Continuous and fully
automatic operation
HV series
n Agglomeration of powders, fibers, films and foams
n Drying of powders, fibers, films and foams
n Recrystallization of PET flakes
n Compounding of thermoplastics with fillers
The end product is free-flowing agglomerate easy to dose and
to mix with other high bulk density material.
PLASTCOMPACTORS
Granulators & shredders | Pulverizers | Plastcompactors/agglomerators | Washing systems/plants | Service
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The process
Material feeding
n The feed material is pre-sized
(granulated/shredded) and collected
in a buffer silo above the
compactor. The operation is continuous
as the granulated material is
fed to the compacting discs via a
variable speed auger which directs
the material into the center of the
stationary and rotating discs.
Agglomerate
Herbold HV series plastcompactors transform low
bulk density plastics into agglomerate with high bulk
density while limiting additional heat history.
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FilmsCarpet fibers FibersFoams PET Flakes
Herbold plastcompactors are able to agglomerate a wide variety of materials
which includes but is not limited to the list below.
n Thermoplastic materials such as fibers, small tapes, foams, films
n Stretch or thin films, fine particles, powder or shavings
n Plastic materials that are difficult to convey, to stock and to mix
(moist or dry)
Friction
n Friction is created on and between
the compacting discs, the amount
of friction is determined by the
distance between discs which is
adjustable, the material is heated
quickly, spun off and conveyed via
a central downstream blower to
the secondary granulator. Since
the dwell time of the material in
the compacting zone is only a matter
of seconds, the thermal impact
on the material is minimal contrary
to extruders or conventional batchtype
agglomerators.
Agglomeration
n The size of the agglomerate is
determined by the screen insert in
the granulator. Before conveying the
regrind into big bags or a silo, the
agglomerate passes a sifting station
where the material is simultaneously
cooled and separated from fines. The
fines are pneumatically returned to
the buffer silo. The end product is air
cooled agglomerate with good
flow characteristics and a high bulk
density. Some materials require
further cooling down to a temperature
suitable for trouble-free silage or
filling into big bags. These additional
steps can be incorporated into the
plastcompactor system.
Fully automatic control
n A fully automatic control system
which includes performance and
temperature monitoring of the
compacting process keeps the
number of operators to a minimum.
Different types of feed stock
and properties will require different
settings (recipes). The control
system can store these recipes
enabling an automatic start-up
and processing.
Compacting zone with
rotor and stator disc
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1 7
2 8
3 9
4 10
5 11
6
5
6
1
2
3
4
7 9
10
11
plastCompaCtors
Belt conveyor
Primary granulator
Suction blower
Buffer silo
Feeding device
Plastcompactor
Cyclone of the central blower
Secondary granulator
Fines separation
Control unit
Mixing and cooling silo
Applications
Drying/Agglomeration
n Herbold plastcompactors are
a perfect addition within the
downstream of a washing line for
increased drying capacity. As material
passes through the compaction
zone moist material is warmed and
moisture is removed. If compacting
is desired at the same time it is
possible to achieve a residual
humidity of well below 1 percent.
With this low residual moisture and
high bulk density the material can
then be further processed either in
an injection molding machine or a
standard extruder.
Addition of additives/compounding
n Fillers can be absorbed during the
heating process in the compacting
zone by using granulated materials
that have been prepared
through processes such as agitation.
Special dosing units mounted
above the feeding screw of the
compactor allow for the feeding
and addition of additives such
as lubricants, plasticizers, color
pigments prior to the compacting
zone.
Compounding and crystallization
Compounding of plastics and fillers.
n The pre-granulated material, is
first prepared, if necessary, in an
agitator, and then warmed until
all the fillers have been absorbed.
Crystallization of PET flakes
n The crystallization of PET flakes
after hot washing is possible by the
softening of the pre-granulated material
between the compactor discs
aligns the molecules and brings
about the crystallization of polyester.
The melting point is not reached.
The IV-value (viscosity) remains
almost unchanged.
