300, 400 & 500 - Rapid Granulator

Rapid300, 400 & 500SeriesDirect access to superior performanceInjection mouldingBlow mouldingExtrusion processes

The formula for successRapid’s “open-hearted” engineering concept is nowbuilt into each granulator model of its Rapid 300,400 and 500 Series. The big benefi t of being openheartedis that it boosts performance by providingdirect and easy access to the heart of a machine toachieve very rapid cleaning and maintenance timesfor fast production changeovers. Such extremelyshort pit stops maximize uptime and minimize laborcosts. The clear access to core machine parts alsoallows “visibly clean” inspection and approval, preventingcontamination at colour and materialchanges.The complete open-hearted family provides athroughput of up to 1200 kg/h (2600 lbs/h).Once again, Rapid confi rms that it leads thefi eld with innovative design and makes no compromisesin providing you with high-performance granulators.Tailored to yourneedsIn addition to different widths that suityour granulation needs, the granulatorscan be upgraded to PowerTech performancesuitable for the toughest technicalplastics containing glass fiber andother abrasive fillers.PowerTech is a granulator equippedwith reinforced parts to take on thehardest granulation jobs.The combination of open-heartedconcept, amazing application flexibilityand the production of even betterquality regrind across the completefamily adds up to the formula for successin the highest-performance granulation.Easy cleaning andmaintenanceThe outstanding ergonomic design of all modelsallows you to rapidly reach the heart of themachine and gain access to appropriate partsto achieve fast cleaning, maintenance andchange over times. “Visibly clean” inspectionand approval is a further benefi t.Less energyThe true double scissors action reduces theforce needed to slice through plastic waste.Therefore a smaller motor can be used to significantly reduce energy consumption.Highest-quality regrindThe Rapid cutting technique, comprising cleandouble scissors-cutting action and constant cuttingcircle, produces granules of a uniform sizewith minimal dust content even with the toughestmaterials.Improved safety interlockThe new design of the safety interlock system allowsquicker opening of a granulator. It is alsosafer because its speed-related sensor ensuresthat the rotor is standing still before the granulatorcan be opened.

Versatile hopperA great number of hopper confi gurations isavailable as standard options depending onapplication and infeed method. Most of thestandard hoppers are of modular designand can be easily re-confi gured later ifneeded.Built-in futureAs the cutterhouse of most models can beconfi gured for injection moulding, blowmoulding or extrusion applications, a granulatoris readily transformed on site for an alternativeapplication after it has been installed.Power-assistedopening/closingRapid opening and closing of the infeedhopper is assured by gas springs or a motor-drivenjack.

Injection mouldingInjection moulding is often characterized by a widevariety of small, medium-size and large products, includingtechnical and/or fi lled materials, and by frequentchanges of end-product type and colour. Thisis where a Rapid 300, 400 or 500 Series granulatorshows its superiority as an essential part of a productionprocess. Regrind derived from reject products,sprues and runners is of a quality required fordirect recycling to the moulding machine.The Rapid open-hearted family is ideal for highvolumecentral or beside-the-press granulation of injectionmoulding rejects like sprues, crates for bottleddrinks, dashboards, bumpers, hubcaps, carlenses, ski boots and a whole lot more.Rapid granulators confi gured for injection-mouldingapplications help to maintain a stable production process.Cutterhouse configuration ■ ■ ■Rapid granulators offer a choice of supertangential or tangentialinfeeds for bulky and smaller product.Supertangential for bulk wasteThe two fi xed knives as shown (red) are typicallyused. A third fi xed knife (green) is optional with theRapid 500 Series for higher capacities.Tangential for thicker walled mouldingsThe two fi xed knives as shown (red) are typically used.One, or two (500 Series), additional fi xed knives (green/yellow) – are optional to increase throughput.

Visibly clean! ■ ■ ■Core components are quickly removed to allow fast cleaning and maintenance.After cleaning, you can visibly ensure that all regrind is removedto prevent contamination when making colour or material changes.• Granulator, front feedhopper• Blower, stand alone• Cyclone, regrind separation• Dust fi lter, separating dustfrom airA band conveyor with optional sound trap results in quieter granulation.

Blow mouldingBlow-moulding waste such as diverse plastic bottles,larger containers – including large water containers,jerry cans, etc. – and big barrels are typical in this applicationsegment. These are quickly turned into highqualityregrind that can be recycled directly to themoulding machine by the Rapid open-hearted family.A combination of double scissor-cut action andthe super-tangential cutterhouse optimizes gripping ofbulky products and minimizes the fl y-back of material.The result is smooth continuous granulation. There isno need for precutting bulky items, and the granulatorsare compact enough to be fed at chest height.All these benefi ts emphasize the importance of integratinga Rapid granulator for direct recycling as animportant unit of your production line.Configuration of cutterhouse ■ ■ ■The supertangential infeed gives Rapid granulators the huge grip neededfor bulky items and preventing parts from “dancing” on the rotor.Supertangential for bulk wasteThe two fi xed knives as shown (red) are typicallyused. A third fi xed knife (green) is optional in theRapid 500 Series for higher capacities.Tangential for thicker walled materialThe two fi xed knives as shown (red) are standardconfi guration. A third fi xed knife (yellow) is optionalfor higher capacities. The Rapid 500 Series caneven be set up with a fourth (green).

Directly to core components ■ ■ ■A motor-driven jack (optional) raises and lowers the infeed hopper. Nowwith direct access to all parts, including fi xed and rotating knives, a Rapidopen-hearted granulator is ready for cleaning, knife changing or servicing.• Granulator, band conveyor• Cyclone, regrind separationwith dust removal• Dust fi lter, separatingdust fromair• Big-bagstandTypical granulator confi guration used for blow-moulding applications.

