Advanced Shredding, Washing and Sorting Technology for Plastic Recycling

The demand for efficient plastics recycling solutions continues to grow as businesses, manufacturers and waste management operators look for better ways to recover valuable materials from plastic waste.

Producing high-quality recycled plastic is not simply about shredding material. The entire recycling process needs to work together, from the initial size reduction and sorting through to washing, drying and the production of high-quality recyclate.

This is where Lindner Recyclingtech has developed a strong reputation.

With integrated solutions covering shredding, washing and sorting, Lindner provides recycling technology designed to improve throughput, efficiency and the quality of recycled plastic.

At K 2022 in Düsseldorf, Lindner showcased a range of innovations designed specifically to address the changing requirements of the plastics recycling industry.

Why Efficient Plastics Recycling Matters

Plastic remains an important material across industries including packaging, manufacturing, automotive, food and retail.

However, recovering plastic from waste streams can be challenging.

Input materials can contain different polymers, contamination, labels, dirt and other unwanted materials. At the same time, recyclers are under increasing pressure to improve throughput, reduce energy consumption and produce higher-quality recycled materials.

This makes the individual stages of a plastics recycling plant increasingly important.

A successful recycling process needs to consider:

• Shredding
• Material preparation
• Sorting
• Washing
• Drying
• Contamination removal
• Particle size
• Energy consumption
• Final recyclate quality

The better these stages work together, the greater the opportunity to recover valuable plastic and return it to the circular economy.

Shredding, Washing and Sorting: A Complete Recycling Process

Lindner’s approach focuses on coordinating the key stages of the plastics recycling process.

The company provides technology for processing rigid plastics, plastic film and PET, with equipment designed to work together as part of an integrated recycling solution.

The process can broadly be broken down into three key stages:

1. Shredding

The first stage reduces incoming plastic waste into a manageable and consistent particle size.

A correctly configured industrial plastic shredder can improve material flow and prepare the waste for downstream sorting and washing.

2. Washing

Washing removes dirt, contamination and other unwanted materials from the plastic.

Different input materials require different washing strategies, which is why modular washing equipment can provide greater flexibility.

3. Sorting

Sorting separates different types of plastic and unwanted materials to create a cleaner, more consistent feedstock for subsequent recycling processes.

The coordination between these stages is critical to producing high-quality recycled plastic.

Lindner Micromat HP for Plastics Recycling

One of the key innovations showcased by Lindner at K 2022 was the Micromat HP.

The Micromat HP is a single-shaft industrial shredder designed specifically around the demanding requirements of plastics recycling.

The machine incorporates a powerful gearless direct belt drive, an adjustable safety clutch and a flexible knife system.

These features are designed to provide high throughput while helping simplify maintenance and protect the machine against non-shreddable materials.

According to Lindner, the Micromat HP increased the throughput for recyclable bales from approximately 3 tonnes per hour to 5 tonnes per hour in testing and application examples.

For plastic recycling companies, increased throughput can have a significant impact on overall plant productivity.

Designed for Efficient Plastic Shredding

Plastic recycling can place significant demands on shredding equipment.

The input material may contain contamination, different plastic types and other unwanted materials, meaning the shredder needs to combine performance with robust protection against contaminants.

The Micromat HP was developed with these challenges in mind.

Its design includes:

• Gearless direct belt drive
• Adjustable safety clutch
• Flexible bolted knife system
• Automatic belt tensioning
• High throughput
• Maintenance-focused design
• Energy-efficient operation

The automatic belt tensioning system is designed to maintain the optimum operating point while reducing maintenance requirements.

Lindner Jupiter BW for Plastic Film Recycling

Plastic film requires a different approach to rigid plastics.

Film can be difficult to process efficiently and conventional shredding methods can generate excessive fines.

The Lindner Jupiter BW was specifically developed to address these challenges.

Its dedicated film shredding configuration is designed to produce consistent A4/A3-sized particles suitable for downstream NIR sorting systems.

Lindner has reported a 44% reduction in fines compared with conventional shredding parameters, meaning more of the incoming material can remain within the recycling stream.

