-up of equipment components. Restart after unplanned shutdown in less than two minutes with full hopper and full extruder
Dump and run operation
The material level in the chute is constantly measured and the feed is regulated accordingly. Conveyor can be loaded intermittently – the rest is handled by the NGR control unit
Specially developed for the challenges of recycling, the universal extruder screws provide optimum melt homogeneity and process material efficiently with minimal loss of physical properties. For special requirements, our expert NGR engineers develop custom-tailored screw geometries.
All equipment functions from feeding to pelletizing are controlled automatically from the easy-to-read NGR touchscreen.
Recipes are managed in the operator control unit, which increases traceability, provides ease of use, and ensures equipment parameters are set properly.
In addition to high quality, the uniform pellet size also provides for homogeneous mixture in new material. NGR thus plays an indirect role in ensuring consistent quality in the final product.
The air separator is used in the production process to continuously recycle film edge trim, which is fed pneumatically into the machine. With “inline operation,” further material handling is unnecessary, and the NGR recycling machine is now fully automated.
With variable feed speed, roll scrap is treated in a process-controlled manner. The virtually unmanned machine is fed continuously. The roll feeder can be operated at the same time with other types of feeding (e.g. conveyor belt).
The conveyor belt transports the feed material through a metal detector into the feed hopper. The belt is stopped automatically, if metallic matter is detected in order to remove it.
Additives such as color pigments, CaCo3, compatibilizers can be added to the material flow in a process-controlled manner. Dosing systems for pellet and/or powdered additives are available.
Designed for light printing and low humidity. The vacuum degassing system includes a vacuum pump and is connected to two venting ports on the extruder.
Vacuum pump with closed water circuit
Each venting combination can be equipped with a closed water circuit. The fresh water consumption at the vacuum pump is thereby reduced significantly.
Hot-die Waterring Pelletizer (HD)
For thermoplastics with a higher viscosity. The melt exits through the wear-resistant die plate, and is knocked off by the pelletizer blades. The pellets cooled in the water ring are flushed out, dried in the centrifuge and discharged. By adjusting the blade pressure, pelletizer blades provide a long service life; replacement is quick and easy.
Strand pelletizer (SP)
For low-viscosity melts. The melt emerges from strand nozzles, is cooled in a water bath, dried by means of a fan and cut to the desired length in the pelletizer. The result is cylindrical, dust-free pellets with excellent mixing properties.
Automatic strand pelletizer (A-SP)
In addition to the benefits of the SP, the A-SP option offers the added convenience of fully automated start-up. The strands are transported automatically by a water slide to the pelletizer, and the pellets are dried in a centrifuge.
Hot die-air pelletizer
Specially designed for inline applications where water is not used. The melt exits through the wear-resistant die plate, and is knocked off by the pelletizer blades. The pellets are carried away in the air stream and cooled.
Underwater pelletizer (UWP)
For difficult-to-process (e.g. sticky) polymers or thermoplastics with a very high melt flow index. The melt emerges from the die plate and is knocked off by the pelletizer blades. The whole process takes place under water. In the centrifuge, the pellets are separated from the process water and dried.
Manual screen changer
For clean, in-house production waste. Using the manual lever, two screens can be swung out alternately to allow for cleaning of the melt stream. The process is discontinuous, because the machine has to be switched off to change the screen.
Double-piston screen changer
For light impurities. The hydraulically operated double-piston screen changer allows continuous filtration of the melt. This allows a screen change without process shutdown.
Back-flush screen changer
For heavily contaminated materials. The hydraulically operated double-piston screen changer filters the melt in a process-controlled and continuous manner. The integrated backwash device automatically cleans the screens. The number of back-flushes and the related service life of the screens depend on the degree of contamination of the material.
The throughput scale is integrated in the machine control system and displays the current production output in kg/h (lbs/hr). The data can be logged in a BDE system.
Gas control unit
This unit provides quality control by continuously measuring pellet density. Based on preset parameters, the unit determines whether to switch the gates to the second choice or to scrap when this value falls below a setpoint. Monitoring is inline and integrated continuously in the production process.
For continuous melt viscosity measurement. Melt is taken from the production extruder, the viscosity is measured, and then the melt is returned to the extruder.
Based on the differential pressure across the capillary, the viscosity of the material (IV value, MVR) is determined by means of a stored recipe.
Solid engineering, high-quality materials and precise execution ensure a long service life for equipment.
Maintenance-friendly access to moveable parts allows you to quickly change material, efficiently disassemble and assemble wear and tear parts, and minimizes downtime.
The solidly-constructed, low-speed shredder combined with pneumatically-driven pushers can also provide efficient shredding of bulky plastic scrap.
Our all-round service – satisfaction included
Excellent technology calls for excellent service. Our 100% commitment to flawless service ensures maximal cost efficiency and minimal downtime.
- Service hubs for the fastest possible processing of all maintenance and repair work
- Spare parts centers for flexible responses to strong markets
- High spare parts availability thanks to particularly high stock levels in Europe and North America
- Worldwide extruder screw production for short-term production or repairs
- Easy ordering of parts in our webshop
- Starter and spare parts packages for every new machine
NGR Applications & Solutions
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