Too much maintenance.
 
 
Plastic recycling lines are running into a dirt, humid and dusty environment.
Having this in mind, maintenance is an issue, no questions about it.
Which is the best and cheapest way to handle this ?
There are no miracles here but something you can do to keep your line up and running.
First, I do hope you got your machines made out of stainless steel, at least tanks and whatever else runs with water, otherwise you are in trouble, period.
In a washing line the machine the need maintenance the most is the granulator.
Blades should be replaced every so often and it takes a while to do the job.
The very best way to make blades life to last longer is a pre-washing system.
This means scraps will get to the grinder with very little contamination left and blades life will be from three to ten times longer.
No kidding.
If you cannot afford a pre-washing system, at least, go with a wet granulator.
Let's go to what are called the "stupid things" nobody normally takes care of.
Unless you have a very good and dedicated maintenance man, bearings will be greased "when I remember" or something like this.
What about automatic greasing or, better, automatic oil lubrication ?
This way you can forget about bearings all together.
Costly ?  If you are down only one day because a 5 dollars bearing went out you will tell me how much this cost.
True, motors bearings need grease once every six month or so but, when it was the last time you did it ?  :-)
The same apply to chains; chains need grease but I saw very few machinery going around with greased chains.
Actually the best way to avoid problems with chains is to avoid having them installed in any machine but this is another story.
Anyway, take care of maintenance in the way your system doesn't stop in the middle of the night.
Preventive maintenance will make your line to run smooth and full capacity all the time.
Instead waiting till the screen of your centrifuge dryer wears out making big holes and therefore jamming pumps, pipes and so on, what about replacing the screen every so often, depending on the material ?
You know more or less how long it last; if you do, use it at about 80% of lasting time and replace it before it can bring bigger problems.
Only easy to say ?  No, even easier to do it.
 
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