In the equipment procurement of plastic processing plants, choosing between small and large plastic shredders mainly depends on capacity requirements, workshop conditions, and processing scenarios. Blindly pursuing "high capacity" or "low cost" may lead to problems such as equipment idleness and production bottlenecks. Based on the core differences between the two types of models and combined with different capacity scenarios, this article provides accurate selection suggestions.
Small and large plastic shredders are not simply "size differences" but have essential differences in capacity, structure, and applicable scenarios. For small plastic shredders (with a capacity of ≤100kg/h), they usually adopt a single-motor and single-knife-set structure, with a small machine cavity volume (≤50L). They are suitable for handling small-sized sprue materials (such as injection molding sprues) and small amounts of waste plastics. These models do not require a fixed foundation, feature a mobile design, and occupy a floor area of ≤2㎡. In terms of operation, they mainly rely on manual feeding, and some support simple automatic feeding. Their single maintenance cost is low (about 200-500 yuan), and the annual power consumption is ≤5000 kWh.
On the other hand, large plastic shredders (with a capacity of ≥200kg/h) typically use a dual-motor and multi-knife-set structure (or a dual-shaft structure), with a large machine cavity volume (≥100L). They are designed for large pieces of waste plastics (such as plastic pallets and plates) and sprue materials from continuous production lines. Installation of these models requires a fixed foundation to prevent vibration, and they occupy a floor area of ≥5㎡; some even need to be matched with supporting dust removal systems. In operation, they must be equipped with automatic feeders (such as conveyors and suction machines) to support unattended operation. However, their single maintenance cost is high (about 1000-2000 yuan), and the annual power consumption is ≥20000 kWh.
Plastic processing plants need to select suitable models according to "daily processing volume" and "production mode" (intermittent production/continuous production) to avoid "overcapacity" or "insufficient capacity".
This scenario is mostly for small injection molding plants (e.g., producing toys, daily necessities), which mainly handle small amounts of sprue materials (e.g., sprues, defective products) generated daily. Small plastic shredders are recommended. The recommended model is a 15HP single-shaft shredder, with a capacity of about 50-80kg/h, a feed port size of 200mm×300mm, and it can handle plastic parts with a size of ≤15cm. The advantages of this selection are that the equipment unit price is low (about 15,000-30,000 yuan), no fixed installation is required, and it can be moved to different injection molding machines according to production needs to reduce material handling costs. Manual feeding can meet the needs, so no additional automatic feeding system is required, which reduces the initial investment. It should be noted that if it is necessary to shred tough plastics (such as PE, PP), a model with an "anti-slip feed port" should be selected to prevent materials from slipping during feeding and affecting shredding efficiency.
This scenario is suitable for medium-sized plastic processing plants (e.g., producing home appliance casings, auto parts) that need to handle sprue materials from multiple injection molding lines and have a continuous operation demand of 4-6 hours per day. "Upgraded small models" or "medium-sized shredders" (between small and large models, with a capacity of 100-200kg/h) are recommended. The recommended model is a 22HP dual-shaft shredder, with a capacity of about 120-180kg/h, a machine cavity volume of 80L, and it can be matched with simple conveyor belts (3-5 meters in length) for automatic feeding. Compared with small models, the dual-shaft structure has higher shredding efficiency and more uniform blade wear (service life extended by 30%); compared with large models, no fixed foundation is required, it occupies a floor area of about 3-4㎡, which is suitable for workshops with limited space. The feeding speed can be adjusted according to capacity fluctuations, meeting both "intermittent" and "continuous" production needs. A key configuration requirement is to select a model with an "overload protection" function – when metal impurities (such as screws, nuts) are mixed in the materials, the equipment stops automatically to avoid damage to the blades and motor.
This scenario targets large plastic recycling plants and extrusion production lines (e.g., producing plastic pipes, films) that need to handle a large amount of waste plastics or sprue materials continuously for 24 hours. For these cases, large plastic shredders must be selected, along with a complete set of auxiliary systems. The recommended model is a dual-shaft or four-shaft shredder with 45HP or above, a capacity of ≥250kg/h, a feed port size of ≥500mm×600mm, and it can handle large plastic pieces with a size of ≤50cm (such as plastic pallets and waste pipes). The multi-motor drive and multi-knife-set design of this model can withstand 24-hour high-load operation, and the crushed particles have high uniformity (qualified rate ≥98%). It needs to be matched with a central dust removal system and automatic sorting equipment (such as magnetic separators to remove metal impurities) to realize the integration of "feeding - shredding - dust removal - sorting", which reduces manual intervention and improves the automation level of the production line. In terms of installation, it is necessary to plan the workshop layout in advance, reserve space for foundation construction (depth ≥30cm), and ensure stable power supply (it is recommended to equip an independent transformer to avoid voltage fluctuations affecting equipment operation); if the workshop is near residential areas, a sound insulation cover should be installed (which can reduce noise by 15-20 decibels) to meet environmental protection requirements.
Some processing plants believe that "the larger the capacity, the better", but if a large shredder operates at low load for a long time (e.g., only 50% of the capacity is used daily), the unit shredding cost will increase (e.g., the electricity cost per kilogram of plastic increases from 0.05 yuan to 0.1 yuan). It is recommended to select a model according to "actual capacity × 1.2" – for example, if 1000kg needs to be processed daily, select a model with a capacity of 1200kg/day (i.e., 150kg/h), which not only meets the demand but also avoids equipment idleness.
Different plastic materials have different requirements for shredder blades and screens. When selecting a model, it is necessary to consider the main materials to be processed. For shredding hard plastics (ABS, PC, PA), regardless of small or large models, cemented carbide blades (instead of high-speed steel blades) must be selected to avoid rapid blade wear. For shredding soft plastics (PE films, PVC hoses), large models need to be equipped with "anti-winding knife sets" to prevent plastics from winding around the knife shaft and causing jamming; small models can select models with "serrated blades" to improve cutting efficiency.
When selecting a model, do not only focus on the equipment unit price but also comprehensively calculate the "initial investment + annual operation and maintenance costs". For small models, the initial investment is 15,000-30,000 yuan, and the annual maintenance cost is about 2,000-5,000 yuan (including blade replacement and electricity fees), which is suitable for small and medium-sized processing plants with limited budgets. For large models, the initial investment is 100,000-200,000 yuan (including auxiliary systems), and the annual maintenance cost is about 10,000-30,000 yuan. However, they have high capacity and high automation, which is suitable for large-scale production scenarios. In the long run, the unit material processing cost is lower (about 0.03-0.05 yuan/kg, lower than 0.08-0.1 yuan/kg of small models).
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