In the plastic recycling industry, the efficiency and quality of the process largely depend on the components used in the recycling machines. Granulating and pelletizing blades are essential elements in this process as they allow the transformation of plastic waste into high-quality reusable materials. EREMA, a world leader in the manufacture of plastic recycling systems, relies on high-precision and durable blades to ensure the optimal performance of its equipment.
Cuchillas Castillo offers a range of blades specially designed to be compatible with EREMA systems. These blades are made from high-resistance and precision materials, guaranteeing their effectiveness and long lifespan in the plastic processing. In this article, we will explore in detail the EREMA systems and the crucial role that granulating and pelletizing blades play in the efficient and sustainable recycling of plastics.
EREMA Systems
EREMA (Engineering Recycling Maschinen und Anlagen Ges.m.b.H.) is one of the world’s leading manufacturers of extruder systems and components for plastic recycling. Its advanced technology addresses a variety of applications, including in-house plastic recycling, industrial recycling, post-consumer recycling, chemical recycling, bottle recycling, PET fiber recycling, and PET inline recycling systems.
EREMA’s recycling machines and components solve plastic waste problems and reduce raw material consumption. These solutions convert waste materials into valuable secondary raw materials, returning them to the production cycle. By doing so, EREMA’s recycling products not only save production costs but also minimize negative environmental impacts.
EREMA’s ability to process a wide range of plastic materials, from production waste to highly contaminated post-consumer plastics, is due to its comprehensive approach, which includes shredding, washing, drying, extrusion, and filtration systems. This approach ensures that processes are efficient and that recycled material maintains high quality, significantly contributing to the circular economy in the plastics industry.
Materials Recycled in EREMA Systems
The list of materials and products that can be recycled and reused with the help of EREMA recycling lines is extensive and includes:
- Blown Films: Types of plastics such as LDPE (low-density polyethylene), LLDPE (linear low-density polyethylene), and HDPE (high-density polyethylene) are commonly recycled in EREMA systems. These films are widely used in packaging applications and consumer products.
- Cast Films: EREMA systems also process cast films of various materials such as PET (polyethylene terephthalate), PP (polypropylene), LDPE, HDPE, PS (polystyrene), and PLA (polylactic acid). These films are found in rigid and flexible packaging.
- Biaxially Oriented Films: Materials like BOPET (biaxially oriented polyethylene terephthalate), BOPP (biaxially oriented polypropylene), BOPA (biaxially oriented polyamide), BOPS (biaxially oriented polystyrene), and BOPLA (biaxially oriented polylactic acid) are efficiently recycled by EREMA.
- Highly Printed/Metalized/Laminated Films: Plastics films with high printing, metalized or laminated, which are typically more difficult to recycle due to their multiple layers and contaminants, can also be processed in EREMA systems.
- Multilayer Films: These films, used in packaging that requires additional protective barriers, are recycled through advanced technology that separates and reuses each layer of the material.
- Agricultural Film: The plastic used in agricultural applications, such as crop covers and irrigation tapes, can also be recycled in EREMA systems, helping to reduce agricultural waste.
- Packaging Films: EREMA systems can handle various types of packaging films, providing an effective solution for the packaging industry by recycling post-consumer and production waste materials.
- PET Bottles: PET bottles are one of the most commonly recycled materials in EREMA systems. These bottles are processed to produce high-quality recycled PET (rPET) pellets that can be reused in new bottles and other products.
- Fibers, Tapes, and Nonwovens: Materials such as PA (polyamide), PP (polypropylene), and PLA (polylactic acid) in the form of fibers, tapes, and nonwovens are effectively recycled, contributing to the circular economy and reducing the need for virgin materials.
EREMA Pelletizing Systems
EREMA pelletizing systems are designed to convert plastic waste into high-quality pellets suitable for a wide range of industrial applications. These systems are known for their efficiency, flexibility, and ability to handle various plastic materials, from production waste to highly contaminated post-consumer plastics.
EREMA’s pelletizing technology includes different methods to meet the specific needs of each type of material and process:
- Dry Cut Pelletizing: This method uses blades to cut the molten plastic into pellets as it exits the extruder. The resulting pellets are cooled and solidified quickly. This process is ideal for high-viscosity thermoplastic materials.
- Underwater Pelletizing: In this method, the molten plastic is cut into pellets while submerged in water. This allows for instant cooling and solidification, making it ideal for low-viscosity materials and plastics that require rapid cooling to maintain quality.
- Air Pelletizing: Similar to underwater pelletizing but using air instead of water to cool and solidify the pellets. This method is suitable for thermoplastics that cannot come into contact with water during the pelletizing process.
- Strand Pelletizing: In this process, the molten plastic is extruded into long strands that are then cut into pellets. This method is commonly used for high-flow rate materials and is efficient for large production volumes.
Each of these pelletizing methods offers specific advantages depending on the type of material and process needs.
EREMA Blades for Plastic Recycling
Plastic waste must be shredded into small pieces or flakes before it can be converted into plastic resin pellets. For this first step, granulating blades are used.
EREMA recycling systems use rotary granulating blades, which are essential for ensuring an efficient and high-quality process. These blades are designed to provide precise and efficient cutting, ensuring that materials are processed uniformly and effectively.
Once the plastic flakes have been produced using granulating blades, they are melted and fed into the pelletizing system. In this second step, both dry cut and underwater pelletizing systems require pelletizing blades or front cut blades. These blades are installed in the pelletizer and rotate in a circular motion to cut the molten plastic resin into pellets.
Granulating Blades for EREMA
Granulating blades for EREMA are vital components in the plastic recycling process. These blades have a trapezoidal shape and vary in sharpening angle, dimensions, and specifications depending on the type of plastic material being processed.
Granulating blades are fixed and rotate in a circular motion while shredding the plastic into smaller parts, optimizing the granulation process. In addition to rotary granulating blades, there are also stationary pelletizing blades designed to complement and enhance recycling efficiency in EREMA systems.
Pelletizing Blades for EREMA
Pelletizing blades are crucial components in the pelletizing process, specifically designed to cut extruded plastic strands into pellets. In the plastic recycling industry, these blades are known by several names: cutter blades, front cut blades, die blades, and densifier blades, among others.
Pelletizing blades are available in various sizes, materials, bevel angles, holes, and slots to suit different recycling systems and meet each manufacturer’s specifications. These blades ensure precise and consistent cuts, minimizing waste and maximizing the efficiency of the pelletizing process.
What stands out about pelletizing blades is their ability to adapt not only to EREMA systems but also to pelletizers from other manufacturers, demonstrating their versatility and efficiency in various plastic recycling environments. This flexibility and durability ensure that the blades maintain their sharpness and performance over time, contributing to a more effective and sustainable recycling process.
25 Years of Excellence in Recycling Blades
Cuchillas Castillo offers high-quality recycling blades in various dimensions and qualities, designed to meet the needs of the plastic recycling industry. We manufacture blades from durable materials, ensuring long-lasting performance. Our blades are suitable for recycling, shredding, and pelletizing plastics in EREMA recycling systems, as well as in systems from other manufacturers.
With over 25 years of experience, Cuchillas Castillo has successfully supplied the waste recycling industry with cutting, pelletizing, and granulating blades. We offer the widest range of blades for plastic recycling and handling. Additionally, we guarantee fast delivery times and competitive prices on our product ranges.
Not sure which blades you need? Send us an email with your specifications at info@cuchillascastillo.com so we can help you provide a high-quality, durable, and efficient solution to your needs. You can also call us at +34 961 255 380, and we will assist you.
