Category: Environmental

Buying Extruder?? Make Right Choice-1

Few days back a friend called me, from Rajkot regarding to machinery. He is already in plastic industry since 5 years and currently planning for installing Plastic waste reprocessing unit and plastic film extrusion unit. From our discussion one can conclude that he is very much confused about which supplier to trust and what major aspects to consider before purchasing machine. And this I think is a biggest concern for those who are completely fresh in the business.

There are major two reasons for these confusions, Many often it happens that buyer is not that much technically sound being new comer in the industry and another reason is sometimes sales people of machine create confusion in between what is and what is not PERFECT for buyer in term of equipment / technology.

So, there are few things for everyone should be knowing before making investment in machinery because it is a long term decision and you don’t want to spend more after purchasing machine.

SCREW DESIGN

Since last 20 years or so, plastic industry has grown manifold with speed of light. In terms of quantum and in terms of quality as well. Constant and continuous inventions in the industry led to sophistication in design of screw barrel compatible to particular resins. Just by altering screw design with technical considerations, one can get 2 to 3 times more output than 25 years ago on the same screw size.

Scre Desing

An Ideal screw, which we can call STANDARD SCREW is a single stage with single flight. By altering one(or more) of following we can perfectly compatible screw with comparing resin or end product

  • L/D Ratio
  • Channel Depth
  • Compression Ratio
  • Helix Angle

L/D Ration

It is the ratio of the flighted length of the screw to its outside diameter. The ratio is calculated by dividing the flight length of the screw by its nominal diameter. By increasing L/D ratio following changes are observed

  • More shear rate can be uniformaly generated in the plastic without degradation
  • Generate opportunity for mixing resulting in better homogeneity of the melt.
  • Greater the residence time of the plastic in the barrel possible permitting faster cycle of larger shots.

COMPRESSION RATIO

The ratio of the channel volume in the feed zone to channel volume in the meter zone is refereed as the compression ratio. It typically ranges from 1.5 : 1 to 4.5 : 1 for most of the thermoplastic resins.

The higher the compression ratio the greater the resulting and….

  • Shear heat imparted to resin
  • Heat uniformity to melt
  • Potential of creating stresses in some resins.

HELIX ANGLE

It is angle of a screw flight relative to a plain perpendicular to the screw axis. Although the helix angle is not commonly altered from the standard square pitch such a change can have majority impact on processing.

A reduced pitch is very common in screws that have short L/D ratio, Two stage screw design or developing mixing section.

A change to a smaller helix angle, hence more flight turns per diameter

  • Increases the axial melting length
  • Conveys stiffer resins with greater ease and requires less troque
  • Reduces the rate at which resin is conveyed

CHANNEL DEPTH

Channel depth in the meter zone of the screw is determined according to the resin to be processed. The channel depths of Feed and Transition zones are depended upon the selected compression ratio and screw profile.

It influences the degree of shear heat developed by the screw and the throughput of the screw. For ex. A Shallow Screw Channel……..

  • Increase exposure of plastic to heated barrel.
  • Increases the shear heat imported to the resin structure
  • Reduces the potential throughput of screw

Deep screw channel would have just the opposite effect helping reduce the shear heat and potentially increasing the throughput of screw.

Normally screws are made of Nitrated Steel. But in easily processed material like LDPE / PP screw can perform well and durable while for engineering material such as Nylon-Glass Filled it might be opposite results. So considering resin / durability it can be hardened in many ways. It can be chrome plated after polishing or It can be Bi-metalised or it can be flame hardened etc.. Definitely the cost is also varied depending upon post treatment is selected.

So Final selection should be made only on the basis of direct practical experience with with the design in the question or on the basis of manufacturer’s guarantee of performance

(PART 2  on 30/12/2017)

Survey : Results

Being actively involved in Plastic Recycling Industry as well as plastic machinery industry we, at BK PlastiX once decided to know CURRENT SITUATION or, we can say CURRENT STAND of people who are directly linked with plastic recycling industry. Thus we tried to conduct a survey with few questions such as,

  1. Which type of material do you recycle?
  2. Does your machine have die face cutter?
  3. Your opinions about die face cutter
  4. Does your machines have forced feeder?
  5. Your opinions about forced feeder
  6. How do you see potential of plastic recycling industry in India.
  7. How GST affected plastic recycling industry of country.
  8. According to you which is best company in India for plastic recycling machines
  9. Why Indian plastic industry is still depended on outdated technology. Why recycling industry is not upgrading technically.

We have ran survey from 2nd November to 27th November and for which we have got 172 responses for which I would like to thank members of whatsapp groups as POT / Plastic Spare Parts / RP GROUP / Virgin RP Granules / ALL INDIA POLYMERS GROUP / Plastic Professionals / World Of Polymers / Scrap Deal  for participating and expressing facts and opinions.

