ZL-PC1200B Premium OEM System Shredder 44kW 2000kg/h Full Integration
Premium OEM operations require complete shredder system integration including feeding, sorting, crushing, and discharge conveying as a unified production line. The ZL-PC1200B Premium OEM System Shredder delivers 2000 kg/h throughput with full system integration features: built-in PLC, integrated HMI, automated sorting, and complete material flow management.
| Model | ZL-PC1200B | 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 | 30 pcs SKD-11 (Premium Grade) | Fixed Blades | 4 pcs SKD-11 (Premium) |
| Screen Hole | 4-16 mm (precision range) | Net Weight | 2600 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, PEEK | Noise Level | max 78 dB (with acoustic enclosure) |
| Warranty | 2 years (extended) | Certifications | CE / ISO 9001:2015 / FDA-compatible |
The ZL-PC1200B ships with built-in PLC (Allen-Bradley CompactLogix compatible) that integrates directly with injection molding, blow molding, and extrusion line controls. The built-in PLC enables automated start/stop synchronization, scrap flow management, and quality monitoring without external integration hardware.
For premium OEM operations, the built-in PLC eliminates USD 3,000-8,000 external PLC integration costs and reduces integration time from 2-4 weeks to 1-2 days. The integrated approach ensures reliable communication and reduces maintenance complexity.
The ZL-PC1200B ships with 10-inch touchscreen HMI (Human Machine Interface) that displays operating parameters, alarm conditions, and production statistics. The HMI enables operator control without external computers or control panels.
For premium OEM operations, the integrated HMI reduces operator training time (familiar touchscreen interface) and enables remote monitoring via Ethernet. The integrated HMI is factory-configured for the specific OEM application.
The ZL-PC1200B integrates with upstream automated sorting equipment (NIR optical sorters, color sorters, density separators) via built-in Modbus TCP communication. The sorting integration enables automated material flow management: sorted materials are routed to appropriate processing streams.
For premium OEM operations, the sorting integration reduces manual labor and improves material purity. The integrated approach supports closed-loop recycling with high-purity output for direct re-injection applications.
The ZL-PC1200B's system integration includes complete material flow management: feed conveyors, magnetic separation, optical sorting, crushing, discharge conveying, and finished material storage. The integrated approach reduces installation time and ensures system compatibility.
For premium OEM operations, the integrated material flow management reduces capital cost (USD 20,000-40,000 vs separate equipment) and reduces installation time (1-2 weeks vs 4-6 weeks). The integrated approach also reduces maintenance complexity (single vendor support).
The ZL-PC1200B's built-in PLC tracks and reports: tonnes processed per shift, uptime percentage, blade wear estimates, energy consumption per tonne, and operator efficiency. The production statistics support ISO 9001 quality system documentation and continuous improvement programs.
For premium OEM operations, the production statistics enable data-driven decision making: identify bottlenecks, optimize production schedules, track equipment ROI. The statistics are exportable to standard manufacturing execution systems (MES).
The ZL-PC1200B ships with built-in Ethernet for remote monitoring and diagnostics. ZILLION technicians can remotely access the PLC for troubleshooting, parameter adjustment, and predictive maintenance alerts. The remote capability reduces on-site service costs (USD 1,200-2,400 per visit).
For premium OEM operations, the remote monitoring reduces unplanned downtime through faster technical support response. The 1-hour remote support response time (vs 24-48 hour on-site response) saves 8-16 hours of unplanned downtime per service event.
The ZL-PC1200B Premium OEM System Shredder ships with 2-year warranty on the complete system (vs 1-year for standard machines). The extended warranty covers the integrated system components: shredder, PLC, HMI, conveyors, sorting integration, and remote monitoring.
For premium OEM operations, the 2-year system warranty covers 100% of typical payback period, reducing financial risk on the capital investment. The extended warranty is backed by ZILLION's global service network with 48-hour parts availability.
Q: What is included in the system integration?
