At prs Europe, taking place in Amsterdam on 5 and 6 May, Hellweg Maschinenbau will be presenting the latest developments in its range of digitally controlled, efficient and energy-saving grinders for plastics recycling. The focus will be on innovations in high-performance wet grinding and advances in digitalisation. The expanded range of grinding results on display at the trade fair includes films, high-performance plastics and technical fibres, demonstrating the grinders' virtually unlimited range of applications.
Credit: Hellweg Maschinenbau GmbH & Co. KG
At prs Europe, Hellweg Maschinenbau will be presenting the latest developments in its range of digitally controlled, efficient and energy-saving grinders for plastics recycling
Wet grinder for perfect flakes
The wet grinder with its forced feed system, launched at the end of 2023, remains at the forefront of film recycling. With its drive concept, which comprises motors with an output of 45 kW to 110 kW, and its low power consumption of just around 70 kWh to 90 kWh, it continues to set new cost-effectiveness standards for throughput rates of up to 5,000 kg of film. New findings show that this high energy efficiency can also be achieved when processing materials such as non-wovens, textiles, and pulp.
The double shear cutting process produces flakes of consistently high quality with a perfect particle size distribution and geometry. Thanks to their sharp-edged and, above all, flat shape, the flakes are ideally suited for further processing. The special blade arrangement and associated pulling cut minimise the amount of unwanted fines. The newly available, advanced closure and operating concept enables the machine to be closed and locked hydraulically. In daily use, this results in significant time savings during maintenance.
Digitalisation boosts efficiency
All Hellweg grinders can be fitted with the smart control system, which monitors parameters such as power consumption, motor speed and bearing temperatures. Operating hour counters are used to record and analyse the service life of blades, screens and V-belts. Furthermore, Smart Control is capable of continuously optimising the ratio between motor load and throughput.
Among the latest developments in the digitalisation of grinders, Hellweg highlights the smart sonic add-on module, using ultrasound to measure the material flow in the feed system. The results are then used to regulate the flow and ensure consistency. Thanks to the reduction in power consumption fluctuations, energy consumption is lowered while the quality of the ground product improves.
Another recent success in the field of developments is the smart flow module, an online throughput measurement system that uses microwave technology. It was unveiled for the first time at K 2025. A maintenance-free sensor positioned in the riser pipe of the extraction system measures the flow of bulk material without physical contact. The smart control system uses these signals to determine the machine’s current output in terms of mass ground per hour, as well as its grinding output over a given period, such as a day, week or month. This data can be used to plan maintenance work and avoid unplanned downtime, for example.
Grinders for (almost) every application
Hellweg’s grinders can shred all types of plastic, whether they are hard, soft, brittle or tough, and can reduce dust and fine particle content by up to 90%. At the same time, the grinding process uses up to 75% less electricity than conventional mills. Hellweg's expertise extends beyond plastics shredding to include textiles and non-wovens, as well as products for the cosmetics, food and pet food industries, including the grinding of tendons, bones, etc.
Hellweg’s range of grinders includes small laboratory and benchtop systems for milling sprues, as well as high-performance systems for solid parts, films and sheets with a throughput of five tonnes per hour or more. The range also includes edge strip grinders and servo-motor-driven edge trimming systems for film or sheet production.
Shortage of virgin material as an opportunity
Commenting on the current situation in the raw materials market, Managing Director Mark Hellweg says: “Stringent recycling requirements and the tight supply of virgin plastic make the availability of regrind a crucial factor for the recycling cycle. The quality of the regrind is a key determinant of the cost-effectiveness of its use. Hellweg’s mills have traditionally set the standard in terms of productivity, energy efficiency, low dust emissions and the ideal geometry of the regrind for further processing. At prs Europe, we will be demonstrating how the use of state-of-the-art grinding technology can help recyclers capitalise on the current circumstances.”