Reducing fines can provide several potential benefits for plastic recyclers:

More material retained
Less material is lost into an unwanted fine fraction.

Improved sorting
Consistent particle sizes can help downstream optical sorting systems operate more effectively.

Better material quality
A more controlled shredding process helps create a consistent feedstock for subsequent processing.

Improved efficiency
Optimising the first stage of the process can benefit the recycling stages that follow.

Improving NIR Sorting Performance

Near-infrared, or NIR sorting, is widely used in modern plastic recycling plants to identify different polymers and separate materials.

The quality and consistency of material entering an NIR system can have a direct impact on sorting performance.

This is why the Jupiter BW’s controlled film shredding process is particularly important.

By producing an approximately A4/A3 particle size, the machine creates a more consistent material stream for downstream NIR sorting.

The result is a recycling process designed around the entire material flow rather than treating shredding as an isolated operation.

Advanced Washing Technology for Plastics Recycling

Shredding is only the beginning.

Once plastic has been reduced to the required particle size, washing can play an important role in removing contamination and improving recyclate quality.

At K 2022, Lindner showcased its Rafter pre-washing system, designed to improve the cleaning performance of contaminated plastic waste.

The system uses a larger rotor to increase material residence time, helping improve cleaning performance.

Lindner reported throughput of up to 3 tonnes per hour for films and 5 tonnes per hour for rigid plastics for the showcased system.

This type of modular approach allows recycling plants to select washing technology according to the contamination level and characteristics of the incoming material.

Energy-Efficient Plastic Drying

Once plastic has been washed, removing moisture is another important stage of the recycling process.

Lindner introduced its EcoDry thermal dryer at K 2022.

The system was designed to use heat exchangers and insulated material-handling components to reduce energy consumption.

Lindner reported potential energy savings of up to 30%, while achieving residual moisture levels below 1% in the relevant process configuration.

Effective drying helps prepare plastic flakes for subsequent processing, including extrusion and other recycling applications.

From Plastic Waste to New Products

One of the most significant demonstrations at K 2022 showed how a coordinated recycling process can move plastic waste through several stages before producing material suitable for a new product.

Lindner demonstrated a process involving:

Shredding → Washing → Drying → Sorting → Injection Moulding

The live demonstration processed post-consumer rigid plastics and produced clean, homogeneous flakes.

In collaboration with Engel, these flakes were then processed directly into new pallets through injection moulding, demonstrating the potential of integrated plastics recycling technology.

The demonstration highlighted the importance of producing a consistent particle size and achieving low residual moisture.

Recycling Different Types of Plastic

Different plastic waste streams require different processing approaches.

Rigid Plastics

Rigid plastics can include containers, packaging, industrial products and other hard plastic items.

These materials can require robust shredding, washing and sorting to remove contamination and separate polymers.

Plastic Film

Film recycling presents its own challenges due to the flexible nature of the material and the potential for excessive fines.

The Lindner Jupiter BW has been specifically developed to optimise film shredding and prepare material for NIR sorting.

PET Recycling

PET is widely used in packaging and beverage containers and can be processed through dedicated recycling systems involving shredding, sorting, washing and drying.

The correct process configuration depends on the input material and required recyclate quality.

The Importance of the Right Plastic Recycling Shredder

Selecting the correct shredder is one of the most important decisions when designing or upgrading a plastics recycling plant.

Factors to consider include:

• Type of plastic being processed
• Input material quality
• Contamination levels
• Required throughput
• Desired particle size
• Downstream sorting requirements
• Washing requirements
• Energy consumption
• Maintenance requirements
• Available space
• Final recyclate specification

A shredder designed for rigid plastics may not provide the same performance when processing film.

Likewise, a machine configured for a specific particle size may not be suitable for another recycling application.

This is why application-specific machine selection is essential.

Complete Plastics Recycling Solutions from Lindner

One of the key advantages of Lindner’s approach is the ability to provide coordinated equipment across multiple stages of the recycling process.

Rather than treating shredding, washing and drying as completely separate processes, the equipment can be configured to work together.

