Tried-and-tested system sets new standards
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.
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
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.
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.
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.
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).
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
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.
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.
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.
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
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.
Best practise in France
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Best practise in Belgium
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.
Malfunction-free, accessible from all sides
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!
Steve Newby, Owner
Malta Recycling, South Africa
The NGR has proven to be a machine of the highest possible quality. It is fully automated which allows our operators more time for other collateral responsibilities. The machine’s design also allows us to maintain an immaculate working area near our production lines which can be easily contaminated by foreign dust or plastics particles.
Softbond Nonwovens, Argentina
Softbond Nonwovens, Argentina
NGR´s excellent output efficiency for our pipe recycling is far above their guaranteed value, that´s why we decided to buy a second machine from NGR for our film recycling, as well.
A.Samed Ciftci, Operations Manager
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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