INTEGRA SERIES

General Description

INTEGRA Series is a completely integrated unit with a cutter compactor to size reduce the material, to convey the material to the extruder, an extruder to melt and homogenise the material, and a pelletising system to produce, cut and dry the material. The complete unit is automatically controlled with a PLC based system. The INTEGRA machine gives;
 
» High quality uniform pellets,
» Direct material feed without any pre-processing or cutting,
» Variable speed extruder motor to ensure complete control of the process,
» Quick and easy maintenance with plugs and sockets for heaters,
» Thermocouples etc and an open construction for fast access
» A range of options to enable it to be tailored to meet your exact requirements
» A stable robust processing system reducing operator intervention to a minimum
» Lowest cost recycling with an energy consumption of typically 0.25- 0.30 kWh per kg of pellets
» Material to be processed: LDPE - LLDPE - HDPE – PP


Technological Explanations

■ The compactor cutter is mounted adjacent to the feed zone of the Integra extruder. Material is fed into the compactor cutter where it is further size reduced and densified by the combined action of the rotating and fixed knives and the frictional heat produced. The densified material is then fed directly into the Integra exruder by centrifugal force. The heat developed during the densificaton process is controlled by both coling fans and water injection.
■ This heat generated also helps moisture removal. The size reduced material is then processed by the Integra screw during which it is heated and plasticised prior to being filtered and then extruded through a multi-hole hot die face. The Integra screw will process the majority of post process scrap, the only changes required would be to the process recipe and, in some cases, a diffirent die face.
■ The polymer is then pelletized using the water pelletizing system. As the molten polymer exits the die face it is cut by a rotating variable speed die face cutter and fed into a water ring where it cools and is then transferred via a water chute into a high-performance centrifuge. Additional drying is via an air conveying system comprising metal ducting/ pipework (nominal length of12- 15m and 160mm dia.) to an air separation cyclone. Granules then exit the cyclone directly into the customer’s day bin or bagging station. 
■ The size reduced material is then processed by the Integra screw during which it is heated and plasticised prior to being filtered and then extruded through a multihole hot die face. The Integra screw will process the majority of post process scrap,
the only changes required would be to the process recipe and, in some cases, a diffirent die face.