ZL-PC1200A High Volume Plastic Shredder 44kW 2000kg/h Extra-Large OEM
Extra-large OEM factories producing 50,000-100,000 tonnes of finished plastic products annually need crusher capacity matched to mega-production scale. The ZL-PC1200A High Volume Plastic Shredder delivers 2000 kg/h continuous throughput with the 44 kW motor and 28 SKD-11 rotating blades that extra-large OEM facilities need to feed downstream wash, separation, and extrusion lines at full rated throughput.
| Model | ZL-PC1200A | Power | 44 kW (60 HP) |
| Voltage | 3-Phase 380V / 50Hz (Customizable: 220V/415V/440V/480V) | Motor Speed | 1480 rpm |
| Capacity | 2000 kg/h | Feed Opening | 950 x 580 mm |
| Rotating Blades | 28 pcs SKD-11 | Fixed Blades | 4 pcs SKD-11 |
| Screen Hole | 8-18 mm (customizable) | Net Weight | 2500 kg |
| Machine Size (L x W x H) | 2300 x 1750 x 2500 mm | Crushing Chamber | 1000 x 620 mm |
| Material Compatibility | PET, PP, PE, PVC, ABS, PS, PC, PMMA, PA, PU | Noise Level | max 95 dB |
| Warranty | 1 year (consumables excluded) | Certifications | CE / ISO 9001:2015 |
The ZL-PC1200A uses a 44 kW three-phase induction motor with a service factor of 1.15 (50.6 kW peak surge). Continuous-rated torque at 1480 rpm motor speed is 283.9 Nm at the motor shaft, which after the hardened steel gearbox reduction (5:1 ratio) reaches 1420 Nm at the rotor hub. That is 16% more torque than the ZL-PC1000 38 kW unit (1226 Nm at the rotor hub) and 47% more than the ZL-PC800 30 kW unit (968 Nm).
For extra-large OEM operations running 24 hours per day, the 16% torque headroom translates directly to sustained throughput on the most demanding materials: thick-walled PVC pipe (12-15 mm wall), large HDPE drums (200L with 12 mm wall), and high-glass-fiber PA66 (40-50% GF). The ZL-PC1200A maintains 2000 kg/h across these demanding materials where the ZL-PC1000 would drop to 1500-1600 kg/h.
The ZL-PC1200A rotor mounts 28 SKD-11 rotating blades paired with 4 SKD-11 fixed blades, giving 56 active cutting events per rotor revolution. SKD-11 is a high-carbon, high-chromium tool steel (similar to AISI D2) with working hardness 58-60 HRC, holding a working edge through 800-1200 hours of continuous PET crushing service before re-sharpening. Each blade is reversible, yielding two cutting edges per blade.
The 28-blade rotor geometry was selected specifically for 2000 kg/h sustained throughput. Compared to 27-blade designs (PC1000) that reach 1500 kg/h ceiling, the 28-blade rotor maintains consistent flake size across the full 1700-2000 kg/h operating range. For a 100,000 tonne/year OEM operation, that extra 300-500 kg/h adds 6,000-10,000 tonnes of annual throughput from a single machine.
The ZL-PC1200A High Volume Plastic Shredder is the workhorse machine for extra-large OEM operations processing 50,000-100,000 tonnes annually. Three typical extra-large OEM applications: automotive OEM (multi-plant production 5,000+ pieces/day generates 400-600 kg/h sprue+runner scrap), chemical OEM (multi-product production 200+ drums/day generates 200-300 kg/h trim scrap), appliance OEM (multi-product housing production generates 150-250 kg/h sprue+runner scrap). One ZL-PC1200A handles all three streams at the rated 2000 kg/h throughput with 3-5x reserve capacity.
For a major automotive OEM running 8 bumper production lines (12,000 kg/h total finished throughput), the ZL-PC1200A processes 1,000-1,500 kg/h of sprue and runner scrap directly back into the upstream compounding line, recovering USD 700-1,050 per hour at USD 700/tonne resin prices. The integration cost (USD 22,800 total: machine + conveyors + installation) is recovered in the first 21 hours of closed-loop operation.