Even though we have got these much responses I do not think one can estimate complete scenario of current times from these results but at least we can say this somewhat describes status/situation of (Recycling)Industry.

So in response we got to know that out of these 172

50% in Commodity material  /  6 % In Engineering Material /  44% BOTH

Material

16% have machine with Die Face Cutter / 84% Does not have.

On asking opinion on Die Face Cutter technology, it is so unfortunate and upsetting as only 98 recyclers mentioned any answer and out out of those 98, 7 responses claimed to have no knowledge.

Die Face Cutter

That somewhat means that out of 172, 64 does not have clearly aware about DIE FACE CUTTER TECHNOLOGY, but positive thing is that 43 recyclers (25%) are very much optimistic about it and planning to equip one with their existing machine or want to go for new machine with this technology.

 

23% have machine with forced feeder / 77% Does not have

From 172 recyclers, 40 posses recycling machine equipped with extruder, and from remaining, 26 responses were as It is not required because they are working with high density waste such as Injection molded articles waste / blown article waste / sheet waste / pipe waste etc. In these cases, normal gravity feeding is fulfilling their purpose satisfactorily and do not require to upgrade in that terms. From total of 87 responses, around 50% (43) appreciated the technology, 18 recyclers mentioned as they are not well familiar with the concept and technology and the questioned remained untended  85 times.

Forced Feeder

About the potential of Plastic Industry in India, We at BK are very pleased that we got total 124 responses, of which 93 mentioned as industry have very bright potential and huge scope of opportunities as growth where 9 recyclers are completely uncertain and 22 are in doubt because of policies of Indian Government. Though it is practically imposiblle to mention all the comments but 2 comments which got attention were

Potential of Industry

 

“Future of Plastic Industry in India in doubt, due to ignoring nature of government”

“It is going to be extremely superb, Packaging is increasing day by day and innovations are always coming up”.

 

About question No 7 and question No 9, which are respectively about Effect of GST in Plastic Industry and reason for not upgrading plastic industry in terms of technology, I would request and insist to all the readers to shout out your opinions in the comment section below, because these topics are matter of detailed discussion but what we got from our survey is that the highest responded question was about GST with total of whooping 148 responses. of which 115 claiming it bad for the industry, 11 don’t have much idea about it while 22 responses claimed GST is positive reform happened and will bring sophistication to the industry. Few eye-catcher comments were…………

Effects of GST

“Recycled Plastics are being costly due to GST, Rates should be lowered down for recycled plastics & goods made from it”

“GST Will hugely affect unorganized units, Not organized players”

“It made industry standstill”

Disappointing is that we got only 31 responses out of 172 about why industry is not upgrading technically, that is why i am leaving it to the readers and share your point of view on the subject. Few of comments were as


“Unviable nature because of non-availability of scrap in volumes. Competitive nature of market which kills sourcing volumes. Corrupt nature of dealers of scrap even at Industrial scrap source which also makes it unviable. Unethical practices used in the industry for orders and payment…. etc., are some of the reasons.”


“Because of the market demands, its highly waving “


“Due to financial problem small industry is not able to invest largely on new technology .Further local machines are available cheap.Further local cheap labour is easily available so people are not upgrading technology.”


“Lack of trained operator, availabilty of spare parts, technician for repairs not trained enough.


About the best recycling machine manufacturing company in India I must say all the machine manufacturers have huge competition in the market. We got total 85 responses with name of total 28 different companies.

Please leave comments and mention your stand about all the questions mentioned.

& please do not forget to like & Follow us on FACEBOOK by clicking HERE

Know something about PLASTIC ROADS

WHO IS RESPONSIBLE…….. PLASTIC WASTE or OUR WASTE MANAGEMENT????

 

THE GREAT PACIFIC GARBAGE PATCH IS LOCATED IN THE NORTH PACIFIC GYRE OFF THE COAST OF CALIFORNIA AND IS THE LARGEST GARBAGE SITE IN THE WORLD, THIS FLOATING MASS OF PLASTIC IS TWICE THE SIZE OF TEXAS, WITH PLASTIC PIECES OUT NUMBERING SEA LIFE SIX TO ONE”

“100,000 MARINE CREATURES IN A YEAR DIE FROM PLASTIC ENTANGLAMENT AND APPROX 1 MILLION SEA BIRDS ALSO DIE BY CONSUMING PLASTICS”

World already was facing environmental challenges and waste  management issues and than plastic came into the picture. In 1950, Commercial production of started and just in under 70 years plastic has truly dominated out 24 Hours. Look around you, You will get at least 25 examples.

Garbage Patch.jpg

In 2014 world produced 320 Million Tons of Plastics

UNITED STATES generates approx 258 Million Tons of Garbage each year. Of which Million Tons is recycled, 33 Million Tons used for energy recovery and whooping 136 Million Tons goes to landfills. An average person in US consumes more than 100 Kg of plastic each year. In 2012, Only 9% of Post Consumer plastic waste has been recycled. Remaining 32 Million Tons discharged into landfills or finds way into ocean via leakages. Due to higher per capita consumption,US has to take some serious steps towards the managing plastic garbage.


