Granulador vs. Triturador de plástico: Diferencias y mejores usos en la industria

In the world of plastic recycling and processing, size reduction is a critical first step. However, the terminology can sometimes be confusing. Two key pieces of equipment often discussed are Granuladores de plástico y Plastic Grinders (also known as pulverisers or micronisers). While both reduce the size of plastic materials, they operate differently, produce distinct outputs, and are suited for varied industrial applications.

At Energycle, we understand the importance of selecting the right machinery for optimal efficiency and end-product quality. This article will delve into the specifics of plastic granulators and grinders, helping you, our valued industrial recycling equipment buyers, engineers, and sector professionals, make informed decisions.

¿Qué es un granulador de plástico?

A Granulador de plástico is a robust machine designed to break down larger plastic items – such as rejected parts, sprues, runners, bottles, profiles, and films – into smaller, relatively uniform pieces called “regrind” or “flakes.”

Cómo funciona:
Plastic granulators typically employ a set of rotating knives mounted on an open rotor that work against stationary bed knives within a cutting chamber. As plastic material is fed into the chamber, these knives shear and cut it. A screen with specific hole sizes is situated beneath the cutting chamber, determining the final size of the granulated particles. Material remains in the chamber until it is small enough to pass through this screen.

Output Characteristics:

• Particle Size: Typically ranges from 3mm to 12mm, depending on the screen size.
• Particle Shape: Irregular, chip-like, or flake-like.
• Uniformidad: Reasonably uniform, suitable for many reprocessing applications.

Aplicaciones comunes:

• In-house recycling of production scrap in injection moulding, blow moulding, and extrusion facilities.
• Pre-processing for washing lines.
• Creating regrind to be mixed with virgin material for new product manufacturing.
• Volume reduction for easier handling, storage, and transportation.

For robust and efficient granulation solutions, explore Energycle’s range of Granuladores de plástico.

[Diagram Idea 1: Simple workflow of a Plastic Granulator. Input (e.g., plastic bottle) -> Cutting Chamber (rotor with knives, bed knives) -> Screen -> Output (flakes/regrind)]

[TEXT REPRESENTATION OF DIAGRAM 1]

+---------------------+      +-------------------------+      +-----------------+      +-----------------+
| Large Plastic Waste | ---> | Plastic Granulator      | ---> | Screen          | ---> | Granulated      |
| (Bottles, Parts)    |      | (Rotating & Fixed Knives)|      | (e.g., 10mm holes)|      | Flakes/Regrind  |
+---------------------+      +-------------------------+      +-----------------+      +-----------------+

What is a Plastic Grinder (Pulveriser/Microniser)?

A Plastic Grinder, more accurately termed a pulveriser or microniser in many industrial contexts, is engineered to reduce plastic materials (often already pre-granulated) into very fine powders.

Cómo funciona:
Plastic grinders, particularly micronising systems, operate on principles of impact, attrition, or a combination.

• Disc Mill Pulverisers: These often use one or two high-speed rotating serrated or toothed discs. Material fed between the discs (or between a rotating and a stationary disc) is ground down by impact and attrition forces. The particle size is controlled by the gap between the discs, the disc design, and often an air classification system that separates finer particles from coarser ones, returning the latter for further grinding.
• Cryogenic Grinding: For some tough or elastic plastics, cryogenic grinding is employed. The material is cooled with liquid nitrogen to make it brittle before being fed into the grinder, allowing for easier pulverisation into fine powder.

Output Characteristics:

• Particle Size: Very fine, typically less than 1mm, often measured in mesh or microns (e.g., 300-800 microns or 35-100 mesh).
• Particle Shape: Fine, powder-like.
• Uniformidad: Can be very uniform, especially with advanced classification systems.

Aplicaciones comunes:

• Producing powders for rotomoulding.
• Creating additives or fillers for compounding.
• Manufacturing masterbatches.
• Applications requiring high surface area, such as in certain coating processes.
• PVC pulverisation for pipe and profile compounds.

Energycle offers advanced solutions for fine powder production with our Sistema de molienda Micronize.

