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.
NGR
In-House Film & Scrap Recycling
F:GRAN
The efficiency star for pre-shredded material
Overview
F:GRAN — flake reprocessing machine
A feeder-extruder combination for regrind and film flakes, offering a wide range of system sizes and significantly increased energy efficiency. For recycling ground-up plastics — predominantly from plastic washing systems — there is no better choice than the F:GRAN.
← All NGR machinesAt a glance
- Processing regrind and film flakes
- Output rate up to 2.500 kg/h (5,500 lbs/h) depending on type
- Switching on and off by a single push button
- Simple, stable process
- Storage silo up to 30 m3 for material buffer
How it works
The operating principle of F:GRAN
In the anti-bridging silo, rotors keep the plastic flakes in motion. This prevents the flakes from bridging and ensures flowability.
In the transition area between the flake conveyor and the extruder input, the feeding screw acts like a feeder. The flakes are gently transported continuously from the large-dimensioned feeder screw into the extruder. This arrangement facilitates the processing of flakes of different sizes (the flake size is of minor importance). The pressure on the plastic flakes increases steadily as they enter the extruder intake, in order to achieve high throughput rates.
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.
Key features
Why the F:GRAN
Anti-bridging storage silo
Rotors in a storage silo of up to 30 m³ handle flakes of varying sizes and prevent bridging from the start.
Automatic feeder control
The feeder screw is regulated automatically according to extruder utilisation for a simple, stable process.
Dump & run operation
One-button ON/OFF with smooth start-up and automatic feed regulation; restart in under two minutes.
Universal extruder screws
Optimised for recycling, with an easy-to-read NGR touchscreen and recipe management.
Uniform pellets
Consistent pellet size for homogeneous mixing into new material.
Technical data
Specifications
| Model | Extruder screw Ø (mm) | Feed screw Ø (mm) | Max output (kg/h) | Max output (lbs/h) |
|---|---|---|---|---|
| F:GRAN 105-20 | 105 | 200 | 600 | 1,320 |
| F:GRAN 125-20 | 125 | 200 | 800 | 1,760 |
| F:GRAN 145-20 | 145 | 200 | 1,100 | 2,430 |
| F:GRAN 165-25 | 165 | 250 | 1,400 | 3,090 |
| F:GRAN 185-25 | 185 | 250 | 1,800 | 3,750 |
| F:GRAN 205-25 | 205 | 250 | 2,100 | 4,410 |
| F:GRAN 225-25 | 225 | 250 | 2,500 | 5,070 |
Options & accessories
Add-Ons
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.
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
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.
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
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.
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.
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
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 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.
Materials & applications
What it processes
Suitable materials
LDPE flakes (agricultural film, post-wash)
HDPE flakes (post-wash line)
PP regrind (fibres, injection moulding)
Fluff & alternative flake sizes on request
Applications
Recycling after plastic washing systems
Regrind & film-flake reprocessing
Post-consumer flake recovery
Gallery
Material samples the F:GRAN processes
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