Frequently Asked Questions

Single-shaft shredders have a single rotor with rotating blades, a hydraulic pusher unit that pushes the material regularly toward the rotor, and a screen system at the bottom of the machine that determines the final output size. These machines are preferred for processing relatively flexible plastics or smaller pieces where a more homogeneous particle size is desired and generally consume less energy than double-shaft units. In double-shaft shredders, there is no need for a hydraulic pusher or a screen system; they feature two powerful steel shafts rotating in opposite directions, and the material is broken into coarse pieces by shearing/tearing force. Because double-shaft systems produce immense torque, they are an absolute necessity for the initial coarse shredding of the most challenging waste, such as thick pipes, wooden pallets, IBC tanks, vehicle tires, and scrap metals.

The PET bottle recycling process consists of precise stages to obtain high-purity rPET flakes suitable for bottle-to-bottle production. The process generally begins with optical (NIR-sensored) or manual sorting systems, where other plastics and contaminants are removed from the system. Then, the baled waste is sized into small flakes with crushing machines. Afterward, in density-based separation (sink-float) pools, PP/PE bottle caps and labels are separated by floating because they are lighter than water, while heavy PET flakes sink to the bottom. In hot washing tanks, which are the heart of the process, stubborn label glues and organic contaminants are deeply removed at 90-100°C with the help of chemicals. Finally, these materials, which are rinsed and dried with mechanical centrifuge systems, are made ready for the extrusion line.

Horizontal squeezing machines (film squeezing machines) are a revolutionary technology for drying flexible plastics like nylon, PP sacks, and LDPE film, which absorb water like a sponge during washing. Positioned between the washing line and the pelletizing (extrusion) unit, these units, unlike traditional centrifuge or hot-air dryers, physically expel water by applying high mechanical pressure (squeezing/pressing) instead of evaporating water thermally. This method effectively removes even trapped, stubborn water that centrifuges cannot remove, and reduces the material's moisture content to levels suitable for extrusion. In addition to providing massive electricity savings because it does not use thermal energy, it significantly increases the feed stability and melt flow capacity of the material entering the extrusion line.

Integrated compact machines, which combine low-speed primary shredding (shredder) and high-speed granulation (crushing) processes in a single frame, primarily provide a significant production area (footprint) saving for businesses. Since the intermediate conveyor belts and transfer processes required when using two separate machines are eliminated, in-facility logistics clutter is prevented and the operation can be easily managed with a single person (one-person operation). The PLC automation integrated into the machine constantly analyzes and synchronizes the amount of material poured from the shredder above to the crusher below, preventing clogging. Moreover, since no extra heat is applied to the material during the process, the chemical structure of the plastic is prevented from deteriorating (degradation), and high-quality, smooth recycled granules are obtained.

Over-band magnetic (permanent or electromagnetic) separators integrated into conveyor belts in recycling lines are vital safety equipment designed to catch iron-based unwanted metals within the transported product piles. With high magnetic pulling power, these systems pull bolts, nuts, nails, or coarse iron scraps hidden inside waste plastic or aggregate toward the air and eject them from the production line. The primary purpose of these systems is to protect the high-cost precision blades of crushing and shredding machines from potential metal jams and fractures, prevent unplanned downtime related to breakdowns, and ensure that the final plastic obtained is 100% pure and free from metal contamination.

The greatest feature that distinguishes the Tyron series and similar high-level double-rotor shredders from standard shredders is that the two shafts within them are motorized and managed completely independently of each other. While in traditional systems, two rotors are connected and rotate at the same speed, in this independent technology, operators can separately control the rotation speed, rotation direction, and reverse maneuvering (reversing) timing of each shaft according to the structure of the material. This independent movement capability creates an excellent self-cleaning mechanism by preventing, especially long textile waste, thick ropes, or wired materials from wrapping (winding) around the shafts. Thus, the clogging rate of the machine approaches zero and ton-based production capacity reaches its peak.

Extending blade life directly affects profitability in recycling facilities. First, it is mandatory to choose blades (e.g., wear-resistant D2 or SKD11 steel) suitable for the hardness of the material entering the machine and to separate foreign hard metals with magnetic separators before they enter the system. High speed (RPM) during cutting will increase friction and blade heat in the material and cause premature dulling, so the optimum operating speed must be determined. A "breaking-in" (run-in) phase should be applied to a newly installed blade by reducing the feed rate for the first 10 minutes. After the process, mud or plastic residues on the blades should be cleaned; blades showing signs of dulling should be regularly sharpened (at accurate angles from 0 to 90 degrees) in industrial CNC blade sharpening machines capable of precision adjustment.

Silos where cleaned granules or flakes from recycling processes are stored are critical structures that provide in-facility logistics and complete automation. Produced from special alloy aluminum or stainless steel, these silos occupy much less space in the facility compared to horizontal storage (sacks or big bags) thanks to their vertical architecture. Since they operate as a completely closed system, they absolutely protect the stored valuable raw material from weather conditions, airborne dust, and the risk of foreign matter mixing (contamination). Thanks to the electronic level sensors (point detection) and mechanical discharge conveyors inside, they provide an uninterrupted and unmanned workflow in shift production by transferring the stored material to the next machine or packaging unit without experiencing filling loss.