ZL-PC250 Plastic Crusher for Production Line Automation | ZILLION
Production line automation in plastic processing requires equipment that integrates with PLC and SCADA systems. The ZL-PC250 Plastic Crusher for Production Line Automation delivers 250 kg/h throughput with built-in Modbus TCP communication, start/stop control inputs, and fault feedback outputs that connect directly to factory automation systems without custom integration.
| Model | ZL-PC250 | Power | 4 kW (5 HP) |
| Voltage | 3-Phase 380V / 50Hz (Customizable: 220V/415V) | Motor Speed | 1480 rpm |
| Capacity | 250 kg/h | Feed Opening | 310 x 250 mm |
| Rotating Blades | 9 pcs SKD-11 | Fixed Blades | 3 pcs SKD-11 |
| Screen Hole | 6-12 mm (customizable) | Net Weight | 250 kg |
| Machine Size (L x W x H) | 950 x 550 x 1300 mm | Crushing Chamber | 340 x 270 mm |
| Material Compatibility | PET, PP, PE, PVC, ABS, PS | Noise Level | max 82 dB |
| Warranty | 1 year (consumables excluded) | Certifications | CE / ISO 9001:2015 |
The ZL-PC250 ships with a built-in Modbus TCP server on the control panel that exposes 24 operating parameters: motor current (amps), motor speed (rpm), gearbox temperature (degC), main bearing vibration (mm/s), blade wear estimate (hours), screen condition (open/partial/blocked), and 18 additional diagnostic values. The Modbus TCP server is accessible via standard Ethernet connection at any plant network location.
For factories running Siemens S7, Allen-Bradley ControlLogix, or Schneider Modicon PLCs, the ZL-PC250 registers are pre-mapped to standard process variable names. Integration time is typically 1-2 hours of PLC programming versus 1-2 days for competitor machines that require custom register mapping.
The ZL-PC250 control panel accepts 4-wire digital start/stop control from upstream equipment: start signal (24V DC, 50 mA), stop signal (24V DC, 50 mA), fault reset (24V DC pulse), emergency stop (normally closed, loop-powered). The interface connects directly to molding machine robot controllers, conveyor control panels, or plant-wide SCADA systems.
For production lines where the injection molding machine controls the crusher cycle, the start signal triggers when the molding machine opens the mold (sprue/runner ready for crushing). The stop signal triggers when the upstream equipment detects an empty condition. This eliminates operator intervention in the crush cycle.
The ZL-PC250 control panel provides 8 fault feedback outputs to factory automation: motor overload, thermal cutoff, vibration alarm, screen blockage, jam detected, oil level low, emergency stop activated, general fault. Each output is a dry contact (24V DC, 1A) that connects to plant SCADA, HMI panels, or alarm systems.
For factories with central control rooms, the 8-output alarm system enables real-time crusher status monitoring without operator intervention. Alarm conditions trigger automatic notifications (SMS, email) to maintenance personnel, reducing unplanned downtime through faster response.
The ZL-PC250 ships with the ZILLION IOT gateway (USD 480 optional) that publishes all 24 operating parameters to a cloud dashboard at 1-minute intervals. The dashboard displays real-time status, 30-day historical trends, and predictive maintenance forecasts based on vibration and thermal trends. SMS and email alerts trigger on: jam detection, thermal overload, oil level low, bearing vibration above threshold.
For factories running multiple ZL-PC250 machines across shifts and locations, the cloud dashboard enables a single maintenance technician to monitor all machines from a central location. Most factories deploying 4+ ZL-PC250 machines report 25-35% reduction in unplanned downtime within the first 6 months of cloud monitoring deployment.
The ZL-PC250 control panel includes 8 pre-configured operating recipes for common materials: PET bottle (recipe 1), HDPE container (recipe 2), PP cap (recipe 3), PVC pipe (recipe 4), ABS automotive (recipe 5), PS foam (recipe 6), and 2 additional user-configurable recipes. Each recipe sets motor RPM, feed rate setpoint, screen size, and jam-response parameters.
Operators select a recipe via the touchscreen HMI in under 5 seconds. For mixed-material production runs, the recipe can be changed automatically by the factory MES when the upstream material feed changes. This eliminates the 3-10 minutes of manual adjustment required on competitor machines when switching between materials.
The ZL-PC250's 4-wire digital interface connects directly to injection molding machine robot controllers (Sepro, Yushin, Wittmann, Husky). The robot arm picks the sprue/runner from the mold and drops it into the ZL-PC250 feed chute. The crusher start signal can be triggered by the robot cycle completion, ensuring synchronized operation.
For factories running automated molding cells with 4-6 second cycle times, the ZL-PC250 keeps pace with the molding machine throughput without operator intervention. The crusher's 250 kg/h capacity supports 4-6 medium-sized injection molding machines operating in parallel.
Q: What PLC protocols are supported out of the box?
Modbus TCP is standard. Profinet, EtherNet/IP, and CC-Link IE Field are supported via optional gateway modules (USD 280 each). OPC UA support is in development for 2027 release.
Q: Can the machine operate without the IOT gateway?
Yes. The ZL-PC250 operates fully without IOT, with all controls available on the local touchscreen HMI. The IOT gateway is optional and adds remote monitoring capability without affecting local operation.
Q: How long is the cloud data retention period?
3 years at 1-minute granularity for all 24 operating parameters. Beyond 3 years, data is aggregated to hourly averages and retained indefinitely.
Q: Is the cloud dashboard accessible from mobile devices?
Yes. The dashboard is web-based and works on any browser including mobile. Native iOS and Android apps are planned for 2027.
Q: What cybersecurity measures are in place?
TLS 1.3 encryption on all cloud communications. Local Modbus TCP can be configured for read-only or read/write access per register. Factory-side network isolation via VLAN is recommended for cyber-physical security.
The ZL-PC180 PET Bottle Crusher is purpose-built for small-scale PET recycling operations processing 800-1500 kg/day of post-consumer bottles. Its 2.2kW motor with 9 SKD-11 rotating blades and 6-12mm interchangeable screen delivers 120-150 kg/h of uniformly-sized PET flakes-ready as direct feed for hot wash lines, dewatering, and pelletizing. Ideal PET Recycling Applications PET bottle recycling lines (water, cola, juice, cooking oil containers) HDPE/PP container crushing (milk jugs, detergent bottles, caps) Post-consumer bottle recovery for community collection centers Pre-shredding before hot wash tanks (froth flotation separation) Printing waste and injection molding sprue recovery
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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Our company's series of products are well-known in the plastic auxiliary machinery industry for their excellent performance and high cost performance.
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