Plastic Pellet Screening Machine for Japan Masterbatch Production

Project Summary

Project Background

The customer in this project is a plastic material manufacturer located in Osaka, Japan. The company mainly produces high-performance masterbatch, engineering plastic pellets, and modified PVC pellets, which are widely used in automotive components, electronic housings, packaging materials, and other industries.

During the high-speed extrusion pelletizing process, the customer faced several production issues.

After leaving the extrusion machine, the plastic pellets had a temperature of around 130℃. Without effective cooling before the next production step, the high temperature could cause:

• Pellet sticking between materials;
• Screen blockage during screening;
• Reduced packaging efficiency;
• Lower storage stability of finished products.

At the same time, the customer found that some pellets had inconsistent sizes, which affected product quality.

The customer required a system that could:

• Connect with the existing pelletizing production line;
• Perform continuous screening;
• Complete cooling and vertical conveying at the same time;
• Reduce manual material handling.

Therefore, the customer needed a complete solution that could combine hot plastic pellet screening, cooling, and vertical conveying in one production process.

Customer Requirements Analysis

Sanyuantang Provided Solution

According to the characteristics of the customer’s hot plastic pellet production process, Sanyuantang designed a complete system:

SYZ-515 Linear Vibrating Screen + Water & Air Cooling Vibrating Spiral Elevator

This combination was designed to complete:

• Pellet size screening;
• High-temperature pellet cooling;
• Vertical conveying;
• Continuous production connection.

Equipment Configuration

1. SYZ-515 Linear Vibrating Screen

Installation Position:

After the extrusion pelletizing machine

Main Functions:

• Remove oversized pellets;
• Separate unqualified particles;
• Maintain consistent pellet size before entering the cooling and conveying system.

Equipment Parameters

Linear Screen Video

2. Water & Air Cooling Vibrating Spiral Elevator

The customer’s initial requirement could be met by a normal 500mm diameter elevator based on the current production capacity.

However, considering future production expansion and better cooling performance, the customer selected:

800mm diameter vibrating spiral elevator.

Equipment Functions:

• Water Cooling System
  • The circulating cooling water removes heat from the pellets and improves cooling efficiency.
• Air Cooling System
  • The air circulation helps release heat faster and reduces pellet sticking during transportation.

Technical Parameters

Vibrating Spiral Elevator Video

Why Choose SYZ-515 Linear Vibrating Screen with Water & Air Cooling Vibrating Spiral Elevator?

In this project, the customer’s material included masterbatch pellets, PVC pellets, and plastic granules. The main challenge was not only screening, but also how to connect continuous screening with cooling and conveying after high-temperature pelletizing.

The customer required a production capacity of 400kg/h. The material temperature was around 130℃ when entering the screening equipment. If the pellets stayed too long inside the screening system or accumulated during processing, pellet sticking could occur and affect screening performance.

According to the customer’s production line layout and material characteristics, Sanyuantang selected the SYZ-515 Linear Vibrating Screen as the front-end screening equipment.

1. Linear Motion Is More Suitable for Online Plastic Pellet Screening

Plastic pellets and masterbatch pellets are different from heavy minerals or powder materials. They have lower weight and better flowability.

In this project, the screening equipment needed to be installed after the extrusion pelletizing line. Therefore, the equipment needed to meet the following requirements:

• Continuous feeding;
• Fast material movement;
• No influence on upstream and downstream production processes.

The SYZ-515 Linear Vibrating Screen uses two vibration motors to generate linear vibration force, allowing materials to move forward on the screen surface while being screened.

Compared with the circular motion of a rotary vibrating screen, the linear movement design is more suitable for continuous production lines. The pellets can move forward while completing screening, reducing material accumulation at the feeding area.

For the customer’s production capacity of around 400kg/h, the equipment can maintain stable continuous operation.

2. 8mm and 2mm Perforated Screen Plates Meet Pellet Size Control Requirements

During production, the customer needed to maintain consistent pellet size and remove abnormal particles.

Therefore, the screening system was equipped with:

• First layer: 8mm perforated screen plate
• Second layer: 2mm perforated screen plate

Instead of traditional woven mesh, perforated plates were selected mainly according to the characteristics of plastic pellets.

