Purui Thin-Film Dewatering Granulator

Product Overview

The Purui thin-film dewatering granulator is an exhaust-type granulation device specially designed for plastic materials after dewatering. It is a customized product with no fixed price, tailored to meet the customer’s production capacity requirements. The equipment can be directly connected to the discharge outlet of the dewatering machine, seamlessly linking the washing line and the granulation process. Without the need for an additional drying step, it completes granulation processing, precisely adapting to PE, PP, and other multi-material plastics whose moisture content has been reduced to below 5% after prior screw dewatering. Standard capacity ranges from 100 to 2000 kg/h, supporting continuous, stable 7×24-hour production, providing an efficient, energy-saving granulation solution for the plastic recycling and regeneration industry.

Technical Principle

This granulator employs an exhaust-type single-screw extrusion process, with its core workflow centered on direct plasticization of wet material, vacuum degassing, and precise shaping. Plastic materials that have undergone physical squeezing and dehydration by a preceding screw dewatering machine, reducing their moisture content to below 5%, can be directly fed into the hopper and then into the barrel. The barrel is equipped with segmented ceramic heating bands, enabling precise temperature control. Combined with the shear friction generated by the screw, the material achieves uniform melting and plasticization within the barrel. A vacuum vent is installed in the middle section of the screw, using a negative pressure of ≥-0.08 MPa to extract residual free water, surface additives, and low-molecular volatile substances from the material. This design completely eliminates the need for a pre-heated air-drying step, greatly simplifying the production process. After plasticization and degassing, the molten material passes through a multi-stage filter die, removing fine impurities. The extruded strands are then water-cooled and shaped, followed by high-precision pelletizing, ultimately producing uniform, dense recycled pellets. The finished pellets can maintain a moisture content of ≤0.3%, with particle size uniformity reaching ≥95%.

Core Configuration Parameters

1. Trademark/Brand: PURUI
2. Place of Origin: NANTONG
3. Screw and Barrel Material: 38CrMoAlA, bimetallic, nitrided treatment
4. Heating Method: Electric heating, electromagnetic heating
5. Heater Material: Cast aluminum, cast copper, mica, ceramic heaters
6. Motor Brand: Siemens, ABB, Weg, or leading domestic brands
7. Pelletizing Method: Die-face pelletizing, strand-cutting pelletizing
8. Bearing Brand: NSK, SKF, INA, FAG, or top domestic brands
9. Inverter Brand: ABB, FUJI, Delta, Siemens
10. Delivery Time: 70–80 working days
11. Warranty Period: 13 months from the bill of lading date

Performance Data

1. Standard Capacity: 100–2000 kg/h
2. Compatible Materials: PE/PP and other multi-material plastics with moisture content ≤5% after dewatering
3. Main Unit Power: 30–355 kW
4. Finished Pellet Moisture Content: ≤0.3%
5. Particle Size Uniformity: ≥95%
6. Filtration Precision: Adjustable between 80 and 120 mesh
7. Operating Mode: Supports continuous, stable 7×24-hour production

Core Advantages

1. Seamless Process Integration: Directly connects to the dewatering machine’s discharge, eliminating the need for a separate drying stage. The washing line and granulation process are seamlessly linked, significantly shortening the production flow and reducing factory space requirements.
2. Deep Vacuum Degassing: Using a vacuum vent with a negative pressure of ≥-0.08 MPa, deeply removes residual moisture, additives, and volatiles from the material, resulting in bubble-free, high-quality pellets and dramatically lowering the defect rate.
3. Significant Energy Savings: Compared to traditional drying-plus-granulation processes, eliminating the hot-air drying step leads to a substantial reduction in overall energy consumption. Electricity costs per ton of pellets can be cut by 25–30 yuan, and annual savings on drying energy exceed 100,000 yuan per production line.
4. Stable and Easy-to-Maintain Equipment: Featuring a mature, stable single-screw structure, it boasts a low failure rate and minimal maintenance requirements, supporting long-term continuous operation and ensuring enterprise productivity.
5. Broad Material Compatibility: Adaptable to various types of dewatered materials, including films, woven bags, PET bottle flakes, rigid plastic fragments, and non-woven fabrics, meeting the needs of diverse plastic recycling scenarios.