[Diagram Idea 2: Simple workflow of a Disc Mill Pulveriser (a type of Plastic Grinder). Input (e.g., granulated plastic) -> Grinding Chamber (high-speed discs) -> Air Classifier/Sieve -> Output (fine powder) + Oversize Return for re-grinding]

[TEXT REPRESENTATION OF DIAGRAM 2]

+---------------------+      +--------------------------+      +-----------------+      +-----------------+
| Granulated Plastic  | ---> | Plastic Grinder          | ---> | Air Classifier/ | ---> | Fine Plastic    |
| (Flakes/Chips)      |      | (e.g., High-Speed Discs) |      | Sieve           |      | Powder          |
+---------------------+      +--------------------------+      +-----------------+      +-----------------+
                                                                      |
                                                                      V
                                                                [Oversize material
                                                                returned for re-grinding]

Plastic Granulator vs. Grinder: Key Differences at a Glance

Understanding these distinctions is crucial for selecting the appropriate equipment:

Característica	Granulador de plástico	Plastic Grinder (Pulveriser/Microniser)
Función primaria	Size reduction to flakes/regrind	Size reduction to fine powder
Output Particle Size	Approx. 3mm – 12mm (chips/flakes)	Typically < 1mm (often 300-800 microns/powder)
Mecanismo	Cutting/Shearing (knives)	Impact, Attrition (discs, hammers, etc.)
Material de entrada	Larger plastic parts, scrap, rejects, film	Often pre-granulated material, smaller pieces
Rendimiento	Generally higher for a given motor size	Generally lower, more energy-intensive
Consumo de energía	Moderado	Higher due to finer particle size requirement
Typical Use Case	Creating regrind for reuse, pre-processing	Producing powders for rotomoulding, compounding
Downstream Process	Extrusion, injection moulding, washing, grinding	Rotomoulding, compounding, masterbatch production

Best Uses in Industry: Making the Right Choice

Choose a Plastic Granulator when:

• You need to process bulky plastic waste, production scrap, or rejected parts into a manageable size for reuse or further processing.
• The end goal is to produce regrind that can be directly fed back into extrusion or moulding machines.
• You are preparing material for a washing line where uniform flakes are preferred.
• Volume reduction for storage or transport is a primary concern.
• Your material is suitable for knife-based cutting (most common thermoplastics).

Choose a Plastic Grinder (Pulveriser/Microniser) when:

• Your final product requires a fine, consistent plastic powder (e.g., for rotomoulding, powder coatings, or specific compounding applications).
• You are processing pre-granulated material to achieve a much finer particle size.
• The material properties or end-application demand a powder form (e.g., PVC for certain pipe formulations).
• You need to achieve specific flow characteristics or surface area properties only attainable with fine powders.

Can Granulators and Grinders Work Together? The Synergistic Approach

Absolutely! In many comprehensive plastic recycling operations, granulators and grinders work in sequence.

1. Shredder (Optional): For very large or tough materials, a shredder might be used for initial, coarse size reduction.
2. Plastic Granulator: The shredded or larger plastic waste is then fed into a granulator to produce uniform flakes.
3. Plastic Grinder (Pulveriser): These flakes are then fed into a grinder/pulveriser to achieve the final desired fine powder consistency.

This multi-stage approach optimises the efficiency of each machine and ensures the desired end-product quality.

Partnering with Energycle for Your Size Reduction Needs

Choosing between a Granulador de plástico and a Plastic Grinder – or determining if you need both – depends heavily on your specific input materials, desired output characteristics, throughput requirements, and downstream applications.

At Energycle, we pride ourselves on our technical expertise and commitment to providing high-quality, reliable plastic machinery. Our team is ready to understand your unique operational needs and guide you towards the most efficient and cost-effective size reduction solutions. Whether you require a standalone granulator, a sophisticated micronising system, or a complete recycling line, we have the technology and knowledge to support your business.

Ready to optimise your plastic processing? Contact Energycle today to discuss your requirements and explore our innovative range of plastic granulators and micronize grinding systems.