Shredding and Crushing Case Study for Bulky Rigid Plastics: 1,500 kg/h Dual-Shaft + GH700/1400 Solution

The system is designed for bulky, rigid plastic waste generated from industrial production and recycling operations.

Typical materials include:

• ABS blocks 
• ABS injection molding rejects 
• PS plastic waste 
• PP blocks 
• Thick-walled PE products 
• Large plastic containers and housings 
• Industrial plastic offcuts 
• Plastic sheets and boards 
• Plastic profiles 
• Plastic pipes 
• Large rigid plastic lumps 

These materials are widely found in:

• Injection molding plants 
• Automotive parts manufacturing 
• Home appliance manufacturing 
• Plastic product factories 
• Plastic recycling companies 
• Industrial solid-waste recovery facilities

Large rigid plastic waste can place considerable mechanical load on a size-reduction machine when fed directly into a high-speed crusher.
For large blocks and bulky products, the first stage therefore focuses on volume reduction, while the second stage performs further size reduction and particle classification.

The process is:

Large Rigid Plastic Waste → Dual-Shaft Shredding → GH Heavy-Duty Crushing → 12 mm Screened Material

This two-stage configuration provides several practical benefits:

• Large material can enter the system without extensive manual pre-cutting 
• The first-stage shredder reduces the size and bulk of the feedstock 
• The second-stage crusher receives pre-shredded material 
• The mechanical load is distributed between two machines 
• The final material is prepared for downstream processing  

The processing flow for this application is:

Feeding → Metal Detection → Dual-Shaft Shredding → Material Conveying → GH700/1400 Heavy-Duty Crushing → Roots Blower Conveying → Downstream Washing or Pelletizing

The system performs two consecutive size-reduction stages.
The first stage handles the large and bulky material, while the second stage further processes the pre-shredded material through the heavy-duty crusher.

The rigid plastic scrap is transferred into the system through the feeding conveyor.
Before entering the shredding stage, the material passes through a metal-detecting conveyor.
This provides an additional layer of protection against accidental metallic contaminants entering the cutting system.
The system also includes emergency-stop protection for safe operation.

The dual-shaft shredder is the first major size-reduction stage.
It is designed to process large, hard, and bulky plastic materials that would be difficult to feed directly into a conventional crusher.

Main Specifications

After the first-stage shredding process, the reduced-size material is transferred toward the GH700/1400 Heavy-Duty Crusher.
The conveying system provides continuous material transfer between the two size-reduction stages.
This allows the shredder and crusher to operate as an integrated front-end processing system.

After pre-shredding, the material enters the GH700/1400 Heavy-Duty Crusher for secondary size reduction.

Main Specifications

The second stage further reduces the pre-shredded rigid plastic and produces material that can be transferred to subsequent recycling processes.

V-Rotor Cutting Design
The GH Series uses a V-shaped rotor configuration.
The cutting tools are arranged to improve the interaction between the rotor and the material during processing.

The design is intended to provide:

• Efficient cutting 
• Stable material processing 
• Reduced energy consumption 
• Controlled cutting clearance 
• Consistent size-reduction performance 

The rotor and cutting chamber geometry are optimized for heavy-duty plastic recycling applications.

Heavy-Duty Machine Construction
The GH700/1400 uses an all-steel welded machine structure designed for continuous heavy-load operation.
The heavy-duty construction helps the machine withstand the mechanical loads associated with processing bulky rigid plastics.

The system also incorporates:

• Large-sized rotor bearings 
• Wear-resistant chamber liners 
• External bearing structure 
• Heavy-duty hydraulic feeding 
• Intelligent control system 

External Bearing Structure
The bearings are positioned outside the cutting chamber.
This design helps reduce the exposure of the bearings to plastic dust and other contaminants generated during size reduction.
It also supports easier maintenance and contributes to the long-term reliability of the machine.

Wear-Resistant Chamber Design
Wear-resistant liners are installed inside the cutting chamber.
These liners help protect the main machine structure from material abrasion during continuous operation.
This is particularly relevant for applications involving heavy and rigid plastic scrap.