8
Plant structure
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HV series
Performance data: (examples)
Feeding material Granulate
density
g/l
(lbs/ft3
)
Throughput kg/h (lbs/hr)
HV 30
30 – 75 kW
(40 – 100 HP)
HV 50
90 – 160 kW
(120 – 215 HP)
HV 70
160 – 315 kW
(215 – 425 HP)
PE film20 µm 335 (21) 200 – 500 (440 – 1.100) 500 – 800 (1.100 – 1.750) 700 – 1.400 (1.500 – 3.000)
PE foam 345 (22) 200 – 500 (440 – 1.100) 400 – 700 (880 – 1.500) 600 – 1.200 (1.300 – 2.600)
PP fiber 345 (22) 150 – 400 (330 – 880) 300 – 700 (660 – 1.500) 500 – 1.200 (1.100 – 2.600)
PS film 10 – 20 µm 450 (28) 150 – 300 (330 – 660) 300 – 700 (660 – 1.500) 500 – 1.200 (1.100 – 2.600)
PS hard foam (broken blocks or plates) 400 (25) 180 – 300 (400 – 660) 300 – 700 (660 – 1.500) 500 – 1.200 (1.100 – 2.600)
PVC hard film 10 – 30 µm 560 (35) 250 – 400 (550 – 880) 300 – 700 (660 – 1.500) 500 – 1.200 (1.100 – 2.600)
PVC soft film 500 (31) 250 – 400 (550 – 880) 300 – 700 (660 – 1.500) 500 – 1.200 (1.100 – 2.600)
PVC soft foam 510 (32) 250 – 400 (550 – 880) 300 – 700 (660 – 1.500) 500 – 1.200 (1.100 – 2.600)
PA film 470 (29) 150 – 300 (330 – 660) 400 – 900 (880 – 2.000) 600 – 1.400 (1.300 – 3.000)
PA 6 fibers 420 (26) 150 – 250 (330 – 550) 400 – 900 (880 – 2.000) 600 – 1.000 (1.300 – 2.200)
PA 6.6 fibers 450 (28) 100 – 250 (220 – 550) 250 – 500 (550 – 1.100) 500 – 1.000 (1.100 – 2.200)
Polyester film 20 – 80 µm 600 (37) 200 – 400 (440 – 880) 400 – 600 (880 – 1.300) 600 – 1.200 (1.300 – 2.600)
Polyester fibers 600 (37) 150 – 300 (330 – 660) 400 – 600 (880 – 1.300) 600 – 1.200 (1.300 – 2.600)
Polyester foam 500 (31) 100 – 250 (220 – 550) 250 – 600 (550 – 1.300) 400 – 1.000 (880 – 2.200)
PET deep-drawn film 540 (34) 200 – 300 (440 – 660) 600 – 900 (1.300 – 2.000) 800 – 1.400 (1.700 – 3.000)
PET cuttings (bottles) 510 (32) 200 – 400 (440 – 880) 400 – 1.000 (880 - 2.200) 800 – 1.400 (1.700 – 3.000)
PP non-woven 380 (24) 150 – 300 (330 – 660) 400 – 700 (880 – 1.500) 600 – 1.200 (1.300 – 2.600)
Polyester-based carpet 360 (22) 100 – 250 (220 – 550) 350 – 600 (800 – 1.300) 600 – 1.000 (1.300 – 2.600)
PP base 330 (21) 100 – 250 (220 – 550) 350 – 700 (800 – 1.500) 600 – 1.200 (1.300 – 2.600)
Depending on the scope of supply, systems can be furnished with the
following components:
n 	Primary granulator in the form of a cutter, single-shaft shredder or a combination of
the two
n 	Pneumatic or mechanical transport of the pre-granulated material
n 	Buffer silo with emptying device and feeding screw
n 	Dosing of additives
n 	Compactor with motorized disc adjustment
n 	Secondary granulator
n 	Air separator for cooling the agglomerate and for the separation and return of fine
particles
n 	Electrical control units and automatic process controls
For abrasive materials such as post-consumer waste or plastics with a high proportion of
glass fibers or calcium, Herbold plastcompactors and granulators are available with wear
protection packages.
(All performance data are reference values.)
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HV series
PE_0004
Advantages of Herbold plastcompactors
n Continuous operating process, not a batch feed design or labor intensive
n Accurate system controls which maintain the parameters for proper
feeding speeds and disc gap to meet recipe requirements as well as the
option to adjustment parameters during machine operation to maximize
performance
n Low wear costs, even with processing highly abrasive materials as
main wear components are bolted in place allowing for easy and quick
replacement
n Durable and virtually insensitive to foreign bodies
n High throughputs in fully automatic continuous operation, few
operators needed
n Plastcompacting is a sintering process, no melting: gentle processing
with a very short dwell time and low process temperatures
Our product range
Guillotines
Shredders
Hammer mills
Granulators
Pulverizing systems
Washing systems & components
Plastcompactors/agglomerators
For more information, please see our videos on our
website www.herbold.com
All indications are not binding and subject to change. 09/2014
Herbold Meckesheim GmbH
Industriestr. 33 | 74909 Meckesheim | Postfach 1218 | 74908 Meckesheim | Deutschland
Tel.: + 49 (0) 6226/932-0 | Fax: + 49 (0) 6226/932-495
E-Mail: herbold@herbold.com | Internet: www.herbold.com
Subsidiary in the US: Herbold Meckesheim USA | Resource Recycling Systems Inc.
130 Industrial Drive | North Smithfield, RI 02896, USA | P.O. Box 239 | Slatersville, RI 02876, USA
Tel.: + 1 401 597/5500 | Toll-free (US/CDN): +1 888/612 RRSI (7774) | Fax: + 1 401 597/5535
E-Mail: info@herboldusa.com | Internet: www.herboldusa.com
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