Densified Flakes
The Densified Flakes' manufacturing process stages are described in the following list.
  • Sorting: after a first rough grinding of the mixed plastics, non-compatible fractions (glass, wood, PET, bulky materials) are preliminarily removed; this operation is typically manually carried out.
  • First Cleaning: iron fractions are removed through magnets properly placed on the conveyor belt.
  • First Grinding: an industrial mill reduces the flakes size to 40 mm; in this way the following second cleaning stage is made more efficient.
  • Second Cleaning: non-ferrous metals are removed by an Eddy Current System selector.
  • Densification and Cooling through Short Extruder (Densifier): the screw movement generates friction in the material, which is heated up to the plastics melting point; the melted plastics operate like a binder for all the other materials (impurities and high melting plastics). The material thus homogenised and plasticized is forced through the die. A calender placed after the die provides to a reduction of the extruded material section.
  • Second Grinding: production of 0-8 mm densified flakes.
  • Sieving: sorting of Densified Flakes with different size (e.g. 3-7 mm or 0-3 mm) according to the granulometry required by the concrete mixing design
Extruded material at the exit of the die of the densifier