Complete system: built-in PLC (Allen-Bradley CompactLogix compatible), 10-inch touchscreen HMI, feed conveyors, magnetic separation, optical sorting integration, crushing, discharge conveying, finished material storage, and remote monitoring via Ethernet.
Q: Can the system integrate with existing factory MES?
Yes, via built-in Modbus TCP and optional OPC UA support. The production statistics export to standard MES formats, enabling integration with factory-wide manufacturing execution systems.
Q: What is the warranty on the complete system?
2 years on the complete system (shredder, PLC, HMI, conveyors, sorting integration, remote monitoring). The extended warranty covers 100% of typical payback period for premium OEM operations.
Q: How does remote monitoring work?
Built-in Ethernet enables ZILLION technicians to remotely access the PLC for troubleshooting, parameter adjustment, and predictive maintenance alerts. 1-hour remote response time saves 8-16 hours of unplanned downtime per service event.
Q: Can the system be expanded for future production growth?
Yes, the modular design supports adding additional sorting equipment, conveyors, and storage capacity. The PLC supports up to 16 additional I/O modules for system expansion.
The ZL-PC1200B is the premium variant of the ZL-PC1200 series, sharing the 44 kW motor and 2,000 kg/h platform with the ZL-PC1200A but engineered with specialty materials, sound engineering, and cleanroom integration for the most demanding industry applications. For other applications or upstream pre-shredding in a two-stage recycling line, consider these related models and engineering resources:
The ZL-PC1200B Premium OEM includes a complete Interface Control Document (ICD) package, FAT testing at ZILLION facility, optional custom PLC brands (Siemens, Allen-Bradley, Mitsubishi), and dedicated project engineering support. The shredder ships with pre-configured I/O mapping for the OEM line control system.
The ZL-PC1200B Premium OEM undergoes 4 hours of Factory Acceptance Testing with the OEM customer present (in-person or remote video). The FAT covers throughput verification, noise level measurement, vibration analysis, control system I/O check, and emergency stop response. ZILLION provides a signed FAT report.
The ZL-PC1200B Premium OEM delivers the full 2,000 kg/h rated throughput. The Premium configuration adds engineering support and documentation but does not constrain mechanical performance.
The ZL-PC1200B Premium OEM includes the standard 24-month warranty plus extended 36-month warranty option. ZILLION provides dedicated project engineering contact for the design and commissioning phase, plus 24/7 remote support for the first 12 months of operation.
The ZILLION engineering team provides integration support for downstream sorting, washing, extrusion, and compounding equipment. ZILLION has integration partners for Tomra (sorting), Steinert (sorting), and EREMA (extrusion) systems.
Standard lead time is 15 to 25 days for production plus 7 to 10 days for shipping. Premium OEM configurations with custom PLC and FAT testing add 15 to 20 days. Total project lead time from order to commissioning-ready delivery is typically 8 to 12 weeks.
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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The 5HP plastic crusher is suitable for crushing various types of soft and hard plastics, including plastic edge materials, recycled materials, semi-finished products, etc. It can crush plastics in the forms of blocks, balls, sheets, strips, bottle shells, basket bags, etc. into granular form for recycling, greatly improving the utilization rate of plastics. This crusher is power-saving and has excellent crushing effect. The base is attached with pulleys for convenient movement, and it has a compact size without taking up too much space.
Plastic crusher is a device designed for crushing various plastic materials. It is widely used in the recycling industry and manufacturing processes. The crusher can handle different types of plastics, including plastic bottles, films, pipes, and various plastic products.
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This machine is usually made of high-quality steel, ensuring durability and stability. It is equipped with powerful motors and sharp cutting blades. The plastic materials are fed into the crusher through a hopper. Under the action of the motor, the cutting blades rotate at high speed, quickly breaking down the plastics into smaller pieces. The crusher machine are widely used in industries such as plastic recycling, manufacturing, and waste disposal.
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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