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Recycling

Jumbo recycling

The KBM JUMBO is a complete recycling system for very large moulding operations.

Recycle EPS/NEOPOR/GRAPHITE packagings and insulation materials into individual beads ready to make new products.

Jumbo recycling

When your recycling needs are of JUMBO sizes

The KBM JUMBO recycling plant for EPS and EPP is made for the very large shape moulding and block moulding operations.

The JUMBO recycling unit breaks down the material to individual beads homogeneous with new pre-expanded beads. This consequently results in minimization of uneven density distribution caused by de-mixing problems. Blocking of core vents due to dust and lumps of material causing hot wire cutting problems in terms of inaccurate sheets with bad surface are also minimized. 

Thanks to the two step/double chamber system and the large sieve surface and granulation chamber the JUMBO recycling plant produces a high quality recycled material which contains a minimum of dust from waste production, cut-offs from block production or even from used EPS and EPP/EPE mouldings.

The recycled EPS and EPP material can be reused in shape moulding production in a ratio of at least 10-20 percent without any perceptible optical or physical change of the product quality. For block moulding 20-50 percent can be added.

Extensions for your JUMBO unit

As an extension to the JUMBO recycling plant, we offer metering/mixing systems compatible with the unit. All units can be delivered separately.

  • The KBM Styromix units are available to give an individual and exact mixing of material for each moulding machine.

  • For block production, Styrometer with two silos and metering/mixing station, to be placed just before the block mould, is available. 


Read more about the KBM metering/mixing systems here. 

For the JUMBO recycling plant, we offer two different sizes of KBM pre-crushers to pre-crush the material. The pre-crushers are designed to separate and collect metal parts, stones, and other heavy parts in the bottom. We suggest to use our heavy particle separator to further collect parts of wood, plastic, and other parts before they reach the blower.  

From the silo above the JUMBO granulator, the pre-crushed material is metered into the sound insulated granulator and broken down to the individual bead size depending on the sieve hole size. Afterwards the dust is extracted in the JUMBO dust separation unit and the recycled material is conveyed to a storage silo.

The dust is blown into the JUMBO cyclone dust compactor, which separate the dust from the air. The dust is collected in the lower part and is compacted into an octagonal rod with a density of 200-300 Kg/M3 (12-19 lbs/ft3). The air is returned from the cyclone air exhaustion into the granulator in a closed circuit. It replaces the large filter bags, which means that the daily cleaning of filter bags is eliminated and maintenance is reduced to a minimum.

For smaller shape or block moulding plants the MINI and MAXI recycling plants are available.

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JUMBO Recycling Line

 

 

JUMBO Recycling - Sketch of the JUMBO LINE

 

 

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Capacity per hour:

(Granulated and dust extracted EPS)

Screen with 6mm holes (Shape) 18-20 m3 630-700 ft3
Screen with 8mm holes (Block) 25-35 m3 875-1225 ft3
Screen with 10mm holes (Block) 35-40 m3 1225-1400 ft3

 

With 20 mm screen the granulator capacity exceeds 60 m3

Screen surface 2 x 1.2m2 = 2.4 m2 26 ft2
Dust compactor with 16 kg/m3 (1,0 lbs/ft3) EPS dust approx. 30-40 kg/h 66-88 lbs
Space required (A-F) approx. 30-40 m2 320-430 ft2

 

Measurements: L x W x H

Silo pre crushed material (C) 3.0m x 3.0m x 6.0m (size silo bag approx. 27 m3) 118" x 118" x 236" (size silo bag approx. 940 ft3)
Metering/Granulator (D) 2.1m x 1.4m x 1.9m 84" x 56" x 76"
Dust seperating unit (E) 1.8 x 1.2 x 2.7m 72" x 48" x 108"
Dust compactor with cyclone type air exhaustion (F) 1.2m x 1.2m x 5.1m 48" x 48" x 204"
Storage silo (G) 2.0m x 2.0 x 6.0 m (size silo bag approx. 17 m3) (any size available) 80" x 80" x 240" (size silo bag 600 ft3) (any size available)
STYROMETER: Mixing station (block) (G) 4.0 x 2.0 x 6.0m (size each silo bag approx. 17 m3) 158" x 80" x 236" (size each silo bag approx. 600 ft3)
Pipe connections (pre crushed material) 250mm 10"
Pipe connections (granulated material) 160/200mm 6/8"

 

Pre crusher hopper top openings: MAXI: 1400x600mm (56x24"), JUMBO (A): 1800x600mm (72x32")

(Values below are experienced by EPS granulated on a KBM granulator)

Re-usable EPS material after recycling min. 93-95%
Extracted EPS dust and fines  max. 5-7% 
Dust content after dust separation  max. 1% 


Electrical load:

Electrical load EPS
Metering/granulator (D) 31.2 Kw
Dust separating unit (E) 14.4 Kw
JUMBO Dust compactor (F) 4.0 Kw
STYROMETER Mixing station (block) (G) 2.3 Kw
Voltage 3x400V/50Hz or other voltages

  

SUBJECT TO  ALTERATIONS
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