If present trends continue, by 2050, there will be 12 Million Tons of plastic in landfills. That amount is 35,000 times as heavy as the Empire State Building


 

Being second highest populated country in the world, India generates 1,33,760 Tons of waste every day ( 1 Million Tons in just 10 days) out of which plastic contributes to 15,342 Tons . Out of total garbage only 68% Of waste is collected. Means more than 40,000 tons of garbage is being littered to land or sea. Only 26% garbage from total is recycled or treated and remaining goes to Landfill. Speaking of Plastics from 15000 Tons generated waste, 9000 Tons were collected while remaining 6000 remains littered. India is listed 12th in top 20 Countries who contributed highest in polluting oceans

PerCapitaConsumption

China wins the contest. In every aspect. CHINA is biggest country in generating garbage. China is solely responsible for 30% of plastic pollution clogging the oceans. Every day china generates about 5,20,000 Tons of garbage. Julie Makinen wrote in the Los Angeles Times, “China has surpassed the United States to become the world’s GarbageToOceanslargest trash producer, churning out more than 260 million tons a year. Beijing’s 20 million residents generate about 18,000 tons a day, most of which goes to landfills. With household trash volume rising at least 5 percent annually, according to the city, authorities are building new incinerators, though that’s caused concern about further dirtying the capital’s already smoggy skies. ” .  With having per capita consumption of Plastic around 40 Kg and highest population on earth, Managing plastic garbage as especiallly Plastic Waste is one of the top most challenge for china. To overcome,  china have banned import on foreign garbage. On 18th July, China Notified the WTO(World Trade Organization) that it would stop accepting shipments of rubbish such as Plastic / Paper as a part of campaign against “FOREIGN GARBAGE” .

GarbageToOceans

Iserael also could not score good grades in Waste management. According to reports, 5.4 Million Tons of solid waste is generated in Isarael each year. Of which plastic contributes 41% by volume (2.21 Million Tons). From total garbage, Isarael is able to recycle 25% while remaining 75% finds way to either landfills or oceans.

Russia also is running out of space for more landfills. Russia generates about 60 Million Tons of waste each year out of which 30% of garbage is of Plastics. From the total garbage Russia is able to recycle only 11-15%. Even though having low recycling rates, Russia dumps not more than 20 Million tons to landfills, They act smart. They just export garbage to other countries like Sweden / China.

Speaking of Sweden, I think it is only country which can impress us considering waste management. RECYCLING REVOLUTION actually has happened in Sweden. In 1975 Only 38% of house hold garbage was recycled. In 2014 Sweden imported 2.7 Million tons of garbage just to keep recycling industry running.

Garbage USed

Sweden recycle it’s 47% of garbage. 52%

 

used in energy conversion thanks to that, 9,50,000 homes are heated and 2,60,000 homes are electrified. Only 1% of Garbage goes into landfills.

I don’t mean to target any government or private body for the messed up Waste management all over the world, What I want to convay is, Plastic is not Bad material. How we use it is important. Properties of Plastic of having flexibility / long durability / easy to process made it prominent are the same properties which made it one of the most hated topic on internet. Because we, The people could not handle.

As a common man in a country we can not change whole waste management systems. But what we can do is,  we can control generation of waste. Natural Home Brands, Suppliers of Eco Friendly Kitchen Tools / Health & Beauty products, Have made an amazing list of 22 Ways to reuse plastic. Click Here. I am sure you will love it.

If you loved or Hated the article than please. Feel free to drop comments.

Also don’t forget to read the previous post SAY YES TO PLASTICS

 

Sources :

MARINE DERBIES https://marinedebris.noaa.gov/sites/default/files/GPmap_2012_NOAAMDP.jpg

TIMES OF INDIA  http://timesofindia.indiatimes.com/india/india-generates-100000-metric-tonnes-of-waste-per-day/articleshow/57917862.cms

CLLECTIVE RESPONSIBILITY http://www.coresponsibility.com/chinas-plastic-waste-epidemic/

REUTERS https://uk.reuters.com/article/us-china-environment/china-says-it-wont-take-any-more-foreign-garbage-idUKKBN1A31JI

NATIONAL GEOGRAPHIC http://news.nationalgeographic.com/2017/07/plastic-produced-recycling-waste-ocean-trash-debris-environment/

Say Yes To Plastics

By searching blogs of PLASTICS one can find hundreds post related to subject.
Of those more than 90% content is blaming plastic as one of the biggest pollutant. Which may be true in some cases but we need to step back and think about it once.

different-plastic

Just ask yourself a question “from waking up in the morning till sleeping at night, can I live without plastics for a single day?” (more…)