The GH700/1400 crusher is equipped with a 12 mm screen aperture.
Material is reduced through the cutting chamber and screened according to the installed screen configuration.
The processed material is then transferred through the conveying system.
A Roots blower conveying system is used for material transportation after the crushing stage.

After the two-stage size-reduction process, the processed plastic material can be transferred to the customer's subsequent recycling process.
Depending on the material and final application, possible downstream processes include:

• Plastic washing 
• Pelletizing 
• Compounding 
• Modification extrusion 
• Injection molding recycling 
• Other plastic reprocessing applications 

The actual downstream configuration depends on the material condition and the customer's final requirements.

 The complete front-end process can be summarized as:
Bulky Rigid Plastic Waste → Feeding Conveyor → Metal Detection → Dual-Shaft Shredding → Material Conveying → GH700/1400 Heavy-Duty Crushing → 12 mm Screening → Roots Blower Conveying → Downstream Washing / Pelletizing / Modification

This two-stage size-reduction system converts large and bulky rigid plastic waste into a more manageable feedstock for subsequent recycling.

 1. Handles Large and Bulky Plastic Waste
The large inlet of the dual-shaft shredder allows large rigid plastic scrap to be processed with reduced manual pre-cutting requirements.

2. Two-Stage Volume and Size Reduction
The dual-shaft shredder performs the initial volume reduction, while the GH700/1400 provides secondary size reduction.
This distributes the processing load between the two machines.

3. 1,500 kg/h Processing Capacity
The system is designed for a processing capacity of approximately 1,500 kg/h for the application described in this case.

4. Hydraulic Feeding
Hydraulic ram feeding supports stable processing of large and irregular rigid plastic materials.

5. Equipment Protection
The metal-detecting conveyor and emergency-stop system provide additional protection during operation.

6. Heavy-Duty Crusher Construction
The GH700/1400 features an all-steel welded structure, large rotor bearings, wear-resistant liners, and an external bearing configuration for demanding recycling applications.

7. Suitable for Multiple Rigid Plastics
The system can be applied to a variety of rigid plastic materials, including ABS, PS, PP, and PE.

The processed material from the two-stage size-reduction system can be used as feedstock for various downstream recycling processes.
Depending on the material type and final application, the material can be further processed through:

• Washing and drying 
• Plastic pelletizing 
• Compounding 
• Modification extrusion 
• Injection molding 
• Other recycling processes 

For contaminated post-consumer rigid plastics, a washing process may be required before pelletizing.
For clean post-industrial production scrap, the shredded and crushed material may be transferred directly to a subsequent granulation or processing stage, depending on the customer's requirements.

Related Articles

Rigid Plastic Pelletizing Solutions
Rigid Plastic Washing Solutions

This application demonstrates a 1,500 kg/h two-stage size-reduction solution for bulky rigid plastic waste.

The system combines:

Feeding → Metal Detection → Dual-Shaft Shredding → Material Conveying → GH700/1400 Heavy-Duty Crushing → Roots Blower Conveying

The dual-shaft shredder is responsible for the initial processing of large and bulky plastic materials, while the GH700/1400 Heavy-Duty Crusher performs the subsequent size reduction.
With a 1530 × 940 mm shredder inlet, 500 mm rotor diameter, 700 mm crusher rotor diameter, 1400 mm crusher rotor width, and 12 mm screen aperture, the system is configured for continuous processing of large rigid plastic scrap.
The solution provides a practical front-end size-reduction system for ABS, PS, PP, PE, and other bulky rigid plastic waste before subsequent washing, pelletizing, modification, or other recycling processes.

Looking for a Rigid Plastic Size-Reduction Solution?

ACERETECH provides industrial size-reduction solutions for bulky rigid plastics, including dual-shaft shredders, heavy-duty crushers, conveying systems, metal detection, and integrated front-end recycling equipment.
The equipment configuration can be designed according to the characteristics of your plastic waste and the requirements of your downstream recycling process.
Contact ACERETECH to discuss your rigid plastic shredding and crushing application.