Industrial Size Reduction for Plastic Recycling
Plastic recycling begins with size reduction.
Before plastics can be washed, separated or processed into reusable material, they must first be broken down into smaller pieces.
Industrial plastic shredders and granulators are used to reduce large plastic products into flakes or regrind suitable for recycling processes.
Rotajet industrial shredders and granulators are used in recycling plants across the UK, Europe and international plastics recycling markets, helping companies process plastic waste efficiently before washing and separation.
Why Plastic Size Reduction Is Essential in Recycling
Large plastic items cannot be processed efficiently without first being reduced in size.
Plastic shredders and granulators prepare materials for washing, separation and pelletising.
Size reduction improves the efficiency of recycling operations.
Increased Processing Efficiency
Smaller plastic particles move more easily through recycling equipment.
Improved Washing Performance
Plastic flakes provide increased surface area during washing processes.
Better Material Separation
Consistent particle size improves sink float separation and other recycling processes.
Easier Handling and Transport
Granulated plastic takes up less storage space and is easier to transport.
Industrial plastic shredders and granulators are therefore essential equipment in modern plastic recycling plants.
Industrial Plastic Shredders
Plastic shredders are designed to break down large plastic objects into smaller fragments.
These machines use high torque cutting systems capable of processing bulky plastics.
Typical materials processed by shredders include:
- plastic drums
- plastic pallets
- rigid plastic containers
- plastic crates
- industrial packaging
- injection moulded parts
- plastic production waste
Shredders are usually the first stage of a plastic recycling process.
After shredding, materials are transferred to granulators or washing systems.
Rotajet engineers design shredders capable of processing rigid plastics, containers and industrial packaging waste streams found in recycling operations.
Plastic Granulators
Granulators perform secondary size reduction.
These machines cut shredded plastics into smaller flakes or regrind suitable for washing and recycling processes.
Granulators operate using high speed rotating knives combined with screens that control particle size.
Granulators are commonly used for:
- rigid plastic recycling
- plastic regrind production
- injection moulding scrap recycling
- production waste recycling
Rotajet industrial granulators are designed to produce consistent particle sizes required for plastic washing systems.
Plastic Shredders vs Plastic Granulators
Although both machines reduce plastic size, they perform different functions.
Plastic Shredders
Used for bulky plastics.
Operate at low speed with high torque.
Produce larger fragments.
Plastic Granulators
Used for secondary reduction.
Operate at higher speeds.
Produce small flakes suitable for washing and extrusion.
Most recycling plants combine shredders and granulators to form a complete plastic size reduction system.
Shredders for Plastic Drums, Containers and Industrial Packaging
Industrial plastic shredders are widely used to process plastic drums, IBC containers and rigid packaging materials.
These materials are commonly generated in industries including:
- chemical manufacturing
- food processing
- industrial packaging
- logistics operations
- manufacturing plants
Large rigid containers must be reduced in size before entering plastic washing systems.
Rotajet shredders are commonly used to process industrial plastic packaging waste streams before washing and separation.
Plastic Materials Processed by Shredders and Granulators
Industrial size reduction equipment must process many types of plastic materials.
Common plastics include:
HDPE
Used for containers, drums and packaging.
LDPE
Used in films and flexible packaging.
PP
Used in automotive components and industrial packaging.
PET
Common in beverage bottles.
ABS
Used in electronics housings and automotive components.
Industrial shredders and granulators must process these plastics efficiently without excessive wear.
Throughput and Capacity of Plastic Shredders
Plastic shredders and granulators are available in a wide range of capacities.
Typical throughput ranges include:
- 200–500 kg per hour for smaller recycling systems
- 500–1500 kg per hour for medium recycling lines
- 2–5 tonnes per hour for large recycling plants
Throughput depends on several factors including:
- plastic material type
- machine power
- rotor design
- blade configuration
- screen size
Rotajet engineers design size reduction systems that match the capacity of downstream washing and separation equipment.
Shredder Cutting Systems and Blade Design
The cutting system plays a major role in shredder performance.
Industrial shredders use high strength cutting blades designed for demanding recycling applications.
Common blade types include:
- hook blades for rigid plastics
- straight blades for general recycling
- multi-edge blades for wear resistance
Granulators use rotor knives and fixed stator knives to cut plastic into controlled particle sizes.
Rotajet systems incorporate engineered cutting systems designed for durability and consistent particle size output.
Integration with Plastic Washing Systems
After size reduction, plastics are typically processed through washing systems.
These processes may include:
- friction washing
- sink float separation
- rinsing systems
- drying systems
Consistent particle size improves washing efficiency and separation performance.
Rotajet engineers design integrated recycling systems combining shredding, washing and separation technology.
Industries Using Plastic Shredders and Granulators
Plastic size reduction machines are used across many industries including:
- plastic recycling plants
- packaging recycling
- automotive plastics recycling
- WEEE recycling
- injection moulding scrap recycling
- industrial plastic waste processing
These industries rely on industrial shredders and granulators to prepare materials for recycling.
Choosing the Right Plastic Shredder or Granulator
Selecting the correct size reduction machine depends on several factors including:
- plastic type
- contamination levels
- desired particle size
- plant throughput
- integration with recycling systems
Rotajet engineers work with recycling companies to design complete plastic size reduction solutions tailored to their recycling processes.
Buy, Rent or Contract Plastic Size Reduction Equipment
Companies installing plastic shredders or granulators have several options depending on their production requirements.
Buy Plastic Shredders and Granulators
Installing a Rotajet plastic shredder or granulator allows recycling plants to control their size reduction process.
Rent Plastic Shredding Equipment
Companies may choose to rent shredding equipment for short-term production increases or trials.
Contract Plastic Size Reduction
Some companies choose to outsource plastic shredding and granulation to contract recycling facilities.
Rotajet equipment is widely used in recycling plants where plastic shredding, washing and separation systems operate together to produce high quality recycled plastics.
Plastic Recycling Trials at Rotajet’s Wakefield Facility
Selecting the correct shredder or granulator often depends on the plastic material being processed.
To support customers in selecting the correct equipment, Rotajet operates a plastic recycling trial facility at our engineering centre in Wakefield, UK.
At this facility we can carry out plastic shredding and granulation trials to evaluate how materials perform during size reduction.
Trials allow customers to evaluate:
- shredding performance
- particle size output
- machine throughput
- blade configuration
- washing compatibility
Materials can also be tested through plastic washing and separation systems.
This allows recycling companies to test materials before investing in full scale recycling equipment.
Companies interested in carrying out trials can contact Rotajet to arrange plastic recycling trials at our Wakefield facility.
Conclusion
Plastic shredders and granulators are essential machines in modern recycling plants.
By reducing plastics to manageable particle sizes, these machines enable efficient washing, separation and reprocessing of recycled materials.
Modern recycling operations rely on industrial size reduction equipment such as Rotajet plastic shredders and granulators to prepare plastics for high quality recycling processes.
Learn more about Rotajet plastic size reduction machines:
Visit Plastic Washing to learn more or to get in contact with us.
