Various processes have been used in the creation of plastics over the years. However, there is a difference between plastic pellets, granules, powder, and other polymeric materials that are formulated during the processing of polymer.
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These different forms of materials are also prepared to be fed into the machine the plastic will be created.
First off, pure polymer does not have very high chemical, mechanical, and thermal resistances after it has been freshly synthesized, which makes it needful for the material to pass through a formulation stage.
In this stage, chemical additives are added to the pure polymer in a bid to improve its characteristics.
Additives such as antioxidants allow the polymer to be processed and plasticized.
Thus, it protects the polymer from degradation and oxidation, and the same can be said about flame retardants and antistatic additives.
Additives could take it one step further to enhance its features such as ultraviolet resistance to protect from:
The formulation stage is where the granules are produced, and there is a melting step where the adjuvants are homogeneously sent into the polymer.
Fillers are also dispersed into the polymer for preparing composites, and this introduction can be carried out in different ways. The latter leads to the formulation of pellets.
Finally, granules help to increase the density of the freshly synthesized polymer since it lacks the flowing properties required to be processed by an extruder.
Plastics are synthetic organic polymer materials that consist of:
They are also formed with raw materials, including oil, coal, and natural gas.
However, the first step in the creation of plastics is in the polymerization of its raw materials which leads to the product monomer.
Raw polymer materials are usually produced and sold in liquid form (sealants, adhesives, and resins); or as bulk pellets, granules, powders, or sheets.
They can be molded or shaped by the application of heat, thanks to their plasticity property.
Other properties of plastic are its low electrical conductivity, low density, transparency, and toughness which has allowed it to be used for the creation of various products.
Moreover, the versatility of plastic has led to its use in a wide range of industries.
As earlier outlined, plastic in its raw material stage is available in several forms, and some of these are granules and plastic pellets.
Thus, they are industrial raw materials for the plastic industry.
The properties of granules and pellets which set either apart are outlined below:
Granules are fine particles, but small in size. Some properties of plastic granules are:
Plastic granules are made up of particles that are formed as a result of the progressive enlargement of primary particles that change their original identity.
Plastic granules are employed in processing recycled plastics.
There are, however, some injection molding processing machines that can support granules and pellets.
Pellets are large-sized particles (small granules, 1-5 millimeters in diameter) that can be separated by hand.
Some characteristics of plastic pellets are:
Pellets are made up of spherical particles that are brightly colored, colorless, or opaque.
They are created during a precise forming and mechanical handling operation.
For this reason, pellets have a better physical appearance in comparison to granules.
In the injection molding process that helps in the formation of plastic parts, pellets are also used.
The thermoplastic pellets are melted and pumped in the direction of the melt reservoir by a rotating screw.
Pellets are used in the manufacturing of plastic products such as food containers and drink bottles.
Despite these benefits, plastic pellets are unintentionally distributed in the environment during manufacturing and transporting phase.
As such, it can be harmful to the marine environment since toxic chemicals are released to it.
These materials have also been pointed out as one of the possible root causes of pollution at sea. Beaches all over the world have these plastics, and the same can be said about the seafloor of the oceans.
On the same note, several marine organisms accumulate these pellets in their stomachs.
Plastic can be used to create a wide array of products, and as such, they have replaced the leather, glass, stone, ceramics, etc. in several applications.
Plastics are employed in the creation of bottles made of polyethylene terephthalate (PET).
In the case of bottles, they can be recycled to form other products.
Similarly, packaging accounts for plastics&#; most significant use case around the world.
Asides its use to create bottles, the same can be said about:
Electrical devices are also made from plastic, and these devices have become an active part of our homes.
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Thus, wherever electrical devices are involved, plastic can be applied.
Plastics are incredibly light, which has also made them very beneficial in the transport industry.
They are also used to design cars, trains, boats, and airplanes in a bid to reduce their weight significantly.
Once this is in place, the weight of the vehicle is reduced, which can reduce fuel consumption.
Other common uses of plastic are:
Plastics consist of hydrogen, carbon, nitrogen, chlorine, and sulfer with additions of other raw materials including oil, coal and natural gas.
Granules are made up of small particles that change their identity and are employed in processing recycled plastics.
Pellets are large particles made up of spherical particles and creates plastic during injection molding process.
Plastic is used to create a wide array of products and are employed in packaging, electrical and electronic applications, and transportation, to name a few.
Plastics are employed in several industries and have become a part of our everyday lives.
However, a lot of process goes into the formation of different forms of plastic.
The differences between plastic pellets, granules, and other raw polymeric material show how they uniquely different from each other.
They are all forms of plastic in its raw material form, and each is best suited for the design that is to be achieved.
Its also worthy to note that addictives can be added to plastic in a bid to improve its chemical characteristics.
What are the advantages of plastic granulates ?
Plastic granulates have several advantages, including their light weight, corrosion resistance and low production cost. They are also easy to mold and can be used in a variety of applications, such as manufacturing automotive parts, packaging and children&#;s toys.
Plastic granulates have better uniformity and greater dosing accuracy than other forms of raw materials. This improves the quality and reproducibility of finished products.
The homogenization process
Homogenization is a necessary process for the reuse of material. Indeed, recycled plastics often come from different sources and can have different properties in terms of density, viscosity, color, strength, etc. These differences can affect the quality of the granulates produced if the plastics are not properly mixed before the extrusion phase.
The homogenization process can be carried out in different ways:manual or mechanical mixing, in which the recycled plastics are agitated or stirred to ensure homogeneous mixing.
Homogenization is a key step to produce high quality pellets from recycled plastics. It guarantees a uniform composition and constant quality of the granules produced.
The stages of plastic regeneration
Plastic regeneration, also called extrusion or granulation, is a recycling process that involves cleaning, melting and re-molding waste plastic into new raw materials. This recycling process recovers plastic and produces high-end recycled plastic granules.
The plastic regeneration process can be carried out in factories specializing in plastic recycling. This step is possible thanks to equipment such as crushers, extruders and granulators to transform plastic waste into quality granules.
The stages of regeneration:
Preparation of raw materials: Raw materials, which can be polymers, additives and pigments, are mixed in precise proportions.
Melting: Materials are fed into an extruder, which passes them through a high-temperature melting zone. This melting zone softens the polymers and blends them with the additives.
Extrusion: The molten mixture is then pushed through a die to form a continuous shape of molten plastic.
Cooling: The continuous form is then rapidly cooled using a water cooling system. This solidifies the plastic and makes it brittle.
Cutting: The solid, brittle form is then cut into small pieces called plastic pellets using a special machine called a granulator.
Storage: The plastic pellets are then stored in bags or containers for later use.
There are other methods to make plastic pellets, such as wet granulation, compression granulation, pressure granulation, etc. But the extrusion process is the most common and widely used in the plastic industry.
Packaging and storage of plastic granules
For the packaging and storage of plastic granules, it is recommended to use big bags, as well as metal or hard plastic containers. It is also important to store the pellets in a dry, cool place and away from direct sunlight to avoid any risk of moisture or degradation.
Industrial handling of plastic granules
Plastic granules are commonly found in the plastics industry, in extrusion and injection processes. The shape thus obtained is easy to store and handle in various industrial operations: filling, emptying, mixing, etc.
Certain plastic granules (Polyamide or PA, Acrylonitrile butadiene styrene or ABS, Polybutylene terephthalate or PBT, Polymethyl methacrylate or PMMA, etc.) are hygroscopic and must, therefore, undergo pre-drying before handling in order to avoid any related problems to humidity.
If you want to learn more, please visit our website Post-Consumer Plastic Reuse.