Extrusion processesTypical waste resulting from extrusion processes consistsof pipes, profi les, sheets and fi lms. These put specialdemands on granulators, particularly different hopperconfi gurations. For example, side infeed is preferredto guide in longer parts like pipes and profi les,roll feeding systems are best for different kinds of fi lmand packaging, and rear feeding suits sheets.Rapid granulators of the open-hearted family morethan meet the challenges presented by extrusion wasteand form an important part of an integrated productionline. The high-quality regrind produced can be recycleddirectly back to the extrusion process without negativelyaffecting the product quality.Roll feed unitSheet infeedPipesand profilesConveyoror manualinfeedIn-line granulator for fi lm granulation. Optional, pneumatic loop controlarm for synchronizing fi lm feeding speed with the line speed.Cutterhouse configuration ■ ■ ■Different types of infeed and a pre-cutting knife make Rapidgranulators ideal for extrusion applications.Tangential for extruded materialsThe two fi xed knives as shown (red) are typicallyused for fi lm or thin plates and profi les. One additionalfi xed knife (yellow) – plus an extra knife for theRapid 500 Series (green) – are optional to increasethroughput.Pre-cut for thicker walled materialsOnly for 500 Series. Recommended for heavy-dutygranulation of sheets, pipes, profi les and thickwalledmaterials etc. A third and/or fourth fi xed knife(green/yellow) is optional for higher capacities.

No tools required ■ ■ ■The green light of a Rapid open-hearted granulator let’s you knowwhen it’s safe to open the machine. No tools are required to gain accessto the cutterhouse and associated components.• Granulator,front feed,side feed,roll feed• Blower, stand alone• Cyclone, regrind separationwith dust removal• Dust fi lter, separating dustfrom outgoing airInline granulation of edge trimmings with a dedicated roll-feed unit.

The most trusted name inDecades of providing the plastics industry with superior granulatortechnology, robust machines that translate into optimal lifecycleeconomy, and excellent regrind quality have made Rapidthe most trusted name in granulators. By keeping and eye on thefuture and listening to what our customers say, we are alwaysready to respond to their present and future needs.Completely integrated production lines and further featuresof the Rapid 300, 400 and 500 Series are presented here alongwith how we support you after granulator installation.Your most profitable investment ■ ■ ■Investing in a high-quality granulator frequently gives a very quick paybacktime and return-on-investment. It’s also important to realize that thegranulator purchase price is often less than 20% of the total lifecyclecosts, whereas running costs represent over 80% of the total costs as presentedin the diagram below.To show exactly how you can benefit, Rapid has developed a cost-calculationfunction on our website www.rapidgranulator.se. Pay it a visitand make your own calculation.The toughestfor the toughest ■ ■ ■Reinforced parts are built into Power-Tech models to enable them to makelight work of granulatingabrasive technical and/orfilled materials and prolonggranulator lifetimefor these tough applications.Jig for optimumknife clearance ■ ■ ■Optional devices are available for resharpeningand presetting of both rotatingand fi xed knives outside the machineto increase uptime and provide optimalknife clearance.3-blade or 5-bladerotor ■ ■ ■605040302018 %21%49 %Bar chart showingthe total runningcosts addingup to more than80 % based ontypical productiondata.The 3-blade rotor works best for bulkyblow-moulded and other voluminouswaste, whereas the 5-blade rotor is idealfor higher throughput appli cations involvingfilm and smaller parts. Either 2,3 or 4 fi xed knives can be specified dependingon the model.100Machineinvestment10 %Energycost1%Service cost(labor)SparepartsCleaningcosts5 blade rotoravailable on400- and 500-Series.

granulatorsComplete systemsolutions ■ ■ ■As part of a totally integrated productionline, a Rapid granulator solution can befully equipped with all types of infeedincluding a conveyor, metal detection andseparation, and dust separation and filterunits.Committed customersupport ■ ■ ■Rapid is represented by a worldwidenetwork of sales companies and qualifieddistributors who meet certifiedstandards of training, granulator performance,and customer care. Wemake every effort to provide theentire backup you need to get the bestout of our granulators.Instant spare partservice ■ ■ ■As we are well aware that satisfiedcustomers are loyal customers,we make sure that Rapidgranulators are kept up and runningfor the maximum time possible.To promote this, we havean instant spare parts deliveryservice aimed at getting parts toyou quickly in the time frameyou choose.Cutterhouse widths, mm300 450 600 900 1200Motorsizes, kWRapid 300 ■ ■ ■ 5.5 – 15Rapid 400 ■ ■ ■ ■ 11– 37Rapid 500 ■ ■ ■ 18.5 – 55

The most trustedname in granulatorswww.rapidgranulator.sePresent worldwide:info@rapidgranulator.cominfo@rapidgranulator.deinfo@rapidgranulator.itinfo@rapidgranulator.cnrapidsea@pacific.net.sg(USA)(Germany)(Italy)(China)(Singapore)Representative:Rapid is the world leader in granulation.We develop, manufacture and market individualgranulators and completely integratedrecycling solutions for the plasticsindustry. With an extensive granulatorrange, from table-top units to giant machines,we can satisfy virtually all yourgranulation needs.Our products are regarded as themost ruggedly built, most dependable andof the highest quality available on themarket. And our excellent spare parts servicehelps to keep them in top condition.We are dedicated to partnering withyou. With over 50 years of experience, aglobal presence, and more than 60,000units installed worldwide, we offer you ourexpertise, our people, and our resources.Rapid strives to exceed your expectationsin recycling plastic waste.IBBRO545-GB-01 © Rapid Granulator AB, 2006, Subject to technicalmodifi cations without prior notice.