Plastic pellets have certain elasticity. During long-term operation, ordinary screen mesh may have problems such as:

• Screen hole deformation;
• Pellets getting stuck in the mesh;
• Reduced screen tension.

The hole size of perforated screen plates remains fixed during operation, providing more stable screening performance and making them suitable for continuous plastic pellet production.

3. Equipment Size and Capacity Match the 400kg/h Production Requirement

The customer’s initial production requirement was: 400kg/h

During equipment selection, two factors were mainly considered:

First, the screening capacity needed to match the continuous output from the production line.

Second, the equipment size should not be unnecessarily large, which could increase installation space requirements and operating costs.

The SYZ-515 Linear Vibrating Screen has a suitable size for the customer’s production line. It can be installed behind the existing extrusion equipment while meeting the current production requirements.

During actual operation, the pellets pass through the screen surface smoothly and complete classification quickly, avoiding production delays caused by the screening process.

4. Combination with Water & Air Cooling Vibrating Spiral Elevator Solves High-Temperature Pellet Problems

The biggest difference between this project and ordinary plastic pellet screening applications is that the customer required both screening and temperature reduction.

When the pellets leave the extrusion machine:

• Material temperature: approximately 130℃

If the pellets directly enter packaging or the next production process, several problems may occur:

• Pellet sticking;
• Material clumping during storage;
• Reduced packaging efficiency.

Therefore, Sanyuantang installed an:

800mm diameter Water & Air Cooling Vibrating Spiral Elevator

After the SYZ-515 Linear Vibrating Screen.

The equipment reduces pellet temperature through:

• Circulating water cooling;
• Air cooling assistance;
• Longer material residence time during vertical conveying.

The complete process was achieved:

130℃ → approximately 35℃

which met the customer’s requirements for subsequent production.

5. Why Did the Customer Choose an 800mm Diameter Elevator?

According to the production calculation, a 500mm diameter vibrating spiral elevator was already enough for the current 400kg/h capacity.

However, the customer considered:

• Future production expansion;
• Better cooling performance;
• Longer pellet residence time.

Therefore, the customer finally selected:

800mm diameter vibrating spiral elevator.

This became one of the key features of this project.

The equipment not only meets current production requirements but also provides additional capacity space for future expansion.

6. Simple Structure Makes Long-Term Maintenance Easier

Plastic production companies usually require long continuous operation, so equipment maintenance was also an important concern for the customer.

The SYZ-515 Linear Vibrating Screen features a simple structure:

• External vibration motors;
• Easy screen plate replacement;
• Low daily maintenance requirements.

When the customer needs to adjust pellet sizes in the future, only the screen plates need to be replaced. There is no need to replace the complete screening machine.

Project Value Provided by This Configuration

Before and After Comparison

Project Results

By installing the Sanyuantang SYZ-515 Linear Vibrating Screen and Water & Air Cooling Vibrating Spiral Elevator, the Japanese customer achieved the following improvements:

1. Fast Cooling of High-Temperature Pellets

Material temperature:

130℃ → approximately 35℃

The cooling process effectively reduced:

• Pellet sticking;
• Screen blockage;
• Packaging difficulties.

2. Improved Product Quality Consistency

Through the combination of 8mm and 2mm screen openings:

• Oversized particles were removed;
• Pellet size was controlled;
• Product consistency was improved.

3. Continuous Automated Production

The complete system was connected with the customer’s plastic pelletizing line and achieved:

• Automatic screening;
• Automatic cooling;
• Automatic vertical conveying.

This reduced manual operation and improved production efficiency.

Conclusion

For this Japanese plastic processing company, Sanyuantang provided a complete Plastic Pellet Screening Machine solution combining the SYZ-515 Linear Vibrating Screen with a water and air cooling vibrating spiral elevator.

The system processed masterbatch pellets, PVC pellets, and plastic granules at a capacity of 400kg/h. The pellet temperature was reduced from approximately 130℃ to around 35℃, while maintaining more consistent pellet size and improving production efficiency.

This project shows Sanyuantang’s experience in providing customized plastic pellet screening and cooling solutions for plastic processing manufacturers worldwide.

If you are currently facing screening challenges, please contact us today. Our engineers will reply within 24 hours and provide a suitable screening solution for your application.

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