Machinery

Recycling with WPC

WOOD-PLASTIC COMPOSITES (WPC’S)

WPC’s are composite materials made of wood fiber / flour and plastics.  In addition to wood fiber and plastic, WPC’s can also contain other inorganic filler materials.  WPCs can also be referred to as natural fiber plastic composites or natural fiber reinforced plastics.  100% Use of Waste Plastics (Dry & Cleaned) can be used to make WPC’s.

USES :
The most widespread use of WPC’s is in outdoor deck floors, but it is also used for railings fences, landscaping timbers, cladding and siding, park benches, molding and trim, window and door frames, and indoor furniture.  Manufacturers claim that wood-plastic composite is more environmentally friendly and requires less maintenance than the alternatives of solid wood treated with preservatives or solid wood of rot-resistant species.  These materials can be moulded with or without simulated wood grain details.

Wood-plastic composite is still a very new material relative to the long history of natural lumber as a building material, but can be substituted in most non-structural instances.  Although being highly resistant to rotting, WPC’s add a stage of upstream use to materials previously considered waste lumber.  WPC Lumber can be nailed, painted, varnished, cut and finished similar to wood products.

A major advantage over wood is the ability of the material to be molded to meet almost any desired spatial conditions.  It can also be bent and fixed to form strong arching curves.  With up to 70 percent cellulose content (although 50/50 is more common), wood-plastic composites behave like wood and can be shaped using conventional wood working tools.  At the same time, they are moisture-resistant and resistant to decay, although they are not as rigid as wood and may slightly deform in extremely hot weather.  A major selling point of these materials is their lack of need for paint as they are manufactured in a variety of colours, though they one mainly available in grays and earth tones.  These colours last for the lifetime of the product.

MANUFACTURING PROCESS :

Wood-plastic composite lumber is composed of wood from recovered saw dust and other cellulose-based fiber fillers such as pulp fibers, rice husk, peanut hulls, bamboo, straw, digestate, other husks, etc. and virgin or mix waste plastics including PE, PP, ABS, PS, alike.  The powder or fibers are mixed to dough-like consistency and then extruded or moulded to the desired shape.  Additives such as colorants, coupling agents stabilizers, blowing agents, reinforcing agents, foaming agents, lubricants help tailor the end product to the target area of application.  The material is formed into both solid and hollow profiles or into injection moulded parts and products.

Wood, resin, regrind and most of the additives are combined and processed in a pelletizing extruder.  The new material pellets are formed in mould and dried or extruded from a fix shaped profile die.

Plastic waste is first cleaned with a Dust Remover (Jatakia) Machine.  It is then cut into small pieces using a Grinder/Agglomerator.  During Grinding also, separated dust is removed from the regrind with the help of dust remover.  The grinded waste is then   pre-mixed in a slow/high speed mixer together with wood, husk or other fillers and other additives as required depending on end use of the profile.  The mix is then put through a Force Fed, Vented Extrusion System.  The melt passes through vacuum duly compressed and then extruded through the die or required shape to achieve the profile.  The profile then passes through a water bath to cool faster and then cut to the required length.

Densifier

  • Good for High output production machines above 250 Kgs per hour.
  • Excellent for light material feeding like Raffia (Woven sacks waste), Film waste, Thermoformed Article Waste, etc.
  • Densification involves cutting to small pieces without heavy agglomeration and feeding to the extruder.
  • Synchronised with Extruder and Belt Conveyor.

Forced Feeder

  • Conveyor for homogenous flow.
  • Suitable for Film, Yarn, Threads, Fabrics which are pre-ground.
  • Also suitable for open cell materials.
  • Use without Agglomeration thereby avoiding double Heat Process.
  • Perfect synchronization with subsequent down stream for compact constant output.
  • Material compaction done at this stage.

