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Recycling

Maxi recycling

A complete system to recycle moulded EPS/EPP/EPE/NEOPOR/ARCEL etc. packagings and insulation materials into individual beads ready to be mixed with new beads to make new products.

Maxi recycling

We developed the completely integrated recycling concept for reusing EPS material in 1978 and have in the past supplied more than 350 complete recycling plants world-wide, where they have solved the recycling problems and brought substantial savings. Our experience in this field enables us to solve the problem of reusing the waste material with optimal result.

 

  • The KBM MAXI recycling plant for EPS and EPP is suitable for the large shape moulding and the block moulding operations.

  • For the small shape moulding operations the MINI Recyc- ling plant is available. For very large shape and block moulding operations the JUMBO recycling line is available.

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

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

  • Due to the fact that the material is broken down to the individual bead size similar to the new beads, it is homogeneous with the new pre-expanded beads and consequently de-mixing problems in the silos causing uneven density distribution are minimized. Problems like 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.

  • The KBM MAXI recycling plant consists of one combined precrushing and granulating unit, and a separate dust separating unit. Both units are sound insulated. After the recycling, the material is blown into a storage silo made from plastic fabric, sewn as one big bag, with steel frame for easy assembling.

  • The dust is blown into the dust compactor, with filter bags for exhaustion. The dust is collected in the lower part and is compacted into a octagonal rod with a density of 200-300 Kg/m³ (12-19 lbs/ft³).

  • Two metering/mixing systems are available for the shape moulding production. The metering unit is steplessly variable to ensure correct metering of EPS before the pre-expander and of EPP before the pre-pressurizing tank.

  • The KBM STYROMIX units are available to give an individual and exact mixing of material for each moulding machine (see special leaflet).

  • For Block production, STYROMETER with 2 silos and metering/mixing station, to be placed just before the block mould, is available. In the same way it can be used to fill pre-pressurizing tanks with recycled and new EPP material mixed in an accurate ratio.

All units can be delivered separately.

 

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MAXI Recycling Version A
Vertical input with precrusher and granulator

 

MAXI Recycling Version B
Input from the side with precrusher and granulator

 

MAXI Recycling Version C
Both vertical input with precrusher and metering of already precrushed EPS from a silo and with granulator

 

MAXI Recycling Version D
Metering of already precrushed EPS from a silo. No side feeding. With granulator only

 

MAXI Recycling Version E
Metering of already precrushed EPS from a silo. No side feeding. With granulator only

 

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Capacity per hour:

(Granulated and dust extracted EPS)

Screen with 6mm holes (shape) 10-12 m3 350-420 ft3
Screen with 10mm holes (Block) 18-20 m3 630-700 ft3
Screen surface: 1.4 m2 15 ft2

 

Dust compactor with 12 kg/m3 (0,75 lbs/ft3) EPS dust approx. 15-20 kg/h 33-44 lbs
Dust compactor with 35 kg/m3 (2,2 lbs/ft3) EPS dust approx. 25-30 kg 55-66 lbs
Space required ca. 16m2 160 ft2

 

Measurements: L x W x H

Pre-crusher/Granulator (3) 1.9m x 1.3m x 2.5m 76" x 52" x 100"
Dust separating unit (4)  1.3m x 1.2m x 2.7m 52" x 48" x 108"
Dust compactor (5) 1.6m x 1.1m x 5.1m 64" x 44" x 204"
Storage silo (6) 2.0m x 2.0m x 6.0m (any size available) 80" x 80" x 240" (any size available)
Size Silo Bag 2.0m x 2.0m x 4.0 m (plus 1m cone) (any size available) 80" x 80" x 160" (plus 40" cone) (any size available)
Metering unit (7) 0.9m x 0.9m x 4.0m 36" x 36" x 160"
Styrometer mixing (9) (block or EPP) 4.0m x 2.0m x 6.0m 160" x 80" x 240"
Size each silo bag 2.0m x 2.0m x 4.0m 80" x 80" x 160"
Pipe connections 160mm 6"

 

Hopper opening: 1400x600mm (56x24")

(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:

  EPS EPP
Pre-crusher/Granulator (1) 26.0 Kw 43.0 Kw
Dust separating unit (2) 7.0 Kw 7.0 Kw
Dust compacter MAXI (5) 2.2 Kw 2.2 Kw
Metering unit (7) with blower 1.0 Kw 1.0 Kw
STYROMETER Mixing (block or EPP) (9) 1.6 Kw 1.6 Kw
Voltage 3x400V/50Hz or other voltages 3x400V/50Hz or other voltages

  

SUBJECT TO ALTERATIONS
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