ZL-PC1200A Continuous Heavy Industrial Shredder 44kW 2000kg/h 24/7
Composite material manufacturers running 24/7 production on glass-fiber and carbon-fiber reinforced plastics need crusher equipment that handles the most demanding materials continuously. The ZL-PC1200A Continuous Heavy Industrial Plastic Shredder delivers 2000 kg/h throughput with reinforced rotor assembly designed for sustained 40%+ glass fiber and carbon fiber composite processing at industrial scale.
| Model | ZL-PC1200A | Power | 44 kW (60 HP) |
| Voltage | 3-Phase 380V / 50Hz | 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 | 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 Continuous Heavy Industrial Plastic Shredder handles 40% glass fiber reinforced plastic at 1100-1200 kg/h sustained throughput over 24-hour continuous operation. The reinforced rotor assembly (55 mm shaft diameter vs 50 mm standard) handles the cyclic loading that glass fiber materials impose on rotor components during continuous processing.
For composite manufacturers running 24/7 production on glass fiber materials, the ZL-PC1200A's heavy material endurance enables 24-hour processing that standard machines cannot sustain. Standard machines typically achieve 4-6 hours of continuous 40% GF processing before requiring shutdown for blade inspection; the ZL-PC1200A sustains 24+ hours.
Carbon fiber reinforced plastic (CFRP) scrap has reclaimed value of USD 50-150/kg for non-structural applications. The ZL-PC1200A processes CFRP materials at 800-1000 kg/h with optional carbide-tipped blades (USD 1,200) that extend blade life to 1500-2500 hours on CFRP service (vs 200-300 hours for standard SKD-11 blades).
For composite manufacturers running 24/7 CFRP production, the ZL-PC1200A with carbide blades enables closed-loop carbon fiber reclamation at USD 50-150/kg reclaimed value. At 1000 kg/h throughput and 24 hours/day operation, the daily CFRP processing generates USD 50,000-150,000 in reclaimed material value.
The ZL-PC1200A features a reinforced rotor shaft (55 mm diameter) that handles the cyclic loading of glass fiber and carbon fiber processing. Standard machines with 50 mm shafts experience premature fatigue failure when processing 40%+ GF at 2000 kg/h continuous throughput. The 55 mm shaft extends fatigue life by 50% under heavy material 24/7 service.
For composite manufacturers running 24/7 heavy material processing, the reinforced rotor shaft provides 15+ year service life vs 8-10 years for standard machines. The extended life reduces unplanned downtime from rotor replacement (typically 24-48 hours) that standard machines require every 8-10 years.
The ZL-PC1200A's 2000 kg/h throughput supports 2-3 composite material production lines running 24/7. Typical composite manufacturing configuration: 2 injection molding lines producing 600-800 kg/h combined GF-reinforced scrap, or 3 extrusion lines producing 400-600 kg/h combined composite profile scrap.
For composite manufacturers running 24/7 production, the ZL-PC1200A's 2000 kg/h capacity matches the production scale. The integration supports future capacity expansion (adding 1-2 more production lines) without additional crusher investment, providing 30-50% throughput reserve.
For aerospace or automotive composite manufacturers running 24/7 production, the ZL-PC1200A Continuous Heavy Industrial Plastic Shredder enables closed-loop carbon fiber reclamation. Annual production scrap generation: 5,000-10,000 tonnes at 40%+ glass fiber or 500-1,000 tonnes at carbon fiber content.
Reclaimed carbon fiber value: USD 50-150/kg vs USD 200-500/kg virgin. At 1,000 kg/day CFRP processing and 300 days/year, annual reclaimed value: USD 15-45 million. The ZL-PC1200A capital cost is recovered in 1-2 days of carbon fiber reclamation. The composite closed-loop economics are the strongest business case for any ZL-PC variant.
Q: What is the maximum glass fiber content the ZL-PC1200A can process continuously?
40% glass fiber content sustained over 24-hour operation with standard SKD-11 blades. With optional carbide-tipped blades (USD 1,200), the ZL-PC1200A handles 50%+ glass fiber content with extended blade life.
Q: Can the ZL-PC1200A process carbon fiber composites?
Yes, at 800-1000 kg/h with optional carbide blades. The ZL-PC1200A with carbide blades enables closed-loop carbon fiber reclamation at USD 50-150/kg reclaimed value vs USD 200-500/kg virgin carbon fiber.
Q: What is the reinforced rotor shaft specification?
55 mm diameter vs 50 mm standard. The 55 mm shaft extends fatigue life by 50% under heavy material 24/7 service, providing 15+ year service life vs 8-10 years for standard machines.
Q: How many production lines can the ZL-PC1200A support?
2-3 composite material production lines running 24/7. The ZL-PC1200A's 2000 kg/h capacity supports typical composite manufacturing configurations with 30-50% throughput reserve for future expansion.
Q: What is the blade life on carbon fiber composites?
Standard SKD-11 blades: 200-300 hours. Carbide-tipped blades: 1500-2500 hours. For high-volume CFRP processing, carbide blades are essential for cost-effective operation.
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:
For 100 to 500 ton-per-month processors, in-plant regrind with the ZL-PC1200A can substitute 20 to 40 percent of virgin material purchases. At virgin cost of $1.50/kg and reclaimed cost of $0.20/kg, each ton of regrind saves $1,300 in material costs. For a 200-ton-per-month processor using 30 percent regrind, monthly savings reach $78,000.
For a 150-ton-per-month processor using 30 percent regrind mix, the ZL-PC1200A pays for itself in 4 to 7 months through material cost savings alone. Assumes virgin material cost of $1.50/kg and reclaimed material cost of $0.20/kg.
The ZL-PC1200A standard configuration integrates directly with the molding or extrusion line via EUROMAP 67 or SPI protocol. Material is fed from the production line into the shredder feed conveyor, shredded, pneumatically conveyed to the material loader, and mixed with virgin at 20 to 40 percent ratio. Installation requires 25 square meters of floor space and three-phase 380V/50Hz power.
The ZL-PC1200A delivers 1,800 to 2,000 kg/h sustained. For a 200-ton-per-month processor running 8 hours per day, this provides regrind capacity for 30 to 35 percent of virgin material substitution.
Granulators typically process 50 to 300 kg/h and are designed for sprues and runners, not whole parts. The ZL-PC1200A processes whole parts, purgings, and bulky scrap at 2,000 kg/h. For small processors producing both sprues and defective parts, ZILLION recommends the ZL-PC1200A for parts and a smaller granulator for sprues.
The ZL-PC1200A produces approximately 82 to 85 dB(A) at 1 meter. For indoor installations adjacent to molding cells, ZILLION recommends the optional sound-attenuating enclosure that reduces noise to 75 dB(A).
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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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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