This can help recycling operators optimise:

Throughput

Maximise the amount of material processed.

Energy Efficiency

Reduce unnecessary energy consumption throughout the process.

Material Quality

Produce cleaner and more consistent recycled material.

Maintenance

Use equipment designed with accessibility and maintenance requirements in mind.

Process Efficiency

Coordinate the individual stages to improve overall plant performance.

Mach Tech Services: Lindner Plastics Recycling Specialists

Choosing the right plastics recycling equipment requires more than simply selecting a machine from a catalogue.

The material, required output, contamination levels, throughput and downstream processes all need to be considered.

At Mach Tech Services, we help businesses identify suitable Lindner shredding technology for their recycling applications.

As the UK’s Lindner Recyclingtech specialists, we provide support throughout the equipment lifecycle.

Our services include:

• Plastic recycling shredder selection
• Application consultation
• Machine installation
• Commissioning
• Preventative maintenance
• Repairs
• Genuine spare parts
• Wear parts
• Precision engineering
• Welding and hardfacing
• Shredder rebuilds
• Technical support

We also hold over £1 million worth of spare and wear parts in stock, helping customers reduce downtime and maintain the performance of their shredding equipment.

The Future of Plastics Recycling

The plastics recycling industry continues to evolve.

Higher recycled-content targets, growing demand for quality recyclate and pressure to reduce energy consumption are all increasing the importance of efficient recycling technology.

The solution isn’t simply one machine.

Successful plastics recycling requires a carefully designed process in which shredding, sorting, washing and drying work together.

The innovations showcased by Lindner at K 2022 demonstrated how integrated recycling technology can help processors improve throughput, reduce energy consumption and produce higher-quality recycled materials.

For recyclers looking to maximise the value of their plastic waste, investing in the right processing technology can make a significant difference.

Looking for a Plastics Recycling Shredder?

If you’re looking to improve your plastic recycling process, upgrade an existing plant or develop a new recycling system, speak to Mach Tech Services.

Our team can help you identify the right Lindner shredding technology for your material and processing requirements.

📞 01706 838246
✉️ sales@machtechservices.com

Frequently Asked Questions

What is a plastics recycling shredder?

A plastics recycling shredder is industrial equipment used to reduce plastic waste into a controlled particle size for subsequent sorting, washing, drying or further recycling.

What plastics can Lindner shredders process?

Lindner provides shredding solutions for a wide range of plastics, including rigid plastics, plastic film and PET. The correct machine configuration depends on the material and required output.

What is the Lindner Micromat HP?

The Lindner Micromat HP is a single-shaft shredder designed for demanding plastics recycling applications. It features a direct belt drive, adjustable safety clutch and flexible knife system designed to support high throughput and efficient maintenance.

What is the Lindner Jupiter BW?

The Jupiter BW is a specialist shredder configuration designed for plastic film recycling. It is designed to produce consistent A4/A3-sized particles and reduce fines for improved downstream NIR sorting.

Why is washing important in plastic recycling?

Washing helps remove dirt, labels, residues and other contamination from plastic waste. The required washing process depends on the type and condition of the incoming material.

What is NIR sorting?

NIR, or near-infrared sorting, is an optical sorting technology used to identify and separate different materials based on their infrared response.

How important is particle size in plastics recycling?

Particle size can have a significant impact on downstream sorting and processing. Consistent particle sizes can help optical sorting equipment operate more effectively and can improve the consistency of subsequent processing stages.

Can plastic flakes be used to make new products?

Yes. Clean, appropriately processed plastic flakes can be further processed through technologies such as extrusion or injection moulding to produce new recycled plastic products.

Does Mach Tech supply Lindner plastic recycling shredders?

Yes. Mach Tech Services supplies and supports Lindner shredding technology in the UK and Ireland and can provide advice on machine selection, installation, maintenance and parts.

How do I choose the right plastic recycling shredder?

The right shredder depends on your plastic type, contamination levels, required throughput, particle size and downstream processing requirements. Mach Tech can assess your application and recommend a suitable Lindner solution.