PRODUCTS & SERVICES

Pelletizing

PELLETIZING BUSINESS

Pelletizing is the process of compressing or molding a material into a shape of a pellet. A wide range of different materials are pelletized including chemicals, iron ore, animal compound feed, plastics, waste materials, and more.

Plastic pelletizing is a system and technology in which plastic scraps are recycled back into a reusable raw material. The melt-filtrated strands are cooled briefly and cut into pellets. Plastic manufacturers are processors can then reuse it for a variety of applications.

Benefits of Pelletizing

Pelletizing a material can offer a number of benefits. Because of this it has become a popular method of improving product performance, easing handling challenges, and even targeting desired product characteristics.

Plastic pelletizing, which involves converting plastic waste or raw materials into small pellets, offers several significant benefits:

Recycling: Plastic pelletizing facilitates the recycling of plastic waste, diverting it from landfills and reducing environmental pollution. By converting plastic waste into pellets, it can be reused in the manufacturing of new plastic products, contributing to a more sustainable and circular economy.
Resource Conservation: Pelletizing allows for the efficient utilization of plastic materials, conserving natural resources and reducing the need for virgin plastic production. This helps mitigate the environmental impact associated with extracting and processing raw materials for plastic manufacturing.
Waste Reduction: Plastic pelletizing helps to reduce the volume of plastic waste by compressing it into denser pellets, making it easier and more cost-effective to handle, transport, and store. This contributes to the effective management of plastic waste streams and minimizes the strain on waste management systems.
Energy Savings: Compared to producing new plastic from raw materials, recycling plastic into pellets typically requires less energy, resulting in lower greenhouse gas emissions and reduced reliance on fossil fuels. This energy efficiency further enhances the environmental benefits of plastic pelletizing.
Product Versatility: Plastic pellets can be used as feedstock in various manufacturing processes to produce a wide range of plastic products, including packaging materials, construction materials, automotive components, and consumer goods. The versatility of plastic pellets allows for diverse applications across different industries.
Quality Improvement: Pelletizing helps to standardize the quality and properties of recycled plastic materials, resulting in more consistent and reliable end products. This is particularly important for applications where specific performance criteria must be met, such as in the automotive or electronics industries.
Cost-Effectiveness: Recycling plastic into pellets can offer cost savings for manufacturers compared to using virgin plastic, as recycled plastic materials are often more affordable. Additionally, reducing waste disposal costs and potential regulatory fines associated with improper waste management can further contribute to cost savings.
Environmental Protection: By reducing the demand for new plastic production and minimizing plastic pollution, plastic pelletizing plays a crucial role in protecting ecosystems, wildlife, and human health from the harmful effects of plastic waste.

Overall, plastic pelletizing is a key strategy for addressing the environmental challenges posed by plastic waste while also promoting resource efficiency, energy conservation, and sustainable development.

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Process About Pelletizing

The process of pelletizing combines mixing of the raw material, forming the pellet and a thermal treatment baking the soft raw pellet to hard spheres. The raw materials is rolled into a ball, then fired in a kiln to sinter the particles into a hard sphere. Plastic pellets are also known as nurdles.

The plastic pelletizing process involves several steps to transform plastic waste or raw materials into small pellets suitable for use in manufacturing. Here's an overview of the typical process:

Collection and Sorting: Plastic waste is collected from various sources, including households, businesses, and industrial facilities. It undergoes sorting to separate different types of plastics (e.g., PET, HDPE, PVC) and remove contaminants such as paper, metal, and other non-plastic materials. This step is crucial for ensuring the quality and purity of the recycled plastic.
Cleaning and Shredding: The sorted plastic waste is thoroughly cleaned to remove any remaining contaminants, such as dirt, labels, and adhesives. After cleaning, the plastic is shredded into smaller pieces or flakes using mechanical shredders or granulators. Shredding increases the surface area of the plastic, facilitating subsequent processing steps.
Melting and Extrusion: The shredded plastic flakes are melted in an extruder, which applies heat and pressure to melt the plastic and convert it into a molten form. The molten plastic is forced through a die, which shapes it into continuous strands or filaments. This process is known as extrusion and forms the basis for pellet production.
Pellet Formation: The extruded plastic strands are cooled and solidified as they pass through a water bath or air cooling system. Once cooled, the solid plastic strands are chopped into uniform-sized pellets using a pelletizer or cutter. The pellets may undergo further drying to remove any residual moisture before being packaged for storage or transportation.
Quality Control: Throughout the pelletizing process, quality control measures are implemented to ensure the consistency, purity, and integrity of the plastic pellets. This may involve monitoring parameters such as pellet size, shape, color, and chemical composition to meet the specifications required for the intended application.
Packaging and Distribution: The finished plastic pellets are typically packaged in bags, containers, or bulk shipments, ready for distribution to manufacturers and processors. Proper packaging helps protect the pellets from contamination and damage during storage and transportation.
End-Use Applications: The plastic pellets are then used as feedstock in various manufacturing processes to produce a wide range of plastic products. These applications include injection molding, extrusion, blow molding, and thermoforming, among others. The versatility of plastic pellets allows for their use in diverse industries, including packaging, automotive, construction, electronics, and consumer goods.

Conclusion

Pelletizing in an invaluable process, utilized accross a wide range of industries to enhance product performance, improve handling and application, and create a premium product with targeted product specifications.

For pelletizing inquiry, please fill out the form here!

ECOMARU BUSINESS

The glass fibers used in cleaning agents (purging agents) containing glass filler are generally GF (glass fiber). Ecomaru uses GW (glass wool) , which has finer fibers than GF , to achieve even higher cleaning performance. Glass wool has short fiber length, thin and soft fiber diameter, and countless glass fiber angles and an overwhelming specific surface area effectively scrape off unnecessary materials.

