The power package for plastic waste of all shapes and sizes
X:GRAN is setting new standards in the high-output segment while at the same time working at maximum efficiency and with improved production capability.
Robust and extremely capable – the power of the inhouse plastic recycling machine X:GRAN is clear to see. The X:GRAN solution does more than just process all types of plastics waste. It even handles bulky materials such as large bales and carpet pads – without any additional preliminary size reduction.
X:GRAN is also at the cutting edge of efficiency. Thanks to its material-conserving shredders and optimally guided extrusion, you can be sure that the X:GRAN will achieve sustainable zero-waste production (all production waste fed back in).
At a glance
- Easy, material-conserving processing, even for difficult industrial plastic waste
- Output rate up to 2,500 kg/h (5,070 lbs/h) depending on type
- Switching on and off by a single button
- Quick and easy start-up and shut-down at any time
- Small footprint saves space
* 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 operating principle of X: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, a hydraulic ram pushes the material to be shredded onto the shredder shaft.
The shredder and extruder drives are controlled separately and automatically, based on load.
After shredding, the ground up material is fed directly into the extruder via the feeder screw. 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.
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 by the feeder screw.
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 hopper is constantly measured and the feed is regulated accordingly. Discontinuous filling of the conveyor is possible – the NGR control unit does the rest.
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.
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).
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.
For damp materials, e.g. after washing, combined venting unit is used, which consists of an atmospheric and vacuum degassing unit.
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.
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
Best practise in Spain
Best practise in Germany
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.
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 hydraulic-driven pusher also provides efficient shredding of bulky plastic scrap.
NGR’s response time and service driven partnership sets a standard unmatched in the industry.
Phillip Goldberg, President
Columbia Recycling, USA
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
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