ZL-PC180 Heavy Duty Plastic Crusher for Recycling 2.2kW 120-150kg/h | ZILLION
The ZL-PC180 is purpose-built as the pre-shredder for plastic recycling lines processing post-consumer and post-industrial waste. Unlike standalone crushers designed for batch operation, the ZL-PC180 is engineered for continuous feed from conveyors, with gravity discharge directly to wash tanks or air separators. This page is for recycling line integrators, recyclers planning to expand capacity, and engineering firms designing turnkey recycling systems.
For a typical PET bottle-to-fiber recycling line, the ZL-PC180 sits between the bale breaker / trommel and the wash tank. The crusher reduces bottles to 6-12mm flakes, then a wash tank removes labels and contamination, followed by friction washer, air separator, and extruder/pelletizer. The ZL-PC180's 120-150 kg/h output supports a 800-1000 kg/day recycling operation per shift.
| Parameter | Value |
|---|---|
| Model | ZL-PC180 |
| Motor | 2.2 kW continuous-duty, 3-phase 380V/50Hz |
| Capacity (recycling line) | 120-150 kg/h continuous feed |
| Rotating Blades | 9 pcs SKD-11 (recycling-grade hardness HRC 60-62) |
| Fixed Blades | 2 pcs SKD-11 (matched hand-fitted) |
| Screen Aperture | 8mm default (optimal for wash line), 6/10/12mm options |
| Feed Opening | 180 x 160 mm (matches 250-300mm belt width) |
| Discharge | Gravity via bottom screen (to wash tank or conveyor) |
| Noise | Max 82 dB (suitable for indoor line integration) |
| Net Weight | 120 kg (forklift-portable for line reconfiguration) |
For a complete PET bottle-to-fiber recycling line, the ZL-PC180 integrates at the pre-shredding stage. Here's the typical workflow:
| Stage | Equipment | Function | Throughput Match |
|---|---|---|---|
| 1. Bale Breaking | Hydraulic bale breaker | Breaks compressed bales into loose bottles | 500-2000 kg/h |
| 2. Pre-Wash (optional) | Trommel / wet drum | Removes loose dirt, sand, labels | 300-1500 kg/h |
| 3. Crushing (ZL-PC180) | Zillion ZL-PC180 | Reduces bottles to 8-12mm flakes | 120-150 kg/h |
| 4. Wash Tank | Hot wash + friction | Removes labels, glue, contamination | 150-200 kg/h (oversized for surge capacity) |
| 5. Rinse + Dewater | Friction washer + centrifuge | Final rinse and water removal | 150-200 kg/h |
| 6. Air Separation | Zigzag air classifier | Removes remaining label/film fragments | 150-200 kg/h |
| 7. Drying + Pelletizing | Thermal dryer + extruder | Dries flakes and extrudes into pellets | 100-150 kg/h |
The ZL-PC180 is the throughput bottleneck for the entire line. For higher throughput, run 2-3 PC180 units in parallel. For lower throughput, the PC180 can be operated intermittently with manual bottle feeding.
For different operating schedules, here are the productivity calculations for the ZL-PC180 in a recycling line:
| Schedule | Hours/Day | Days/Week | Daily Output | Weekly Output | Annual Output |
|---|---|---|---|---|---|
| 1 shift, 5 days/week | 8h | 5 | 1,080 kg | 5,400 kg | 281 tons |
| 1 shift, 6 days/week | 8h | 6 | 1,080 kg | 6,480 kg | 337 tons |
| 2 shifts, 5 days/week | 16h | 5 | 2,160 kg | 10,800 kg | 562 tons |
| 2 shifts, 6 days/week | 16h | 6 | 2,160 kg | 12,960 kg | 674 tons |
| 3 shifts, 7 days/week | 24h | 7 | 3,240 kg | 22,680 kg | 1,179 tons |
For recyclers planning 500-1000 ton/year capacity, the ZL-PC180's 2-shift, 6-day/week schedule delivers 674 tons/year - more than enough. For 1000+ ton/year capacity, run 2-3 ZL-PC180 units in parallel or upgrade to the ZL-PC250 (250 kg/h) or ZL-PC300 (300 kg/h).
For 16-24 hours/day recycling line operation, here's the proven maintenance schedule based on real-world installations in Southeast Asia, Latin America, and Africa:
| Interval | Maintenance Task | Time | Tools Required |
|---|---|---|---|
| Every 4 hours (per shift) | Visual check of chamber, listen for unusual noise | 2 min | None |
| Daily (end of shift) | Clean chamber, inspect screen for holes/clogging | 10 min | Brush, scraper |
| Weekly | Check V-belt tension, motor current, bearing temperature | 20 min | Tension gauge, clamp meter, IR thermometer |
| Monthly | Lubricate gearbox, inspect electrical panel, test safety interlock | 45 min | Grease gun, multimeter |
| Every 500 hours | Rotate blade set (3 positions per blade = 3x life) | 30 min | Socket wrench set |
| Every 1500 hours (recycling-grade use) | Replace rotating blade set | 45 min | Socket wrench set |
| Every 4500 hours | Full wear kit: blades + screen + V-belt + bearing inspection | 2 hours | Socket wrench + bearing puller |
Recommended spare parts inventory for 24/7 recycling line: 3 rotating blade sets, 2 fixed blade sets, 4 screens (6/8/10/12mm), 4 V-belts, 2 motor contactors, 1 emergency stop button. We can ship these from Dongguan within 3-5 days by air freight.