Extruder

  • Fundamental Part of the Regeneration System.
  • A.C. Drive with A.C. Motor.
  • Multipurpose Extruder for processing a wide variety of polymers.
  • Ergonomic Design.
  • Degassing Unit + Vacuum Pump, Vented Extruder.
  • Power Saving Features.
  • High output as against small screw diameters.

Screen Changer

  • Manual or Hydraulic Type options available.
  • No need to stop the line when changing filters.
  • Reduces downtime.
  • Ensures purity & quality of final product.
  • New design of piston type seal free Hydraulic Screen changers available.
  • Tried & tested with proverbial GMS skill.

Die Face Cutter

  • Ideal for Masterbatch production.
  • Water ring type pelletizer.
  • Available as an individual stand alone unit.
  • Good for PE, PP, PS, ABS, PC, EVA, POM, CA, TPR, TPE etc.
  • Various models like TF/TFD with an hourly output from 50 to 1000 kg/hr.
  • Very Low Power Consumption compared to standard Spaghetti Strand Pelletizer Systems.
  • Easily adaptable to your existing line without major modifications.
  • Made from Stainless Steel Material for long life of equipment.
  • Closed Circuit Water system with very low consumption and minimum Wastage.
  • Advanced ergonomics yet simple Control Panel.
  • Our Die-face recycle technology delivers excellent quality granules with purity to its maximum and accurately cut virgin like pellets, which permits the final consumer to get improved processing and flow characteristics.  This enhances the price of reprocessed material tremendously.

Under Water Pelletizer

  • Nylon and PET require special attention whilst reprocessing because of the high MFI.
  • We offer the standard strand pelletizer or preferably the underwater pelletizer.
  • Cutting process completely immersed in water.
  • Each part of the machine made with precision and High quality material.
  • Closed Circuit Water System with very low consumption and minimum wastage.

Centrifugal Drier

  • Wet Granules Hopper made in stainless steel.
  • Water collecting tank in stainless steel to facilitate cleaning operations.
  • Vertical centrifugal Drier 280mm diameter made of stainless steel and driven by a 3.0KW Electric Motor.
  • Hot Air Blower Drier with 6 meters of pipe vertically and horizontally fitted as per requirement and design.
  • Decantation cyclone in carbon steel fitted to hot air blower drier pipes.
  • Cartridge Electric Heaters enclosed in a specially designed cabinet.
  • Electric panel with all the devices for protection and control of different equipment.

Washing Line

  • Wet Granules Hopper made in stainless steel.
  • Water collecting tank in stainless steel to facilitate cleaning operations.
  • Vertical centrifugal Drier 280mm diameter made of stainless steel and driven by a 3.0KW Electric Motor.
  • Hot Air Blower Drier with 6 meters of pipe vertically and horizontally fitted as per requirement and design.
  • Decantation cyclone in carbon steel fitted to hot air blower drier pipes.
  • Cartridge Electric Heaters enclosed in a specially designed cabinet.
  • Electric panel with all the devices for protection and control of different equipment.

Eco Clean De-printing Machine

  • Eco Clean removes the ink deposited by the printing machines on the plastic films for packaging, bringing the processed material back to a virgin film which makes recycling of these films more profitable.
  • Eco Clean process is suitable for all types of flexible printed materials rolls which are printed or contaminated on the top surface.
  • Eco Clean equipment can de-print or clean the film at a speed of 40 metres per minute.
  • Eco Clean equipment is fully automatic and hence rarely requires labour to load and unload the rolls which are to be treated.
  • The recycling system of the detergent is included in the Gamma Clean Equipment package.
  • This equipment has a section for the final re-washing and for the drying.
  • The detergent cost is very low and the additional benefit is that the detergent can be reused after recycling.
  • ECO-CLEAN removes 100% printing which allows the final film to be recycled back to virgin Granules using Gamma Meccanica / GMS Plastic Machinery Recycling Machines.
  • All Gamma Meccanica Equipment’s are Energy Efficient which includes “Eco Clean” a well.