NXT:GRAN

NXT:GRAN

Tried-and-tested system sets new standards

Shredder-feeder-extruder combination

The NXT:GRAN continues to combine size reduction, feeding and extruding into one extremely efficient work step (ONE-STEP technology). In doing so, it draws upon the experience gained from having over 1000 patented shredder-feeder-extruder combination installations worldwide.

Description

Residual products left behind by the industrial production of plastic products are a high-quality and valuable raw material. To ensure that they can be fed back into production without losses, we build recycling machines with maximum technological sophistication to handle this task flawlessly. When building these machines, we focus primarily on economic and environmental sustainability.

The NXT:GRAN offers maximum performance in all areas. Zero-waste production between input and output guarantees that the full value of the material is preserved. At the same time, as with all NGR technologies, input of work and energy are reduced to an absolute minimum.

At a glance

  • Simple, material-conserving processing of industrial plastic waste of any type
  • Patented single-shaft shredder/ extruder combination from the inventor
  • Output rate up to 800 kg/h (1,760 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
  • Small footprint saves space
More materials: PA, PC, PPS, ABS, EVA, bioplastics, blends, …

Technology

The operating principle of NXT:GRAN

Using the material efficiently in each work step: The patented shredder-feeder-extruder combination provides maximum performance for extremely high output and quality.

First, the materials being fed are pressed against the solid shredder shaft by the hydraulic pusher. The shredded material is then conveyed into the extruder by the revolutionary Duo-Direct feeder. Both of these process components feature load-dependent and fully automatic control.

In the extruder, the polymer is efficiently melted and homogenized, and, if necessary, the melt is vacuum degassed at the same time. The shredder outlet and extruder intake components are placed close together so the heat generated in pre-processing is transferred into the extruder. This design feature optimizes the energy balance and gives the NXT:GRAN extremely efficient operation.

One-step-technology

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

Even with discontinuous feeding, the NXT:GRAN enables simple DUMP & RUN operation through continuous fill level measurement during size reduction.

Dump and run operation

Thanks to the tried-and-tested ON/OFF single-button operation, it is easy to start up the system or shut it down smoothly at any time. It is also possible to restart within less
than a minute after an unexpected shutdown.

NXT:GRAN Extruder

Extruder screw

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.

NXT:GRAN Control Unit

Control unit

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.

High-quality pellets

High-quality pellets

Pellet size

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.

Add-Ons

  • Feed-in

  • Degassing

  • Pelletization

  • Filter

  • Peripherals

  • Test equipment

Feed-in

Air separator

Air separator

Air Seperator

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.

Roll feeder

Roll feeder

Roll Feeder

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).

Conveyor belt

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.

Dosing unit for additives

Dosing unit

Dosing unit

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.

Degassing

Single venting

Single venting

Single venting

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.

Double venting

Double venting

Double venting

Designed for plastics printed, for example, on all surfaces and/or moist plastics. The simple venting unit can be supplemented by another modular unit with two venting openings and an additional vacuum pump.

Heavy duty vacuum pump

Heavy duty vacuum pump

High-performance vacuum

In addition to the modular venting unit, a combination of water ring pump and high-performance vacuum pump runs in order to increase the vacuum performance (e.g. PET processing).

Combined venting

Combined venting

Combined venting

For damp materials, e.g. after washing, combined venting unit is used, which consists of an atmospheric and vacuum degassing unit.

Vacuum pump with closed water circuit

Vacuum pump with closed water circuit

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.

Pelletization

HD pelletizer, hot die-face pelletizer

HD pelletizer

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

Strand pelletizer

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

Automatic strand pelletizer

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.

Under water pelletizer

Under water pelletizer

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.

Filter

Manual screen changer

Manual screen changer

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

Double piston screen changer

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.

Backflush screen changer

Backflush screen changer

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.

4K Backflush screen changer

4K Backflush screen changer

4K back-flush filtration

For heavily contaminated materials. In contrast to the standard backflush screen changer with 2 screen cavities, this system is equipped with 4 screen cavities. The double filtration surface with the same frame size results in a longer filter life.

Automatic band melt filter

Automatic band melt filter

Band melt filter

For high contamination at high throughput rates. With the lowest melt losses and low filter costs, fully automatic operation ensures excellent filtration results. It is used particularly for post-consumer plastics.

High-performance melt filter

High-performance melt filter

The continuous melt filters in the ERF series are suitable for a wide range of moderate and highly contaminated polymers and provides a pressure constant operation, long screen lifes, very low melt losses and a compact design. By the permanently rotating filter drum foreign particles are being constantly and effectively removed, depending on the application ERF melt filters enables throughputs from 150 to 10,000 kg/h.

Peripherals

Customized solution for film rolls

Customized solution for film rolls

Film Manufacturing

Best practise in France

Customized solution for decored film

Customized solution for decored film

Film Manufacturing

Best practise in Spain

Customized solution for containers and boxes

Customized solution for containers and boxes

Injection-molded boxes

Best practise in Germany

Customized solution for pipe production

Customized solution for pipe production

Pipe Manufacturing

Best practise in Belgium

Test equipment

Flow scale

Flow scale

Flow scale

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

Gas control unit

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.

Online viskosimeter

Online viskosimeter

Online Viscometer

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.

Malfunction-free, accessible from all sides

Images

Problem-free maintenance thanks to maximum ease of use

The faster and easier it is to carry out maintenenace and repair work, the shorter the associated downtimes will be. The NXT:GRAN features outstandingly easy-to-maintain accesses.

Testimonials

NGR is a real game-changer for us, beside the strength of the implemented Shredder and the reliability it makes a real difference because of easiness of operation. After using several Cutter-Compactor machines we are very happy taken the next step to go for NGR´s Shredder-Feeder-Extruder Combination making our life much easier!

Malta Recycling

Steve Newby, Owner
Malta Recycling, South Africa

In our company,there are 3 NGR machines, E:GRAN and two S:GRAN which are taken at various times. These machines are easy to use.  Production and Labor Safety in the forefront. The automation system of the machine has been selected from the brands that maintainers can easily reach. PLC and motor drives can be easily backed up. Operators can easily use the operator panel. And the service that NGR offers, is fully dependable and trustable. Thank you NGR for your excellent cooperation

NGR-Sekuro

Abdülaziz Aktaş, Factory Manager
Sekuro, Turkey

NGR machines are very good and very strong machines to work with. The old baby is still going strong, even-though it´s already almost 20 years old. NGR´s service technicians are very experienced and knowledgeable during the few occasions we needed them. Spares are easily available even in South Africa.

Spunchem

Rishi Nunkumar, Waste General Officer
Spunchem, South Africa

Support

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.

Our services

  • 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

NXT:GRAN

[2 MB]

NGR Applications & Solutions

[4 MB]

Webshop

Visit our webshop and benefit from even easier procurement of NGR spare parts.

Visit shop

Put us to the test!

Your plastic waste is tomorrow’s raw material.

In our test centers, we will demonstrate to you the performance of NGR recycling machines using your raw materials. We’ll be pleased to show you the benefits in person.

Contact us
NXT:GRAN recycling machine