For extra-large OEM operations calculating ROI on the ZL-PC1200A: USD 11,000 total investment + USD 2,400 installation + USD 2,800 first-year maintenance = USD 16,200 first-year cost. Revenue at USD 700/tonne recovered resin x 16,000 tonnes/year (2000 kg/h x 16 hours x 250 days x 1.0 utilization) = USD 11,200,000 gross revenue.
Annual operating cost: electricity 44 kW x 16 hours x 250 days x USD 0.10/kWh = USD 17,600; blade replacement 10 sets x USD 580 = USD 5,800; bearing service 3 events x USD 680 = USD 2,040; labor USD 18,000; overhead USD 12,000. Total: USD 55,440. Net annual revenue: USD 11,144,560. First-year ROI: USD 11,144,560 / USD 16,200 = 68,793% return, or approximately 5 days to payback. The ZL-PC1200A is one of the fastest-payback capital investments in extra-large OEM operations.
For an extra-large OEM operation running 4,000 hours per year (single shift), the ZL-PC1200A 5-year operating cost: purchase USD 11,000; electricity 44 kW x 4,000 hours x 5 years x USD 0.10/kWh = USD 88,000; blade replacement 25 sets x USD 580 = USD 14,500; bearing service 6 events x USD 680 = USD 4,080; gearbox oil change 5 x USD 160 = USD 800. Total: USD 118,380.
At 2000 kg/h throughput and 4,000 hours per year, the ZL-PC1200A processes 8,000 tonnes of input material annually. Revenue at USD 700/tonne recovered flake = USD 5,600,000 gross. After subtracting the USD 118,380 5-year operating cost, net annual contribution is USD 1,096,324. That is the financial basis for the ZL-PC1200A selling into extra-large OEM operations with a payback period of 12-15 months.
Q: What power supply configuration does the 44 kW motor need?
44 kW at 380V three-phase draws approximately 84 amps per phase. A 100A breaker with 35 mm squared copper cable from the distribution panel is the minimum specification. For plants with older 220V infrastructure, a step-up transformer (USD 2,000-4,000 additional) is required.
Q: How often do the SKD-11 blades need re-sharpening under heavy OEM service?
Under normal PET bottle service with 12 mm screen at 2000 kg/h continuous operation, blades hold a working edge for 800-1200 hours. At 16 hours per shift, 5 days per week, that is 6-10 weeks between sharpening. Each sharpening service (10-12 hours downtime) costs approximately USD 580 if sent out.
Q: What is the warranty coverage?
1 year on motor, gearbox, and main structural components. Blades, screens, and gaskets are wear items and not covered. Warranty is void if blades are run on incompatible materials (e.g., metal objects above 5 mm) or if the machine is operated without the specified screen installed.
Q: Can the machine handle 24/7 continuous service?
Yes, with the standard oil cooler maintaining gearbox oil below 80 degC and predictive maintenance via the optional IOT gateway (USD 480). Most extra-large OEM operations run the ZL-PC1200A in 24/7 service with 95% uptime availability.
Q: What is the delivery time for a 3-unit order?
35-45 days from deposit for 1-3 units, 50-70 days for 5+ units. Each unit ships in reinforced export plywood case packaging from Dongguan. FOB Shenzhen, CIF, and DDP pricing available.
The ZL-PC1200A sits in ZILLION's ZL-PC industrial shredder range between the smaller PC1000 and the larger PC1400A. At 44 kW and 2,000 kg/h, it is the right size for mid-volume applications that need more throughput than PC1000 but do not justify the capital cost of the PC1400A. For other applications or upstream pre-shredding in a two-stage recycling line, consider these related models and engineering resources:
The ZL-PC1200A handles agricultural film with up to 30 percent contamination (sand, soil, plant residue, moisture) without screen blinding. The standard 20 mm screen is paired with a reversing cycle that engages when the motor current exceeds 110 percent of nominal for more than 3 seconds, automatically ejecting dense contamination. For heavily contaminated film, ZILLION recommends pairing the ZL-PC1200A with a ZL-PC800 pre-shredder and a drum wash upstream.
For dry agricultural mulch film at less than 10 percent moisture, the ZL-PC1200A delivers 1,800 to 2,000 kg/h. For wet silage film and stretchage film at 15 to 25 percent moisture, throughput typically settles at 1,400 to 1,800 kg/h. For greenhouse film with high contamination, expect 1,200 to 1,500 kg/h.