For incredible reduction of black dots defect High cleaning purging pellet (cleaning agent for injection molding machines) ecomaru

ecomaru is “purging pellet(cleaning agent)” highly blended glass wool by putting black spot removal feature its highest priotity.

High cleaning purging pellet preventing black dots defects,Make great contributions to quality improvement!

About Ecomaru, High-cleaning Purging Pellet

High cleaning purging pellet preventing black dots defects, Make great contributions to quality improvement!

1. What is cleaning agent (purging pellet) for injection molding machines?

Cleaning agent for injection molding machines (purging agent) iscleaning pellet used for color change, resin change, reduction on appearance defect rate and prevention of foreign materials generation. “Cleaning” for injection molding machine is to discharge molding material, burnt carbide and dirt left in cylinder. There are purging agents such as glass filler , surfactant type and foaming type, etc. and are used property in accordance with usages.

Purging pellet mixing glass wool cleans with strong frictional force. Best fitted for cleaning carbides stuck to screws and cylinders.

Purging agents containing surfactants improve discharging performance by controlling interfacial tension between prior material (subsequent material) and metal surface.

Foaming type purging agent is to extrude by removing stickings on screw wall using foamability resin.

2. First in the world! Purging pellet using GW (cotton like glass wool)

Glass fiber used in cleaning agent (purging agent) mixing glass filler is generally GF (glass fiber). However, GW (glass wool) which has finer fibers than GF is used and mixing for “ecomaru” and high cleaning is achieved. It scrapes off unnecessary materials very effectively with countless glass fiber angles and overwhelming specific surface area. Since glass wool’s fiber length is shorter, its fiber diameter is thinner and it is soft.

Conventional cleaning agent

Ecomaru

Features of ecomaru

1. High cleaning purging pellet (cleaning agent) being realized washing never seen before. Improving black dots defects and making great contributions to reducing the defect rate.

Please take a look at test samples from major electric manufacturer. Showing comparison on cleaning for each shot when ABS (black) is purged. By looking at the 5th shot, ecomaru’s result showing darker black. There are chances ecomaru’s having darker black colors than those from the other purging agents when compared by the same number of shots. That is becuase fine glass wools in ecomaru clean all corners of dirts left and accumulated in modling machines before, though it also suject to the dirtiness level of modling machines.
Hitting 10 and 15 shots without intervals. Cleaning was completed earlier by ecomaru, and when compared at the 15th shot, black materials are still seen and remained by other companies’ purging agents. It certifies and has confirmed showing very big differences in cleaning capability.

2. 60% recycled material for new material GW is used. Eco-friendly upcycling product.

Glass wool (glass fiber) is made by melting glass at high temperature and making it into fine(thin) fibers in cotton-like shape. It has excellent heat insulation, sound absorption and vibration isolation characteristics, and has been used to block heat/cold, noise, and vibration.
We are the first company in the world to develop “purging pellet (cleaning agent) using glass wool as its material” making use of glass wool scraps usually using as heat insulation material. It is a material friendly to global environment and higher cleaning capability than that of conventional purging agents mixing glass fiber is achieved.

3. Excellent in subsequent resin replacement, Preventing "purging agent residue" molding defects.

Subsequent resin replaceability is the property how quickly and reliably purging agent is discharged and switched to next resin when succeeding resin is added after cleaning by purging agent. It is important that purging agent has high cleaning capability and needs to be discharged completely as well after cleaning. It seems likely especially puring agents mixing glass filler are showing hesitation to be used due to concerns on glass residues and “cleaning twice” is performing at molding production sites? When purging agents are not discharged and are left over, those will be “purging agent residues” and purging agent which should be preventing black dots defects causes molding defects, which will end up being overwhelming situation and getting priorities wrong truely.

ecomaru is purging agent having high cleaning capability as well as exhibiting excellent replaceability. For verification, red ABS resin was purged by ecomaru (using glass wool) and purging agent mixing glass fiber. The upper row of the photo in the below is for ecomaru and the cleaning was completed at 8 shots, and the amount of resin discharged was 360g. (The photo showing the resin discharged in order from upper left to right. One lump is for one shot.) On the other hand, the lower row is the case of purging by purging agent mixing glass fiber and cleaning is completed at 10 shots. The amount discharged up to here was 400g. This is showing and certifing the high detergency of ecomaru. And this is showing the high substitutability of ecomaru.

After cleaning, when “AS transparent” was used as subsequent resin, switching from purging agent was verified. Replacement was completed at 3 shots for ecomaru and 5 shots required for company A’s purging agent (Furthermore, you are able to see that the red color appears again on the resin cleaned by company A’s despite of its completion of cleaning).

4. No need to clean twice. Making great contributions to shortening lead time and reducing costs.

ecomaru is “cleaning agent mixing glass filler”, however, does not need to be cleaning twice. * However, subject to the resin used, there are chances cleaning twice might have better result.
Cleaning twice is to be cleaning by purging agent mixing glass filler and cleaning again by purging agent not mixing glass filler or inexpensive pellets so that glass is not left over in the subsequent resin. Usually ecomaru does not need to be cleaning twice, because one glass fiber is thin and short and ecomaru has excellent discharging capability (good subsequent replacement) even at narrow tunnels (nozzle part, etc.).

5. Compatible with a wide range of resins in 2 grades. It can be used under simple conditions at production sites.

GWP…Priority on glass discharge, for color change / resin change. High cleaning and excellent subsequent resin replacement (material: PP + GW)
GWS: Priority on carbide removal. Priority on balance over a wide range of applicable resin and temperature range (material: AS + GW)