process
THE TECHNOLOGY
1.MIXING:
In this stage, plastic waste is collected and sorted based on its type and composition. Different materials have distinct melting points and properties, so sorting ensures that the final product meets our desired characteristics. Items such as bottles, containers, packaging materials, or other discarded objects are included.
Technology used:
AUTO LOADING SYSTEM
Our Auto Loading System does more than just load materials. It's instrumental in the initial mixing phase, ensuring our production process is streamlined and efficient. Here's a glimpse into its operation:
Mixing Phase: The journey begins with introducing both plastic and biodegradable products into the system. This plastic could be household, commercial or agricultural waste plastic. The primary role of the Auto Loading System is to achieve a uniform mix of these materials, setting the stage for crafting our eco-friendly products.
Loading Phase: Once the materials are well-mixed, the system transitions to its secondary function, ensuring the precise loading of the blend into our advanced Heating and Melting Machine.
Key Benefits of the Auto Loading System:
Simplified Operations: The system's ability to mix and load using a single mechanism reduces the need for multiple machines, streamlining the process.
Consistent Quality: It guarantees a uniform blend of waste plastic and biodegradable products, ensuring the high quality of our end products.
Enhanced Efficiency: The integrated approach boosts our production speed, minimizes manual intervention, and elevates productivity.
Sustainability: The system's precision reduces material wastage, aligning with our eco-friendly objectives.
Safety First: Equipped with top-tier safety features, it ensures our team operates in a secure environment.
Future-Ready: The system's adaptability means we can effortlessly scale our operations as demand grows.
Incorporating the Auto Loading System into our manufacturing process is a testament to our dedication to innovation, sustainability, and superior product quality. It amplifies our capacity to deliver top-notch, environmentally-conscious products while reducing our ecological footprint.
2.MELTING
Once sorted, the plastic waste and other biodegradable material undergo a melting process. The waste is typically shredded or chopped into smaller pieces to increase the surface area, making it easier to melt. The shredded material is then fed into a melting machine, such as an extruder, which applies heat and pressure to melt it. The melting temperature varies based on the type of material being processed.
Technology used:
Heating-and-Melting System (HMS) at Mother Earth.: The Heart of Our Production
Our HMS is central to our polymer-composite waste production, merging heating, melting, and mixing processes into one efficient system. Here's a snapshot of its capabilities:
Operational Dynamics:
Pre-mix Engagement: A pre-mixed compound is introduced into the preheated HMS, with a rotating screw pushing it towards the output.
Heating Stages: The compound moves through distinct heating zones, ensuring even heat distribution without relying on HFCs.
Temperature Mastery:
Self-regulating Controllers: These ensure each heating zone operates within set temperature parameters, preventing issues like polymer burns.
Adaptive Mechanism: Allows for temperature adjustments to cater to different plastic types.
Screw Innovation:
Enhanced Extrusion: The screws are designed for optimal extrusion forces, ensuring steady compound feeding.
Blade Durability: Screw blades undergo tempering, increasing their longevity against abrasive materials.
Temperature & Capacity:
Wide Range: The system operates at an optimal temperature to turn it into a slush. These custom-designed machines provide us with a material that can withstand Canadian weather conditions for years.
Efficiency: A single HMS can serve two presses, boosting production rates.
Energy Conservation:
Thermal Insulation: Advanced insulation on heating elements minimizes heat loss, promoting energy savings.
Versatility & Output:
Polymer Flexibility: HMS can handle a range of polymers, even those with high contamination or moisture, without sacrificing efficiency.
In essence, the HMS epitomizes efficiency, precision, and environmental responsibility, reflecting Mother Earth's dedication to innovative waste recycling and environmental stewardship.
3.Molding
After melting, the material is ready for molding. Several molding techniques can be employed. We will use the Compression Molding method to shape the molten material into the desired form. Compression Molding is an ideal technique for producing larger and more complex items.
Technology used:
Press Molds:
Press molds are integral to our polymer composite waste production, shaping the final products with precision. Crafted from construction alloy steels, specifically 40 x 45 (US analogues – AISI, ASTM, ASME 5140 & 5145), they are chosen for their resilience and longevity. Post-construction, these molds undergo thermal hardening, ensuring durability for millions of molding cycles.
Cooling for Perfection:
Precision Cooling System: Each mold boasts a system of ducts connected to water circulation through nozzles. This ensures optimal cooling of the polymer-composite waste during dwelling time, crucial for achieving the desired strength and surface finish.
Diverse Product Portfolio:
Range of Products: Our molds are versatile, designed to produce a spectrum of sustainable products from recycled materials, including:
Sidewalk Slabs
Driveway Tiles
Interlock Tiles
Parking Truck Stops
Road Barriers
Parking Curbs
Mini Barriers
Tailored to Demand:
Customization: We can adapt molds based on specific product drawings or designs. While we currently focus on Paving Slabs and Blocks and Outdoor Parking Tiles, our collection can expand based on market needs.
In essence, our press molds are the foundation of our manufacturing, allowing us to transform polymer-composite waste into innovative, eco-friendly products.
CONTACT US
Do you have questions about any of our work, products or solutions? We are happy to provide additional information, offer personalised advice, and listen to any feedback or suggestions you may have.