Core Product Value

1. Significant Cost Reduction: Eliminates equipment investment and energy costs associated with drying, cutting electricity expenses per ton of pellets by 25–30 yuan, saving over 100,000 yuan annually on energy costs per production line, while also reducing factory footprint by 20% and lowering site and labor costs.
2. Enhanced Product Quality: The vacuum degassing design effectively prevents issues such as bubbles, broken strands, and hollow pellets, keeping bubble rates below 2% and reducing defect rates by 80%. With particle size uniformity reaching ≥95%, the finished pellets exhibit superior appearance and stronger market competitiveness.
3. Improved Production Efficiency: Shortens the production process by 30%, increases output per unit time by 25%, supports continuous 7×24-hour production, and significantly boosts overall production scale and shipping efficiency.
4. Reduced Maintenance Complexity: Thanks to its mature single-screw structure, the equipment features a low failure rate and minimal maintenance requirements, minimizing downtime and labor costs for repairs.

Target Customer Groups

Plastic washing and granulation integrated plants, small and medium-sized recycled pellet factories, plastic recycling processors, renewable resource treatment enterprises, and packaging film/woven bag manufacturers—all these businesses have substantial demand for processing dewatered plastic materials. This equipment precisely matches their production workflows and cost-control needs.

Application Scenarios

This equipment is primarily used for direct granulation of dewatered PE/PP films, woven bags, PET bottle flakes, rigid plastic fragments, and non-woven fabrics. It can also serve as the core auxiliary equipment for integrated production lines combining washing, dewatering, and granulation, providing efficient, energy-saving granulation solutions for various plastic recycling and regeneration applications. Whether it’s batch processing at small and medium-sized recycled pellet factories or continuous production at large-scale washing-and-granulation integrated plants, this equipment adapts reliably, ensuring both production efficiency and product quality.

Solutions to Industry Pain Points

1. Addressing the pain point of needing extra drying for wet materials after washing, which increases equipment investment and energy costs: This equipment eliminates the need for a pre-drying step, connecting directly to the dewatering machine’s discharge, thus saving on the purchase cost of drying equipment and long-term energy expenses. Annual energy savings per production line exceed 100,000 yuan.
2. Solving the issue of bubbles, broken strands, and hollow pellets caused by direct granulation of moist materials, resulting in high defect rates: By utilizing a vacuum vent in the middle section of the screw to extract residual moisture and volatiles under a negative pressure of ≥-0.08 MPa, the finished pellets achieve bubble rates below 2% and reduce defect rates by 80%, significantly improving yield.
3. Tackling the problem of extended production cycles, increased factory space usage, and higher labor and maintenance costs due to the drying process: Removing the drying step shortens the production flow by 30%, reduces factory space by 20%, and decreases the need for maintenance personnel, thereby lowering labor costs.
4. Overcoming the limitation of ordinary granulators unable to handle dewatered materials with moisture levels below 5%, leading to unstable production: This equipment precisely accommodates plastics with moisture content ≤5% after dewatering, employing segmented ceramic heating bands for precise temperature control and screw shear friction for plasticization, ensuring stable production and supporting continuous 7×24-hour operation.

Frequently Asked Questions (FAQ)

Q1: Why doesn’t this granulator require a drying step?
A: This equipment uses an exhaust-type single-screw extrusion process, with a vacuum vent installed in the middle section of the screw to extract residual free water, surface additives, and low-molecular volatiles under a negative pressure of ≥-0.08 MPa. It can handle materials whose moisture content has been reduced to ≤5% after dewatering, so there’s no need for a pre-heated air-drying step.
Q2: What is the equipment’s capacity range? Can it be customized?
A: The standard capacity ranges from 100 to 2000 kg/h. As a customized product, it will be tailored according to the customer’s production needs, matching the requirements of enterprises of different scales.
Q3: What types of plastic materials can the equipment process?
A: The equipment is compatible with PE/PP and other multi-material plastics whose moisture content has been reduced to ≤5% after dewatering, including washed PE/PP films, woven bags, PET bottle flakes, rigid plastic fragments, and non-woven fabrics.
Q4: How long is the warranty period?
A: The warranty lasts 13 months from the date of the bill of lading. During this period, any quality issues not caused by human error are covered by the manufacturer’s after-sales service.
Q5: Compared to traditional granulation processes, how much cost can this equipment save?
A: Compared to the conventional drying-plus-granulation approach, this equipment can reduce electricity costs per ton of pellets by 25–30 yuan, save over 100,000 yuan annually on drying energy per production line, and decrease factory space usage by 20%, thereby lowering site and labor maintenance costs.