Granulator Maintenance Tips to Boost Efficiency and Prevent Downtime

As a manufacturer or plastic recycling professional, you’re likely looking for ways to reduce waste and reuse materials, which is why you have a plastic granulator. This piece of equipment is essential for recycling and repurposing plastics by breaking them into smaller pieces. But without proper granulator maintenance, you risk increased downtime, lower regrind quality, and a shorter equipment lifespan.

Why Consistent Granulator Maintenance Drives Better Performance

Replacing an industrial-grade plastics granulator can cost up to $500,000. Routine maintenance is essential for protecting your investment and keeping your granulator performing like new for as long as possible. Skipping maintenance impacts multiple performance areas. 

Throughput

The throughput refers to the processing rate of your granulator. A large new granulator can process thousands of pounds of plastic per hour. If your granulator is functioning well, plastics should move through it with ease and make little noise. 

Dull blades and worn-out rotors increase your machine’s processing time, as it has to work harder to grind plastics.

Power Use

Without proper maintenance, your granulator will require more power to grind materials. The machine generates more friction and heat as it works, while debris from regular use can also clog the motor. Altogether, these issues can add strain and increase power consumption.

Reduced Quality

A new granulator cuts plastics into pellets that are uniform in size and composition. Skipping granulator maintenance impacts your machine’s consistency and impacts regrind quality. As dust, oil, and debris collect on the blades, you end up with inconsistent sizes, contaminated pellets, and high levels of dust and fine particles. 

Regular maintenance helps you catch potential issues before they escalate and bring your operations to a halt. It also keeps your machine running smoothly and maintains its intended throughput.

Daily Checks To Keep Granulators Running Smoothly

Plastics granulators process abrasive materials. If you’re in the recycling industry, the plastics you’re processing may also be dirty. The process also involves high-speed rotation, meaning your blades are constantly cutting at high force.

Daily checks will help you keep your machines running smoothly between regular maintenance appointments. 

Inspect the Machine for Damage

At the end of the workday, check your granulator for signs of damage or excessive wear. Carefully inspect your output for quality and consistency. While the machine is off, check the feed hopper for blockages or residue from sticky materials.

Check your blades to make sure they’re not dulling or chipped. Sharpening blades at the early stages of wear extends blade life.

Listen to Your Machine

A well-maintained granulator should be relatively quiet. If your machine is making noise or vibrating excessively, check your blades and all machine components. Noise could mean your machine is smashing plastic rather than making uniform cuts.

Tighten any loose gears, belts, or other parts. Then check your blades for signs of dulling. Look for rounded edges and small chips or breaks. 

Service Your Machine

Your plastic granulator machine needs regular lubrication to run properly. As with other engines, skipping oil changes increases friction and eventually causes the engine to stop. Consult your owner's manual and follow a regular oiling and lubrication schedule.

Clean Your Machine

Finally, remove all dust and debris from your machine. Daily granulator maintenance services also include emptying the catch bin and wiping down your machine with a lint-free cloth or industrial vacuum.

While you’re inspecting your blades for signs of dulling or damage, clean off any dust or debris and then replace them in your machine. 

Scheduled Maintenance That Prevents Downtime

High-quality machinery keeps you in business. Each year, businesses in manufacturing, plastics recycling, and other industries lose money to unscheduled downtime. One global survey estimates that unexpected downtime costs companies about $125,000 per hour.

Regular granulator maintenance keeps your machines up and running, reducing downtime. Even if you follow your daily checklist, you still need weekly and monthly maintenance. 

Weekly Maintenance Tasks

Add these tasks to your monthly checklist: 

• Inspect blade thickness and look for cracks, wear, and tear. 
• Check screens for cracks, clogs, and deformities. Clean them if needed. 
• Check drive belts for cracking or fraying and test the tension.
• Tighten bolts and other fasteners. 

Monthly Maintenance Tasks

Once a month, add these tasks to your to-do list: 

• Thoroughly clean the screen, catch bin, cutting chamber, and collection area.
• Check blade gaps and sharpen if needed. Regularly sharpening and replacing plastic granulator blades gives you consistent throughput. It also reduces wear and tear since dull blades put more strain on mechanical parts. 
• Check and test all machine lubricants based on your owner’s manual recommendations. 
• Inspect electrical connections for loose wires and other potential issues. 
• Test the machine’s safety features. 

Biannually or Annually

As the blades wear or show signs of dulling, sharpen or replace them and reset and balance them. Replace bearings and other worn-out fasteners. Replace worn belts or motors and damaged or worn screens.

Troubleshooting Performance Drops in Granulators

If you notice your throughput dwindling or your energy bills rising, use this guide to troubleshoot:

• Overheating: Cut back on operational run time, check ventilation, and clean or replace your air filter.
• Inconsistent Granule Size: Clear feedstock jams, change particle screens, and check your blades to see if they're blunted or dull. 
• Noise or Vibration: Balance your rotors, replace your bearings, tighten bolts, and check your blades for dulling. As blades wear out, your machine has to work harder, and this can cause excessive vibration.
• Material Jams: Check the machine for foreign objects, debris, metal, or other contaminants. 
• Lower Throughput: Sharpen or replace your blades. 

If you’re experiencing consistent issues, work with a qualified technician or blade manufacturer such as Hyde Industrial. We can inspect your blades and diagnose the issue quickly to get you up and running. 

How Hyde Helps Optimize Granulator Performance

Consistent granulator blade maintenance will help extend your plastics granulator’s useful life and maintain consistent product quality. With more than 150 years of experience in industrial blade manufacturing and maintenance, Hyde Industrial is your go-to for regular inspection and blade sharpening services. 

Don’t risk wasting time and money on unplanned downtime. Contact us today to set up routine maintenance services and enhance your plastics processing efficiency.