ZL-PC250 Plastic Crusher for Production Line Automation | ZILLION
The ZL-PC250 is engineered for modern automated production lines requiring inline plastic scrap crushing with PLC integration, conveyor feed, and Industry 4.0 connectivity. The 4kW continuous-duty motor delivers 250kg/h throughput, matching the typical scrap output of mid-size automated manufacturing lines (injection molding, blow molding, extrusion).
For production engineers and automation integrators, the ZL-PC250 offers standard industrial interfaces that drop into existing PLC/SCADA control systems without custom integration work. The 240x200mm feed opening matches 350-400mm conveyor belt widths, and the gravity discharge delivers crushed material to downstream collection bins or conveyors.
| Parameter | Value |
|---|---|
| Model | ZL-PC250 Automation |
| Motor | 4 kW continuous-duty (S1) |
| Capacity | 250 kg/h continuous inline operation |
| Feed Opening | 240 x 200 mm (matches 350-400mm belt) |
| Blades | 9 rotating + 2 fixed SKD-11 |
| Screen | 6-12mm interchangeable |
| Control Interface | 24VDC contactor / 4-20mA motor sensor (optional) |
| Conveyor Compatibility | 350-400mm belt width, 0.5-1 m/s speed |
| Power | 3-phase 380V/50Hz (custom voltages) |
| Compliance | CE, ISO 9001, IEC 60204-1 |
The ZL-PC250 supports standard industrial control interfaces for drop-in integration with PLC and SCADA systems:
| Interface | Type | Function | Compatibility |
|---|---|---|---|
| Start/Stop Control | 24 VDC digital input | Remote start/stop from PLC | Siemens S7, Allen-Bradley, Mitsubishi |
| Motor Run Feedback | 24 VDC digital output | Confirm motor running state | All major PLC brands |
| Emergency Stop | 24 VDC digital input (NC) | Safety circuit integration | Cat 3 / PL d safety standard |
| Motor Current Monitor | 4-20mA analog output (optional) | Real-time load monitoring | Predictive maintenance integration |
| Chamber Door Open | 24 VDC digital input (NO) | Detect door open state | Safety interlock |
| Emergency Stop Reset | 24 VDC digital input | Acknowledge E-stop pressed | Operator HMI feedback |
All interfaces use 24 VDC standard industrial signals, compatible with major PLC brands without voltage conversion. We provide wiring diagrams with each shipment for integrator reference.
For automated production line mounting, the ZL-PC250 is designed for direct conveyor feed integration. Here are the mechanical specifications for line integrators:
| Parameter | Specification | Notes |
|---|---|---|
| Feed Opening Size | 240 x 200 mm | Matches 350-400mm belt width |
| Recommended Belt Width | 350-400 mm | For maximum part feed |
| Belt Speed Range | 0.5-1.0 m/s | Adjustable via VFD |
| Feed Height (above floor) | 1,200-1,400 mm (adjustable feet) | Matches typical conveyor heights |
| Discharge Height (bottom screen) | 550-650 mm | For bin or conveyor collection |
| Discharge | Gravity via bottom screen | 8mm default screen |
| Required Floor Space | 1,500 x 1,000 mm | Including clearance |
| Mounting | Floor-standing, 4x M12 anchor bolts | Anti-vibration pads included |
For 350-400mm belt conveyors, the PC250 sits directly below the conveyor discharge with adjustable feet (100mm range) to align with the line height. The bottom screen discharge delivers crushed material to a collection bin, conveyor, or pneumatic transfer system.
Three typical production line automation configurations for the ZL-PC250:
For most mid-size production lines, Configuration B provides the best balance of automation and cost. Configuration C is justified for 24/7 lights-out manufacturing where labor cost is a major factor.
For Industry 4.0 / smart factory integration, the ZL-PC250 supports optional smart sensors:
Smart sensors add USD 200-500 to the base price and require integration with your factory's IoT platform. Contact us for specific Industry 4.0 integration requirements.
Q1: What PLC interfaces does the ZL-PC250 support?
Standard 24VDC digital inputs/outputs for start/stop, motor run feedback, emergency stop, and chamber door open detection. Optional 4-20mA analog output for motor current monitoring. Compatible with Siemens S7, Allen-Bradley CompactLogix/ControlLogix, Mitsubishi MELSEC, and Schneider Modicon without custom interface modules.
Q2: Can the ZL-PC250 be controlled via Modbus or Profinet?
Standard configuration uses 24VDC digital I/O. For Modbus/Profinet integration, we offer an optional IoT gateway (USD 300-500) that converts the digital signals to industrial protocols. Contact us with your specific PLC system requirements.
Q3: What conveyor width is compatible with the PC250 feed opening?
240x200mm feed opening matches 350-400mm belt conveyors. For smaller conveyors (250-300mm), you can still use the PC250 with a feed chute adapter. For larger conveyors (500mm+), the smaller PC180 or the larger PC300/PC400 may be more suitable.
Q4: Can the PC250 integrate with my SCADA system for remote monitoring?
Yes - via the optional 4-20mA motor current output and digital I/O, the PC250 can be integrated with any SCADA system supporting these standard signals. For cloud-based monitoring, we offer an optional IoT gateway with MQTT/OPC-UA support.
Q5: What's the safety rating of the emergency stop circuit?
The E-stop circuit is rated for Safety Category 3 / Performance Level d (PL d) per ISO 13849-1. This is the standard for industrial machinery safety circuits and is compatible with safety PLCs and safety relay systems.
Q6: Can the PC250 detect jam conditions and trigger automatic shutdown?
Yes - with the optional 4-20mA motor current sensor, the PLC can monitor motor load in real-time. Jam conditions cause current spike, which can trigger automatic shutdown via the PLC. This protects the motor and blades from damage.
Q7: How long does integration typically take?
For Configuration B (conveyor + PLC), typical integration time is 2-3 days including mounting, wiring, and PLC programming. For Configuration C (full automation), 1-2 weeks including pneumatic transfer system installation. We provide integration support via video call and on-site engineer (extra cost) if needed.
Q8: What's the recommended VFD for variable speed control?
For 4kW motor, we recommend a 5.5kW VFD (Schneider ATV12, ABB ACS150, or equivalent). VFD allows adjusting belt speed and motor RPM to match different materials. VFD is not included with the PC250 - we can supply compatible VFD as an accessory (USD 400-600).
Q9: Can the PC250 operate continuously in a 24/7 lights-out production line?
Yes - the PC250 is rated S1 continuous duty and can run 24/7 with the recommended maintenance schedule. For lights-out operation, we strongly recommend the optional motor current sensor for jam detection and automatic shutdown protection.
Q10: What kind of safety compliance does the PC250 have for automated lines?
CE certified to Machinery Directive 2006/42/EC and IEC 60204-1 (electrical equipment of machines). Safety category 3 / PL d for E-stop circuit. Light curtain integration supported via safety relay (not included). For North American buyers, UL 508A panel is available as a custom option.
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