In a renewable plastics industrial park, a mountain of beverage bottles after 72 hours of open storage,
PET bottles and HDPE bottle caps due to thermal expansion to produce 5 times the bonding force, the
traditional sorting equipment can not do anything. The new generation of intelligent crushing and
sorting system can complete the separation of 98.7% of the materials in just 23 minutes, and this
technological innovation is reshaping the pattern of the plastics recycling industry.
Crushing process evolution: from simple crushing to precise
dissociation
The production data of a modified plastics enterprise shows that after adopting gradient crushing technology,
the purity of ABS/PC alloy waste recycling jumped from 82% to 96%, and the core breakthrough lies in
three major technological upgrades:
1. Revolution in tool dynamics
Dual-axis differential speed design: the speed difference between the main and secondary axes is
maintained at 120-150rpm.
Multi-tooth combination blade: three-stage configuration of roughing, shearing and grinding teeth.
Temperature compensation system: constant temperature control of the cavity at 45±3℃.
2. Material dissociation control
Elastic collision bin: Reduce the hot sticking phenomenon during the crushing process of PP/PE film.
Static electricity elimination device: ≥5000 ions/cm³ per cubic meter of space.
Humidity adjustment module: to stabilize the moisture content of the material at 0.8-1.2%
Sorting technology matrix: let the plastics “go to their place”.
Comparative tests at a demonstration base show that the intelligent sorting system reduces the impurity
rate of PET bottle flakes from 3‰ to 0.5‰, and key technological breakthroughs include:
Recognition technology evolution:
Hyperspectral imaging: 128 bands scanning, recognizing 20μm thickness difference
Laser Induced Breakdown Spectroscopy (LIBS): 0.1 seconds to complete elemental composition analysis
Dielectric Sorting: Separate PVC from PET by utilizing the difference in dielectric constants
Sorting Execution System:
Array valve: response time ≤5ms, positioning accuracy 0.2mm
Multi-stage ballistic sieve: 8-layer screen to achieve 0.5-12mm particle size classification
Eddy current sorting: 99.3% removal rate of non-ferrous metals
Intelligent control system: the awakening of industrial brain
The practice of an intelligent factory shows that the equipment equipped with AI control system reduces the
energy consumption of ton processing by 42%, and its core technology architecture contains:
1. digital twin platform
Real-time mapping of equipment operating status
91% predictive maintenance accuracy
Process parameter self-optimization cycle <15 minutes
2. material traceability system
RFID tag tracking
Batch quality traceability response time <8 seconds
Process defect correlation analysis accuracy of 87
3. Energy efficiency management module
Dynamic power adjustment: automatically matching energy consumption according to load.
Thermal energy recovery system: 31% conversion efficiency of crushing friction heat.
Vibration power generation device: 0.8kW-h energy recovery per hour
Special Material Disposal Program: Technical Tackling Fact Sheet
Aiming at the industry's five major pain points, innovative solutions are pushing the limits:
1. Composite film disposal
Low-temperature embrittlement technology: -45℃ liquid nitrogen quick-freezing crushing
Laminate separation device: peeling accuracy up to 0.01mm
2. Glass fiber reinforced plastic
Nitriding treatment on tool surface: hardness increased to HRC62
Multi-stage air separation system: 89% fiber recovery rate.
3. Medical waste
High-temperature steam sterilization bin: 135℃ for 45 minutes treatment
Negative pressure anti-leakage design: 99.99% aerosol retention efficiency
Win-Win Model for Economy and Environment
The operation data of a circular economy industrial park shows that the intelligent crushing and sorting
system improves the annual economic benefit by 3.8 million yuan, and the main value points include:
Material value-added: for every 1% increase in sorting purity, the profit per ton increases by 150 yuan.
Energy consumption control: Intelligent speed control system saves 280,000 yuan/year in electricity costs
Labor optimization: reduce sorting positions by 12 people
Environmental benefits: reduce landfill costs 740,000 yuan / year
Conclusion: When the EU requires the plastic packaging recycling rate of 55% in 2030, when the total
amount of marine microplastics exceeded 150 million tons, intelligent crushing and sorting equipment
is not only a production tool, but also a technology for the construction of ecological civilization.
From the microstructure innovation of blade alloy material to the algorithm breakthrough of AI visual
recognition system, this technology is building the bottom support system of plastic recycling economy.
In the next five years, with the application of quantum sensing, terahertz detection and other
cutting-edge technologies, the plastics recycling industry will usher in a real “zero loss” era.