Injection Moulding Project Management Services UK

The Process

Step 1: Shredding

Initial Traceability & Shredding

Once plastics are acquired, traceability starts with thorough documentation and photographs. The material is then fed into the shredder, breaking it down into 40mm pieces. Unlike many others, we take pride in producing single-colour polymers by processing individual colours together to maintain their purity. This approach is particularly advantageous for customers with specific colour requirements.

Step 2: Granulating & Toll Work

Metal Removal & Granulation

The shredded pieces are evenly distributed between two conveyor belts, each fitted with powerful magnets designed to remove any metal contaminants and ensure the plastic is free from impurities. The material then moves through two grinders, which further reduce the 40mm pieces to 8-12mm granules. This step is crucial for preparing the material for the next phase as the granules enter the wash tank.

Step 3: Sink Float

Saline Separation Process

Once dropped into the water, a saline solution is adjusted with salt to match the specific plastic being processed (PP, HDPE or LDPE), causing the target plastic to float to the top while other unwanted materials will sink to the bottom. The materials that settle at the bottom are extracted and placed into a bag beside the machine, ready to be sold on for their individual purpose.

Step 4: Drying

Friction Drying & Cleaning

In the tank, rotating paddles are used to direct the floating material toward the end of the system. From there, it is transferred through a pipe known as a friction dryer, where it undergoes vigorous drying. This process effectively removes old labels, ensuring the plastic emerges clean, free from dust and thoroughly dried leaving the plastic ready for the next stage of processing.

Step 5: Bagging

Bagging & Traceability

The plastic is transferred to the bagging plant in a dry, paper-free, and dust-free condition. Each bag is assigned a unique code for precise tracking, this code corresponds with our in-house systems, to trace the material’s origin, the specific lorry it was transported in, and the production details. This meticulous tracking ensures full transparency and compliance with environmental agency standards.

Step 6: Internal Storage

Storage & Shipment Preparation

All bags are meticulously data-logged and stored in a dry, spotless, dust-free environment to maintain the highest standards of cleanliness and integrity. They are covered with protective plastic to safeguard them from any potential contamination. When ready for shipment, the bags are securely packed to prevent moisture and damage, ensuring they remain in optimal condition throughout their journey.