ZL-PC400 Waste Plastic Recycling Crusher 7.5kW for MRF Operations | ZILLION
Material Recovery Facilities (MRFs) processing mixed plastic streams from regional collection networks need crusher capacity matched to their sorting throughput. The ZL-PC400 Waste Plastic Recycling Crusher delivers 400-500 kg/h throughput with rotor geometry and screen range optimized for MRF multi-stream processing.
| Model | ZL-PC400 | Power | 7.5 kW (10 HP) |
| Voltage | 3-Phase 380V / 50Hz (Customizable: 220V/415V/440V) | Motor Speed | 1480 rpm |
| Capacity | 400-500 kg/h | Feed Opening | 380 x 320 mm |
| Rotating Blades | 15 pcs SKD-11 | Fixed Blades | 4 pcs SKD-11 |
| Screen Hole | 8-14 mm (customizable) | Net Weight | 450 kg |
| Machine Size (L x W x H) | 1200 x 850 x 1400 mm | Crushing Chamber | 410 x 340 mm |
| Material Compatibility | PET, PP, PE, PVC, ABS, PS, PC, PMMA | Noise Level | max 86 dB |
| Warranty | 1 year (consumables excluded) | Certifications | CE / ISO 9001:2015 |
The ZL-PC400 Waste Plastic Recycling Crusher delivers 400-500 kg/h throughput, supporting MRFs processing up to 25,000 tonnes per year of mixed plastic. At 450 kg/h average throughput and 16 hours/day operation, a single ZL-PC400 processes 2,600 tonnes annually.
For MRF operators, the ZL-PC400 capacity matches the throughput of mid-size MRFs (10,000-25,000 tonnes/year) processing curbside collection streams. A typical 25,000 tonne/year MRF runs 8-10 ZL-PC400 machines in parallel for product-mix flexibility and operational redundancy.
The ZL-PC400 processes mixed-resin streams (PET, HDPE, PP, occasional PVC, PS) at 350-450 kg/h. The 15-blade rotor geometry produces consistent flake size distributions that work with downstream sink-float separation and optical sorting. Mixed-stream throughput is 80-90% of pure-stream throughput, reflecting stream variability.
For MRFs receiving curbside collection streams (typically 60% PET + HDPE, 25% PP, 10% mixed rigid, 5% film + contamination), the ZL-PC400 maintains 350-400 kg/h sustained throughput. The 7.5 kW motor's torque reserve handles contamination events without stalling.
The ZL-PC400 produces flake at 8-10 mm screen size that feeds directly into Near-Infrared (NIR) optical sorters without intermediate granulation. NIR sorting separates PET, HDPE, PP, and other polymers with 95-99% purity at throughputs up to 2,000 kg/h per sorter.
For MRFs adding optical sorting to existing operations, the ZL-PC400 output is calibrated for direct sorter feed. The 8 mm screen produces flake that NIR sorters can identify and separate efficiently. Plants skipping NIR sorting and relying on density separation alone see 85-90% purity.
MRFs collect mixed plastic bales at tipping fees of USD 50-150 per tonne (varies by region and contamination level). Sorted output sells at USD 200-1,100 per tonne depending on polymer and grade. The ZL-PC400 Waste Plastic Recycling Crusher is the critical equipment that determines whether the MRF operates at a profit or a loss.
For a 25,000 tonne/year MRF: input cost USD 2.5 million (USD 100/tonne avg tipping fee); sorted output revenue USD 3.75 million (mixed bale USD 600/tonne avg); processing cost USD 0.5 million (USD 20/tonne); net revenue USD 0.75 million. The ZL-PC400's reliable throughput determines whether the MRF achieves this net revenue projection.
Smaller municipalities and waste haulers often cannot justify a full MRF investment (USD 2-5 million). The ZL-PC400's USD 1,250 price point enables regional processing networks where 3-5 small haulers share a single MRF, transporting baled mixed plastic to a central facility for sorting and processing.
For a regional network serving 100,000 households across 5 municipalities, the central MRF runs 8 ZL-PC400 machines processing 25,000 tonnes of mixed plastic annually. Tipping fees from haulers (USD 80/tonne) plus sorted output revenue (USD 500/tonne avg) generate USD 9.5 million annual revenue against USD 7 million operating cost, yielding USD 2.5 million net annual revenue shared among the 5 municipal partners.
MRF operators must meet quality specifications for sorted resin output. PET flake purity targets: 95-97% for food-grade rPET, 90-95% for fiber-grade rPET. HDPE flake purity targets: 92-95% for blow-molding applications. PP flake purity targets: 88-93% for injection molding applications.
For MRF operators, the ZL-PC400's output purity depends on upstream sorting and downstream processing. Pure-stream inputs achieve 95%+ purity; mixed-stream inputs achieve 88-93% purity. The ZL-PC400's 8 mm standard screen produces flake that supports both sink-float separation (85-90% purity) and NIR sorting (95-99% purity) downstream.
MRF operators typically expand capacity by adding parallel ZL-PC400 machines rather than upgrading single units. The modular ZL-PC400 design supports expansion from 2 units (800-1,000 kg/h, 5,000-7,000 tonnes/year) to 10+ units (4,000-5,000 kg/h, 25,000+ tonnes/year) without infrastructure changes beyond electrical panel capacity.
For MRFs reaching 50,000+ tonnes/year, the PC600 (15 kW, 500-800 kg/h) replaces the parallel PC400 configuration as the primary crusher. The PC400 retains its role in secondary streams or specialty processing where the 7.5 kW capacity matches specific product requirements.
Q: What is the maximum contamination level for MRF streams?
15% non-plastic contamination is the practical limit. Above 20% contamination, throughput drops 30-40% and blade life shortens. Pre-sorting with magnetic separator and air classifier is recommended for streams above 10% contamination.
Q: Can the ZL-PC400 process plastic film and flexible packaging?
Limited. Rigid plastics process at rated throughput. Flexible film tends to wrap around the rotor and requires different rotor geometry. For mixed rigid + flexible streams, pre-sort the film out and process rigid-only at the ZL-PC400.
Q: How is metal contamination handled?
Metal objects below 5 mm pass through without damage. Larger metal objects trip the thermal overload and require manual clearing via the reversing switch. Magnetic separator upstream (USD 2,500-4,000) is recommended for all MRF streams.
Q: What is the typical MRF payback period for a ZL-PC400?
10-16 months for a 10,000-25,000 tonne/year MRF. The ZL-PC400 represents 8-12% of total MRF capital cost (USD 1,250 of USD 15,000-25,000 total equipment cost per MRF line including wash, separation, optical sorting, and baling).
Q: Does the ZL-PC400 require special operator training?
Basic training (2 hours) covers start-up, shut-down, jam clearing, and screen changes. Most MRF operators learn the ZL-PC400 within 1 shift. Advanced training on rotor alignment and bearing service is available from ZILLION technicians (USD 1,200 on-site).
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