The 1,420 mm feed opening accommodates full-width rolls of agricultural film up to 6 m diameter after initial slit removal. For compacted bales of film waste, the standard rotor configuration handles bale sections up to 800 mm cross-section without pre-shredding. For dense bale cores, ZILLION recommends a ZL-PC800 pre-shredder.
Yes. The ZL-PC1200A carries CE marking under Machinery Directive 2006/42/EC, complies with EN ISO 12100:2010, and is designed per ISO 13849. For agricultural installations, ZILLION provides an optional wash-down-rated configuration with 316L stainless steel fasteners in the cutting chamber.
In a typical seasonal operation processing agricultural mulch film from May through October, the ZL-PC1200A delivers 25 to 30 tons per day at 2,000 kg/h over 16-hour operating days. A single machine processes approximately 4,000 to 4,500 tons per 6-month season, equivalent to 8,000 to 9,000 tons per year for year-round operations in warmer climates.
Specialized agricultural film recycling lines typically cost $400,000 to $800,000 and require 5,000+ square feet of space. The ZL-PC1200A at a fraction of the capital cost delivers 80 to 90 percent of the throughput of specialized lines for typical mulch film. For highly specialized operations, ZILLION provides custom-engineered turnkey lines.
The ZL-PC1200 series delivers 44 kW of motor power at 2,000 kg/h of rated throughput. The following five worked examples let you verify throughput, lifecycle cost, and return-on-investment for your specific application before purchasing. All calculations use conservative operating assumptions and can be re-run with your site-specific energy rate, labor cost, and feedstock moisture content.
Question: How many tons per day can the ZL-PC1200 actually process in a real plant?
Calculation:
Interpretation: A single ZL-PC1200 delivers mid-sized plant throughput. For comparison, the larger ZL-PC1400A delivers 34 tons/day at 55 kW power, and the ZL-PC1400B delivers 60 tons/day. If your application requires more than 30 tons/day consistently, consider the PC1400A.
Question: What is the fully-loaded cost per ton over a 5-year life cycle?
Assumptions: 27 tons/day × 26 days/month × 12 months/year × 5 years = 42,120 tons over 5 years. Energy rate: $0.08/kWh. Labor: $5/hour for one operator.
Annual costs:
Total 5-year cost: ($4,000 + $9,799 + $1,900 + $400 + $24,960 + $1,000) × 5 = $210,295
Cost per ton over 5 years: $210,295 / 42,120 tons = $4.99/ton
Interpretation: At $4.99 per ton fully-loaded, the ZL-PC1200 is competitive with mid-size industrial shredders in the 1,500 to 2,000 kg/h class. Plants with lower energy rates (large industrial contracts at $0.05/kWh) can drive this below $4.50/ton; plants with higher labor costs push it toward $6.00/ton.
Question: How long do the SKD-11 blades last and what is the per-ton blade cost?
Calculation:
Interpretation: At 19 cents per ton, blade resharpening is a small fraction of TCO (about 3.8% of $4.99/ton). The four-edge indexable design effectively gives 4,000 to 4,800 hours between resharpening cycles, reducing labor cost as well.
Question: If we currently run a ZL-PC800 (30 kW / 1,000 kg/h), what is the payback period for upgrading to the ZL-PC1200?
Current state (ZL-PC800):
After upgrade (ZL-PC1200):
Annual savings:
Capital investment delta: $20,000 (PC1200) - $14,000 (PC800) = $6,000 net incremental investment
Payback period: $6,000 / $269,700/year = 0.022 years (about 8 days)
Interpretation: For plants running ZL-PC800 with available market demand, upgrading to a single ZL-PC1200 pays back in less than two weeks through throughput expansion. The 3.4× capacity increase creates substantial option value for new contracts.
Question: What does it cost in electricity to process one ton of plastic?
Calculation:
Cost per ton at common energy rates:
Interpretation: The ZL-PC1200 has similar energy efficiency to the larger ZL-PC1400 (15.4 kWh/ton) due to scale efficiency. The smaller motor (44 kW vs 55 kW) and lower throughput (2,000 vs 2,500 kg/h) cancel each other out at this capacity range.
The specifications, safety standards, blade material claims, lifecycle calculations, and ROI examples for the ZL-PC1200A and ZL-PC1200B industrial plastic shredders reference the following industry bodies and standards:
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