Lesson 1Dewatering and drying ways: centrifuges, heat dryers, vacuum, target moisture before extrusionLooks at dewatering and drying washed flakes before extrusion. Compares centrifuges, mechanical dewatering, heat and vacuum dryers, and sets target moisture for polymers to avoid hydrolysis, gaps, and process wobbles.
Mechanical dewatering: screw presses and centrifugesThermal dryers: hot air, infrared, and contact typesVacuum drying for hygroscopic polymers like PETTarget moisture levels for PET, PA, and othersEnergy optimization and dryer performance controlLesson 2Solid-state cleaning and post-extrusion: melt filtration, SSP for IV recovery in PETCovers steps after extrusion for top recyclates, like melt filter polish, pellet cooling, and solid-state polycondensation for PET IV boost. Explains conditions, quality checks, and rules for food-contact.
Melt filtration polishing and fine contaminant removalStrand and underwater pelletizing system choicesSolid-state polycondensation principles for PETIV monitoring, residence time, and temperatureFood-contact compliance and decontamination testsLesson 3Separation and density processes: float-sink tanks, hydrocyclones, gravity windows for PET/PEExplains density separation in recycling, like float-sink tanks and hydrocyclones. Covers gravity windows for common polymers, water prep, and how settings affect separation sharpness and yield.
Principles of density separation in water mediaFloat-sink tank design and operating parametersHydrocyclone configuration and cut-point controlSpecific gravity windows for PET, PE, and PPWater chemistry, surfactants, and contaminationLesson 4Receiving and pre-sorting: hand sorting, trommels, ballistic separators, size and throughputIntroduces receiving and pre-sorting plastic waste. Covers feed checks, hand picking, trommels, ballistic separators, stressing non-conformity removal, throughput handling, and steady feed for auto sorting.
Incoming load inspection and quality checksManual sorting stations and ergonomicsTrommel screens for size classificationBallistic separators for 2D and 3D separationBalancing throughput, staffing, and safetyLesson 5Reject handling and residue processing: contaminants, fines, wastewater solids, disposal optionsHandles rejects and leftovers from sorting, washing, extrusion. Deals with common contaminants, fines, wastewater solids, with safe disposal, energy recovery, or value options meeting enviro and rule needs.
Typical contaminants and off-spec plastic streamsCollection and treatment of fines and dustWastewater solids thickening and dewateringSafe landfill, co-processing, and incineration routesValorization options: RDF, co-processing, and reuseLesson 6Sizing and shredder choices: coarse shredding, granulators, knife mills, size targets, energyDetails size cutting from coarse shredding to fine granulation. Explains machine types, rotor and knife setups, and how size targets, throughput, energy hit washing, drying, extrusion work.
Coarse shredders for bulky plastic feedstocksGranulator design, rotor types, and screen selectionKnife mill applications and wear managementParticle size targets for film, rigid, and fiberEnergy use, throughput, and maintenance trade-offsLesson 7Auto sorting tech: NIR, VIS cameras, float-sink, eddy current, X-ray, sorting efficienciesDescribes auto sorting tech in plastic recycling: NIR, VIS cameras, float-sink, eddy current, X-ray, and usual efficiencies. Reviews limits and how design affects purity, yield, running costs.
NIR sorting for polymer type identificationVIS cameras for color and label detectionEddy current separators for non-ferrous metalsX-ray systems for PVC and metal contaminationSorting efficiency, purity, and yield metricsLesson 8Washing and cleaning stages: hot-wash, counter-current, caustic, surfactants, temps, timesDetails washing stages for flakes: pre-wash, hot-wash, caustic, surfactant systems. Talks temp, stay time, mechanical action, removing labels, glues, organic bits.
Pre-wash and friction washer configurationsHot-wash conditions for label and glue removalCaustic washing chemistry and controlSurfactant selection and foaming managementResidence time, agitation, and soil loadingLesson 9Compounding and additive dosing: stabilisers, odour absorbers, impact modifiers, dosingLooks at compounding recycled plastics, focusing stabilisers, odour control, impact modifiers, colourants. Discusses dosing tech, feed accuracy, mix quality, tailoring to apps and rules.
Thermal and UV stabilizers for recycled resinsOdor absorbers and deodorization approachesImpact modifiers and toughness enhancementColor masterbatches and pigment selectionGravimetric and volumetric dosing system designLesson 10Extrusion, filtration, degassing: single vs twin screw, melt filtration, melt tempsExplores extrusion in recycling, single vs twin screw, melt temp control, degassing. Covers filter hardware, pore picks, how they cut contaminants and boost pellet quality.
Single-screw extruder design and operating windowsTwin-screw extruders for compounding and devolatilizationMelt temperature control and residence time effectsMelt filtration hardware, screen changers, pore sizesVacuum degassing, vent design, and volatile removal
