How to Choose a Mold Temperature Controller for an Extrusion Line: Configuration Guide and Applications
15/10/2026
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How to Choose a Mold Temp
For injection molding factories, blow molding plants, plastic product manufacturers and recycling companies, buying a plastic crusher is only one part of the recycling process.
The real challenge is designing a complete automated plastic crushing and recycling system that can operate continuously, handle the required capacity and reduce labor, dust and material loss.
A typical system may include:
Feeding → Conveying → Crushing → Dust Collection → Metal Separation → Material Transfer → Storage
At Wensui, we often find that production problems such as low output, frequent blockages and excessive dust are not always caused by the crusher itself. In many cases, the main reason is that the upstream and downstream equipment has not been properly matched.
This guide explains how to design a more efficient plastic crushing system and which factors should be considered before selecting equipment.
The first step is not choosing motor power or machine size. It is understanding the material.
Different plastics behave very differently during crushing.
For example, a crusher handling PP injection molding runners may require a very different rotor, blade configuration and feeding system from a machine processing HDPE drums or PVC profiles.
Common materials include:
For standard injection molding scrap, crushing capacities may commonly range from approximately 300 to 800 kg/h.
For larger centralized recycling applications, thick-walled plastic parts or bulky containers, system capacities may reach 1,000 to 3,000 kg/h or more, depending on the material, feed size and required output particle size.
Before designing the system, the following information should be confirmed:
These factors determine the crusher size, blade type, screen opening and conveying method.
Continuous feeding is essential for stable crusher performance.
For low-volume applications, manual feeding may still be practical. However, when production capacity increases, manual feeding can become inconsistent and labor-intensive.
Automated conveying is usually more suitable for centralized recycling systems.
Common conveying options include:
A belt conveyor is suitable for:
It allows operators to load material continuously while maintaining a relatively stable feeding rate.
Screw conveyors are commonly used after crushing.
They can transfer flakes or regrind material from the crusher outlet to:
For lighter crushed materials, pneumatic conveying can provide a cleaner and more compact transfer solution.
It is especially useful where floor space is limited or where operators want to reduce direct material handling.
A properly designed conveying system helps prevent sudden overfeeding, which is one of the common causes of crusher overload and blockage.
The crusher is the main processing unit, but motor power alone does not determine performance.
Important design factors include:
One of the most overlooked parameters is the screen opening.
For example, reducing the screen size from 12 mm to 6 mm can produce smaller regrind, but the material usually remains in the crushing chamber for a longer period.
This may reduce hourly output and increase energy consumption.
Therefore, the final particle size should be selected according to the downstream process rather than simply choosing the smallest possible screen.
At Wensui, crusher configuration is typically based on the actual material and production requirement instead of increasing motor power unnecessarily.
Not every material should be sent directly into a plastic crusher.
For bulky or thick materials such as:
a two-stage system may be more efficient.
The process can be designed as:
Shredding → Conveying → Crushing → Separation
The shredder performs primary size reduction, while the crusher produces a smaller and more uniform final particle size.
This configuration can reduce shock loading on the crusher and improve overall system stability.
Plastic crushing can generate fine particles and airborne dust, especially when processing brittle or fiber-reinforced materials.
If dust is not controlled properly, it can:
Depending on the application, the system may include:
Dust control is particularly important when processing materials such as ABS, PS, PET or glass-fiber-reinforced plastics.
Metal contamination can seriously damage crusher blades and downstream equipment.
Screws, nuts, metal inserts and small steel parts may accidentally enter the recycling stream together with plastic scrap.
Depending on the material source, the system can include:
This helps protect the crusher and also improves the purity of recycled material.
For applications requiring cleaner regrind, additional screening equipment can be used to separate dust, fines and oversized particles.
One of the most common purchasing mistakes is selecting a crusher based only on the rated capacity shown in a product catalog.
Actual throughput depends on several factors.
For example, two materials may both require a nominal capacity of 1,000 kg/h, but the equipment configuration for PP runners may be very different from that required for large HDPE containers.
Actual production capacity is affected by:
This is why capacity should always be evaluated based on a real material sample or detailed material information whenever possible.
A typical centralized recycling system may include the following process:
Plastic Scrap → Belt Conveyor → Plastic Crusher → Cyclone Separator → Dust Collector → Magnetic Separator → Pneumatic Conveying → Storage Bin
For larger materials, the system may be upgraded to:
Large Plastic Waste → Shredder → Conveyor → Plastic Crusher → Dust Separation → Metal Separation → Storage
This type of automated system can reduce manual handling and make the recycling process more consistent.
Wensui provides not only standalone plastic crushers, but also integrated solutions for plastic size reduction and material recycling.
Depending on the application, a Wensui system can combine:
Instead of recommending equipment only according to motor size, the system configuration should be based on the customer’s real production conditions.
For most projects, three pieces of information are especially important:
If available, material dimensions, photos and workshop layout can also help engineers select a more suitable configuration.
If your current recycling process has problems such as:
Wensui can help evaluate the system from feeding to final material collection.
Send us your plastic type, maximum material size, required capacity and target particle size.
Our engineering team can recommend a suitable plastic crusher and provide suggestions for conveying, dust collection, metal separation and automated material handling.
Tell Wensui how many kilograms of plastic you need to process per hour, and we can help you build a more suitable crushing and recycling solution.
An automated plastic crushing system combines a plastic crusher with feeding, conveying, dust collection, separation and storage equipment to reduce manual handling and improve recycling efficiency.
Crusher capacity should be selected according to plastic type, feed size, wall thickness, required particle size and feeding method. Rated capacity alone should not be used as the only selection criterion.
The final size depends on the downstream process. Common regrind sizes may range from several millimeters to more than 10 mm. Smaller screens generally create finer particles but may reduce throughput.
A shredder is recommended for bulky, thick or oversized plastic waste. It performs primary size reduction before the material enters the crusher.
Yes. Plastic crushers can be integrated with conveyors, dust collectors, metal separators, pneumatic conveying systems, storage bins and granulation equipment.
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Since 1990, Wensui Intelligent Equipment Inc. specializes in plastic peripheral equipment for more than 35 years.
Plastic crusher, Chiller, Dehumidifier, Hopper dryer, Resin mixer, Vacuum loader, and robotic arm.
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