XPS Foam Tray Recycling Solution: KSP100 Pelletizing Machine
At Kitech, we are proud to showcase our KSP100 recycling and pelletizing line, custom-built for a long-term partner in Jordan. This high-performance system is specifically designed to recycle XPS plastic tray regrind, achieving a stable on-site output of 240 kg/h – perfectly meeting the customer’s daily production requirements. It is widely applicable for recycling and pelletizing XPS, EPS, and EPE materials from food packaging, advertising displays, insulation materials, and protective transport packaging.
I. A Streamlined and Automated Process Flow
The KCP100 single-stage pelletizing line integrates the entire recycling process into a singular, automated ecosystem. This integration minimizes manual intervention, reduces labor costs, and ensures that the physical properties of the plastic are preserved through gentle yet effective processing.
The standard operational sequence includes:
Side Feeding > 2. Extrusion > 3. Piston Filter > 4. Water Ring Cutting > 5. Vibration Drying > 6. Silo Storage
II. The Innovation of side feeding Technology
One of the standout features of the KCP100 line—and a primary reason for its success in processing lightweight foam materials—is its specialized side feeding system. Unlike traditional top-fed extruders, which often struggle with the low bulk density of crushed XPS or EPS, the Kitech side-feeding mechanism ensures a consistent and smooth flow of material into the screw.
- Smoother Flow: Prevents material buildup and clogging, keeping the production process running naturally.
- Compact Design: Reduces the machine's height and weight, making the equipment lighter and easier to move.
- Better Quality: Ensures even distribution, producing uniform, high-density pellets without breakage.
III. Key Components of the KCP Series
3.1 Single-screw extruder: At the heart of the line is a precision-engineered screw and barrel. These components work in tandem to mix, soften, melt, and plasticize the XPS material.
3.2 Advanced Double Vacuum Degassing: XPS waste, particularly from food packaging, often contains moisture, volatile organic compounds (VOCs), or ink residues. Kitech’s optimized double vacuum degassing system applies high-vacuum pressure to the melt, stripping away impurities that would otherwise cause porosity or odors in the final pellets. This results in a dense, high-clarity granule suitable for high-end manufacturing.
3.3 High-flow Piston Screen Changer: Contamination is the enemy of quality. Our double-column piston screen changer provides a massive effective filtration area. This allows the line to capture even the finest impurities without requiring a machine shutdown for screen changes, ensuring a truly continuous production cycle.
3.4 European-style Water Ring Cutting: To ensure uniform pellet size and prevent sticking, the system employs closed-loop water ring cutting. The cutting speed is managed via a variable frequency drive (VFD) that automatically adjusts based on the melt pressure feedback. This "smart" adjustment ensures that every pellet is uniform, regardless of slight variations in material flow.
3.5 Integrated Vibration Drying System: Post-cutting, the pellets enter a drying phase. By combining horizontal centrifugal drying with a vibration drying system, Kitech ensures that the final product has a moisture content as low as 3-5%. Dry pellets are essential for preventing defects during the subsequent injection molding or extrusion processes.
3.6 Intelligent PLC Control System: The entire line is governed by a high-end PLC control system utilizing premium components from Siemens, Schneider, or ABB. The interface offers:
- One-button Start/Stop: Simplifying complex sequences into a single command.
- Recipe Memory: Storing parameters for different material types (e.g., XPS vs. EPE).
- Safety Interlocks: Automated shutdown and maintenance alerts to protect both the machine and the operators.
IV. Kitech Machinery: Your Global Partner in Recycling
- Pelletizing Machine: Transforms plastic waste into high-quality pellets efficiently.
- Plastic Recycling Washing Line: Convert post-consumer waste into reusable flakes.
- Shredder and Crusher: Easily process large volumes of plastic waste into small flakes.
- Squeezer and Centrifugal drier: Effectively remove residual moisture from both rigid and soft plastics.
We are ready to provide a tailored plastic recycling solution based on your specific material and production needs.
remond@kitechpm.com
https://www.kitechrecycle.com/contact-us