Q1: How does the ZL-PC180 integrate with my existing recycling line?
The ZL-PC180 has a standard 180x160mm feed opening that accepts conveyor-fed material (matching 250-300mm belt width). Discharge is gravity through the bottom screen directly to a wash tank, conveyor, or collection bin. We provide CAD drawings (DWG + PDF) with dimensional details for line layout planning. Most recycling line integrators can incorporate the PC180 into their design within 1-2 days.
Q2: What screen size do you recommend for PET bottle recycling?
8mm is the optimal screen size for most PET bottle-to-fiber recycling lines. 8mm flakes provide the right balance between surface area (for label/contamination removal in wash tank) and bulk density (for efficient air separation and extrusion). The PC180 ships with a 10mm screen standard - we can ship an 8mm screen as an accessory for recycling applications.
Q3: Can the ZL-PC180 handle contamination (metal, glass, sand) common in post-consumer waste?
Yes - the SKD-11 blades (HRC 60-62) handle typical post-consumer contamination well. However, we recommend pre-sorting and trommel washing to remove large metal/glass fragments before crushing, as these can chip blades. For heavily contaminated streams, the ZL-PC series with hardened blades or upgrade to the ZL-PC300/PC500 for larger chambers may be more suitable.
Q4: How often do blades need replacement in continuous recycling operation?
For 16-24 hours/day PET bottle recycling, expect 1000-1500 hours per rotating blade set (vs 1500-2000 hours in less abrasive HDPE). With the 3-rotation blade position system, total blade life extends to 3000-4500 hours. We recommend keeping 2-3 blade sets in inventory for 24/7 operations to avoid downtime.
Q5: What's the recommended maintenance schedule for continuous operation?
For 16-24h/day recycling lines: daily chamber cleaning (10 min), weekly V-belt + motor check (20 min), monthly gearbox lubrication (45 min), 500-hour blade rotation (30 min), 1500-hour blade replacement (45 min). Total scheduled maintenance: 2-3 hours/week. We provide a detailed maintenance log template and video guides with each machine.
Q6: Can the ZL-PC180 be operated continuously with contaminated feed, or do I need a pre-wash?
We strongly recommend a pre-wash stage (trommel or wet drum) before the ZL-PC180 for post-consumer streams. Pre-wash removes 70-80% of contamination, extending blade life by 2-3x and reducing dust carry-over to the wash tank. For post-industrial waste (clean factory scrap), pre-wash is not required.
Q7: What safety features are included for operator protection?
Emergency stop button (red mushroom, IP65), safety interlock on chamber door (cuts power if opened during operation), motor thermal overload protection, phase sequence relay (prevents reverse rotation damage), main power lockable disconnect. CE certified to IEC 60204-1 machinery safety standard. For high-throughput lines, we recommend additional light curtains or safety mats at the feed point.
Q8: How do I integrate the ZL-PC180 with my PLC / SCADA system?
The ZL-PC180 has standard motor contactor wiring that accepts remote start/stop signals. For integration with PLC/SCADA, we provide: (1) wiring diagram showing contactor coil terminals, (2) motor current sensor output (4-20mA, optional), (3) emergency stop circuit terminals. Most integrators can wire the PC180 into their control system within 1-2 hours.
Q9: What is the dust level, and do I need a dust collection system?
The ZL-PC180 produces minimal fines due to the SKD-11 blade geometry. For indoor recycling line installations, we recommend a basic cyclone dust collector (USD 800-1500) to capture airborne flake fragments. For outdoor installations or well-ventilated facilities, no dust collection is required.
Q10: How do I scale from 1 ZL-PC180 to higher throughput?
Three options: (1) Run 2-3 ZL-PC180 units in parallel (each independently feeding the wash tank) - lowest cost, easiest to implement. (2) Upgrade to ZL-PC250 (250 kg/h, USD 800) or ZL-PC300 (300 kg/h, USD 1050) - doubles or triples capacity per unit. (3) Add a second shift - doubles capacity without equipment investment. Most recyclers start with option 3, then move to option 1, then option 2 as the business grows.
The ZL-PC180 PET Bottle Crusher delivers reliable size reduction for plastic recycling lines. Powered by a 2.2kW motor with 9+2 SKD-11 blades and a 6-12mm screen, it produces 120-150 kg/h of uniformly crushed PET flakes ready for washing, separation, and pelletizing. Recycling Applications PET bottle recycling (water/cola/juice bottles) HDPE/PP container crushing Plastic scrap recovery from production lines Pre-shredding for washing plants
The ZL-PC180 Industrial Plastic Crusher is engineered for factory production lines requiring reliable 120-150 kg/h throughput. Its 2.2kW heavy-duty motor paired with 9 SKD-11 rotating blades delivers consistent particle size for downstream extrusion or compounding lines. Industrial Features Heavy-duty 2.2kW motor for continuous operation SKD-11 blades rated for 1000+ hours of use Industrial-grade frame and bearings CE certified for global deployment
The ZL-PC180 Plastic Crusher Machine is manufactured in China by Zillion — a leading plastic crusher supplier with 15+ years of OEM/ODM experience. This 2.2kW industrial model produces 120-150 kg/h and ships directly from our Dongguan factory at competitive wholesale pricing. China Supplier Advantages Factory-direct pricing with no middleman markup OEM/ODM branding and packaging available Multi-voltage: 220V/380V/400V/415V/440V CE certified for global markets
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