As plastic waste volumes rise across the globe, industries need advanced recycling machinery to support circular manufacturing goals. Industrial granulators play a critical role by breaking down plastic scrap – such as injection-molded parts, sheets, films, bottles, and lumps – into high-quality regrind. The right granulator improves efficiency, reduces operational costs, and delivers uniform output for reprocessing.
Virtus Equipment designs and supplies Heavy-Duty Industrial Granulators engineered for a wide range of recycling applications – from light trim waste to thick industrial purging.
Why Granulation Matters in Plastic Recycling
Granulation is the first major step in mechanical recycling. A high-performance granulator:
- Improves material recovery and reuse rates
- Produces consistent granule size for reprocessing
- Reduces waste disposal cost
- Increases production efficiency
- Supports sustainability goals and environmental compliance
Without an efficient granulator, downstream extrusion or pelletizing operations can be limited by inconsistent particle sizes and contamination.
Best Industrial Granulators for Plastic Recycling
Different applications require different granulator designs.
Below are the top-rated granulator categories widely used for plastic recycling
- Heavy-Duty Industrial Granulators:
Engineered for maximum strength and endurance, these granulators process extremely thick and large plastic parts such as purgings, pipes, automotive bumpers, and industrial rejects. Their rotors, typically made with high-strength alloy blades, deliver powerful cutting performance with high torque and stable throughput — ideal for continuous heavy-load operations.
- Central Granulators:
These machines operate as a central recycling hub for multiple molding or extrusion machines. They are designed for medium to high volumes, handling sprues, runners, rejected parts, and general plant scrap. With adjustable rotor geometry and screen options, they support a wide range of material types while maintaining consistent granule quality.
- Beside-the-Press Granulators:
Compact units installed beside injection or blow molding machines for in-line recycling at the source. They reduce scrap handling labor and contamination issues by returning freshly granulated regrind straight into production. Perfect for processors focused on zero-waste manufacturing and high material recovery.
- Low-Speed / Screenless Granulators:
Ideal for sensitive plastic materials where low dust and low heat are critical. Their slow-rotating cutting wheels minimize friction to protect material characteristics — especially useful for sprues and runners in high-quality molding applications. Operators also benefit from significantly reduced noise levels.
- Pipe & Profile Granulators:
Feature long, wide feed openings and special angled cutting chambers to handle continuous pipes, channels, and window profiles without pre-cutting. This eliminates additional labor while preventing jams, making them excellent for extrusion-based industries.
- Sheet & Film Granulators:
Built to process lightweight materials with high risk of wrapping such as plastic sheet edges, laminates, thermoformed scrap and films. These granulators use tangential cutters and airflow assistance to ensure smooth infeed and consistent flake size — making them popular in packaging recycling lines.
- Specialty Granulators for PET, Rubber or Fibers:
Customized machines designed for specific materials with tough physical properties:
- PET bottle granulators with water-cooling options
- Rubber foam granulators with serrated blades
- Fiber-reinforced material granulators with abrasion-resistant build
They enable sectors to recycle what would otherwise be costly industrial waste.
Key Features to Look for in the Best Plastic Recycling Granulators
| Important Feature | Why It Matters |
| Rotor Design & Blade Configuration | Determines cutting efficiency and granule consistency |
| Durable Construction | Withstands heavy wear and increases service life |
| High Throughput & Energy Efficiency | Improves productivity and lowers operating cost |
| Ease of Maintenance & Accessibility | Reduces downtime and enhances operator safety |
| Noise & Dust Control | Ensures better workplace conditions |
| Customizable Feed & Discharge Options | Adapts machine to specific recycling workflow |
A well-chosen granulator reduces operational cost while boosting recycling value.
How to Choose the Right Granulator:
Selecting the right granulator depends on several operational and product-related factors. Here’s a clearer breakdown:
| Selection Criteria | What to Look For | Why It Matters |
| Material Type | Hard/rigid plastics → heavy-duty rotors • Films & soft plastics → tangential chamber design | Ensures blade efficiency & prevents clogging |
| Part Dimensions & Thickness | Large bulky purgings require bigger cutting chambers; smaller sprues suit compact units | Prevents machine overload & improves feeding |
| Required Throughput | ≥ kg/hr tonnage capacity optimized for production line volume | Avoids bottlenecks & improves ROI |
| Desired Outputs | Adjustable screen sizes for controlled granule size | Supports consistent reprocessing quality |
| Installation Space | Floor layout and integration with existing machines | Ensures smooth workflow & easy maintenance |
| Energy Efficiency | Low-power drives and rotor designs optimized for continuous use | Reduces total operational cost |
| Maintenance Accessibility | Quick-change blades, easy chamber access, wear-resistant materials | Minimizes downtime & labor |
| Noise and Dust Control | Insulation options, slow-speed rotors, dust extraction | Improves worker comfort & safety |
| Automation Compatibility | Conveyor, blower, robotic feed options | Future-proofs production |
Why Choose Virtus Equipment?
Virtus Equipment is an industry leader in recycling innovation, offering:
- A complete range of plastic recycling industrial granulators
- Heavy-duty machines designed for demanding operations
- Engineering excellence and German-inspired performance standards
- Custom configurations for every recycling application
Reliable service, spare parts availability, and expert consultation
We help businesses:
- Reduce waste handling costs
- Improve processing efficiency
- Maximize value from recycled plastics
With our proven technology, we help transform waste into valuable regrind — supporting sustainability and profitability.
Conclusion:
Industrial granulators are the backbone of mechanical plastic recycling. Choosing the right machine is crucial to ensure durability, efficiency, and high-quality output. From heavy-duty machines for bulky scrap to precision granulators for delicate materials, Virtus Equipment provides tailored solutions that deliver exceptional performance.
Whether you are a small manufacturer or large recycling plant, partnering with a knowledgeable Plastic Recycling Equipment Supplier ensures scalable success and a stronger circular economy. Virtus Equipment stands ready to help you select the perfect granulator for your recycling goals.
Frequently Asked Questions (FAQs):
1. What is an industrial granulator used for?
A granulator cuts scrap or waste plastic into uniform granules that can be reprocessed into new products, reducing raw material usage and waste.
2. Which granulator is best for thick plastic parts and purgings?
A heavy-duty industrial granulator offers the robust cutting power required for bulky and high-strength materials.
3. Do I need a central or beside-the-press granulator?
Use a beside-the-press granulator for on-site scrap recycling near molding machines. Use a central granulator for medium-to-large volume scrap collection across multiple machines.
4. Can industrial granulators handle films and soft plastics?
Yes, film and sheet granulators are specifically designed with tangential chambers to prevent material wrapping around the rotor.
5. How do I determine the right rotor size and speed?
It depends on material type and desired output granule size – our experts analyze your production needs to recommend the ideal configuration.
6. Are Virtus Equipment granulators energy-efficient?
Yes, our granulators feature optimized cutting systems that reduce power consumption while maintaining high throughput.
7. Does Virtus Equipment offer after-sales support?
Absolutely — we provide installation guidance, maintenance support, operator training, and spare parts availability.
