Cleanliness is not subjective. It is measured in:
Residual contamination (%): What remains after washing
Black specks per kilogram: Direct function of melt filtration load
Ash content (%): Inorganics that survive washing
Moisture retention: Affects drying energy and extrusion stability
If your flakes vary batch to batch, the problem is rarely the material. It is the washing system's inability to respond to changing feed conditions. This Modular Plastic Washing System is designed around that reality.
Process Design Logic
A washing line is not a collection of machines-it is a series of unit operations, each with a defined function:
1. Pre-wash (Optional but Recommended)
Removes loose dirt and fines before they enter friction stages;
Protects downstream equipment from abrasive wear;
Reduces contaminant load on main washing circuit;
2. Friction Washing (Primary Contaminant Removal)
High-speed rotor (20–35 m/s tip speed) creates turbulence and particle-on-particle scrubbing;
Removes surface-adhered contaminants: label glue, oil films, embedded dirt;
Adjustable rotor clearance prevents material damage while maintaining cleaning efficiency;
3. Counter-Flow Rinsing (Polishing)
Water flows opposite to material direction;
Maintains concentration gradient: cleanest water meets cleanest material at discharge;
Removes loosened contaminants and suspended solids;
4. Density Separation (Optional, Material-Specific)
Sink-float tank separates polyolefins (PP/PE, float) from heavier materials (PET, contaminants);
Water temperature adjustable to enhance separation of specific polymer types;
5. Dewatering and Drying
Mechanical dewatering (centrifugal or screw press) removes free moisture;
Thermal drying only required for moisture-sensitive processes (e.g., PET extrusion);
Modular Configuration: What Changes Based on Your Feed
| Contaminant Type | Required Module | Why |
|---|---|---|
| Loose dirt, sand | Pre-wash drum or friction washer | Removes abrasives before they wear downstream components |
| Labels, glue | High-intensity friction washing | Adhesives require mechanical scrubbing, not just rinsing |
| Oils, grease | Hot wash option (40–80°C) | Heat reduces oil viscosity, aids emulsification |
| Mixed polymers | Sink-float tank | Separates PP/PE from PET/PVC/contaminants |
| High fines load | Fines removal screen (200–500 µm) | Prevents recirculation of abrasive solids in wash water |
Technical Parameters
|
Model |
PX500 |
PX600 |
PX800 |
PX1000 |
PX1200 |
|
Output(kg/h) |
200-300 |
300-400 |
400-500 |
500-600 |
600-800 |
|
Power(kW) |
15-40 |
20-40 |
30-60 |
40-80 |
90-110 |
|
Weight(kg) |
4000 |
5000 |
7000 |
8000 |
10000 |
|
Dimension(m) |
7*1.1*1.8 |
8*1.5*2.2 |
9.4*1.8*2.5 |
10.6*2.1*2.7 |
12.4*2.1*2.7 |
FAQ (Process Engineering Focus)
Q: What causes inconsistent washing results day to day?
A: Three things: feed variability (contamination spikes), water quality degradation (dissolved solids build-up), and mechanical wear (blunt blades, worn screens). This system addresses all three: adjustable friction intensity, continuous water treatment, and wear components sized for industrial duty.
