Recycling Processes:

Processing:

Polymer Sciences Inc. (PSI) has in-house processing capabilities in the platforms listed below. If you have a process you require but it is not listed, please contact our sales department as we perform many other services that are not listed or overlap in our equipment capabilities. In addition to these in-house services, we also have the capability to send in mobile crews for sorting and size reduction on temporary assignments, and we have several smaller satellite operations for remote programs that are ongoing.  Although geography plays a key role in processing costs, we have developed operations throughout North America that allow us to overcome these limitations. Please allow us the opportunity to review your program and if we can't manage it effectively we will recommend a reliable alternative.


SORTING:

Material Sorting can be a daunting task. Material values increase significantly once segregated, however segregating comingled material in part, regrind or pellet form is never easy. PSI has integrated several strategies and technologies to segregate co-mingled materials. Please let us know about your applications no matter how difficult they may seem and we can help you determine the likelihood of recovery as well as the costs.


SIZE REDUCTION:

Shredding is the first phase in size reduction. This is where whole parts or a large mass of plastic material is reduced to a more manageable size (2"-4" in size). Most molding equipment requires further size reduction after shredding before it can accept the material for making new parts or product. PSI has incorporated some single shred strategies that allow one material pass before pelletizing or molding instead of two. This eliminates further stress on the material and reduces processing costs.

Equipment:
1- Vecoplan RG-52 100hp Shredder
2- Vecoplan RG-62 125hp shredder
3- Other proprietary shredding operations

Grinding is typically the second step in size reduction after shredding or as a single pass process for small, mid-sized or thin gauge parts. A grinding operation is just as it sounds, materials are sent through cutting blades to reduce the size of material further into what the industry has coined "regrind". This regrind can be pieces of plastic ranging anywhere in size from 1/8 to 3/4 inches. The smaller grind is more easily processed in molding operations to make new parts, completing the recycling process

Equipment:
3- Cumberland 125 Hp grinders;
3- Weiser 35Hp grinders;
2 –Rapid 25Hp grinders;
2- Hammer Mills;
3 - 5Hp Pre-Break operations


SEPERATION & WASHING

Separation & Washing processes are normally handled in-line between the shredding and grinding operation. PSI incorporates several stages of magnetic and metal separation in our process to eliminate foreign materials, fines and metals through all processing operations. We also incorporate a float-sink wash system to eliminate more difficult materials and to classify materials by specific gravity and weight designations in house. All separation and classification technologies employed at PSI include Air or pneumatic cyclone systems, vibration technologies, magnetic, wash or float-sink and sensor systems.

Equipment:
Metal detection and removal operations, shaker tables, elutriation systems and other proprietary processes



PELLETIZING

Pelletizing returns the greatest benefit for downstream end users who are molding new parts or in compounding operations. Plastic materials tend to feed more easily into molding equipment designed to process plastics in pellet form. Material also melts more uniformly in molding operations when reduced to a small spherical pellet. The shape and smooth surface of pellets blend more consistently during compounding operations assuring an even mix of materials with less effort, energy consumption and equipment strain. Once materials are shred, ground and separated, they can be fed into PSI extruders for melting and forming into pellets. Pellets might be round or barrel shaped, depending on the material and equipment used during the process. PSI has extensive pelletizing capabilities for polyethylene - PE, polypropylene - PP, and Polystyrene - PS. Polymer Sciences is among one of the few companies in the US with dedicated extruders specifically fabricated to process expanded polystyrene - EPS (also known as Dow- Styrofoam™) utilizing Reclaim extrusion technologies.. PSI is also capable of processing a number of engineering grade materials.

Equipment:
1 – Hartig 12'/3 extruders with Extek hydraulic screen changers and Berringer water ring pelletizers #1
1 – Hartig 12'/3 extruders with Extek hydraulic screen changers and Berringer water ring pelletizers #2
1 – Hartig 12'/3 extruders with Extek hydraulic screen changers and Berringer water ring pelletizers #3
1 – Hartig 12'/3 extruders with Extek hydraulic screen changers and Berringer water ring pelletizers #4
1 – Hartig 6" 30/1 extruder with Kreyenborg dual bolt screen changer and a Gala under water pelletizer system #5


COMPOUNDING

Compounding is the mixing of 2 or more materials in dry bulk, melt or liquid to achieve a plastic material formulation that behaves as a sum of the materials in the formulation. PE and PP might be mixed together to increase strength in elasticity or process-ability from either of the two components. PSI has compounding capabilities and material testing on site for developing customer formulations.

Equipment:

1 – Extended Auger feed system blender 18' L x 22" D
1- Jumbo mixing silo with mixing screw; 7,500 lb. batch or continuous blending / compounding
3- Adjustable internal silo containment systems and mixing processes 2,500 cu. Ft.
2- Adjustable internal silo containment systems and mixing processes 5,500 cu. Ft.
1- External 120,000 #  bulk silo for mixing, storage or loading/unloading bulk trucks