Plastic Size Reduction Systems: How Manufacturers Recover Value From Plastic Waste
Plastic waste is part of everyday manufacturing.
Injection moulders produce sprues and runners. Extrusion lines generate edge trim and offcuts. Packaging manufacturers handle purgings, rejected product, and start-up waste.
Without the right process, valuable material becomes expensive waste.
Common problems include:- high disposal costs
- production areas filling with scrap
- inconsistent regrind size
- labour spent handling bulky plastic waste
- lost opportunity to reuse material internally
This is where plastic size reduction systems become critical.
Machines from ZERMA, supplied in Australia by Telford Smith, help manufacturers and recyclers shred, granulate, and recover plastic material for reuse or downstream recycling.
This guide explains how size reduction systems work, how to choose the right setup, and how manufacturers improve efficiency by recovering value from plastic waste.
Quick Answer: What Is a Plastic Size Reduction System?
A plastic size reduction system uses shredders and granulators to reduce plastic waste into smaller, reusable material.
Most systems are used for:
- reclaiming in-house production scrap
- reducing bulky plastic waste
- preparing plastics for washing or recycling
- processing PET bottles, drums, film, pipes, and containers
Complete systems from ZERMA can include:
These systems help businesses improve material handling, reduce waste costs, and recover reusable plastic material.
The Real Problem With Plastic Production Waste
Most manufacturers already know plastic scrap has value.
The challenge is handling it efficiently.
Plastic waste often creates operational problems before it becomes a recycling problem.
Common examples include:
- sprues accumulating beside machines
- bulky drums taking up floor space
- film scrap difficult to handle
- purgings requiring manual disposal
- inconsistent material flow back into production
For many businesses, the issue is not “whether to recycle.”
It’s how to process waste efficiently enough for recycling or reuse to make commercial sense.
How Plastic Size Reduction Systems Work
A size reduction system breaks larger plastic material into smaller, controlled particle sizes.
The workflow typically looks like this:
- Plastic scrap is collected from production or waste streams
- Material enters a shredder or granulator
- The material is reduced into smaller pieces
- Regrind is transferred for reuse, washing, or further processing
Some systems process material beside the press, while others form part of central recycling systems.
Complete solutions from ZERMA are often integrated with conveying, feeding, dust extraction, and wash systems supplied by Telford Smith.
Shredders vs Granulators: What’s the Difference?
This is one of the most common questions manufacturers ask.
Plastic Shredders
Shredders are designed for larger or bulkier material.
Typical applications include:
- drums and containers
- purgings
- pipes and profiles
- thick-walled plastics
- post-consumer waste
Shredders operate at lower speed with higher torque, allowing them to process difficult materials efficiently.
Plastic Granulators
Granulators reduce plastic into smaller, more uniform particles.
Typical applications include:
- sprues and runners
- film and sheet
- injection moulding scrap
- edge trim
- lightweight production waste
Granulators are commonly used for in-house material recovery and regrind reuse.
Which Industries Use Plastic Size Reduction Systems?
Injection Moulding
Manufacturers reuse sprues, runners, and rejected parts to reduce virgin material consumption.
Extrusion & Pipe Manufacturing
Large offcuts and profiles are reduced and reprocessed.
PET & Bottle Recycling
PET recycling systems prepare bottles for washing and downstream processing.
Film & Sheet Processing
Edge trim and lightweight scrap are recovered directly from production.
Plastics Recycling Facilities
Shredders and granulators prepare post-consumer plastics for washing and separation systems.
Types of Zerma Equipment
Slow-Speed Granulators
Typically installed beside processing machinery.
Suitable for:
- sprues
- runners
- small-volume in-house scrap
Central Granulators
Used for higher throughput processing.
Suitable for:
- film
- sheet
- larger production scrap volumes
Single Shaft Shredders
Designed for bulky plastics and difficult materials.
Suitable for:
- drums
- containers
- purgings
- thick-walled plastics
Heavy-Duty Recycling Systems
Used in larger recycling facilities and integrated wash lines.
These systems often include:
- conveyors
- metal separation
- wash systems
- pneumatic transfer
- dust extraction
How to Choose the Right Plastic Size Reduction System
Start with four key questions.
What material are you processing?
Different plastics behave differently.
Examples include:
- rigid plastics
- film
- PET
- purgings
- thick-walled containers
Material type heavily influences machine selection.
What size is the input material?
Small sprues require very different equipment compared to drums or pipes.
What throughput do you require?
Low-volume beside-the-press recycling differs significantly from continuous central recycling systems.
Will the material be reused internally or sent for recycling?
This determines required output size and downstream processing requirements.
Businesses across Australia work with Telford Smith to design integrated recycling and size reduction systems using ZERMA equipment.
Complete Integrated Systems
Many businesses no longer buy standalone machines.
Instead, they implement integrated systems that improve material flow throughout the facility.
These systems may include:
- shredders
- granulators
- conveyors
- wash systems
- feeding systems
- dust extraction
- pneumatic transfer
This integrated approach improves:
- operational efficiency
- material handling
- automation
- production workflow
This is an area where the local project engineering and integration support provided by Telford Smith becomes especially valuable.
Why Manufacturers Recycle Plastic Scrap In-House
For many manufacturers, plastic scrap is no longer treated as waste.
It is treated as recoverable material.
Benefits include:Reduced material costs
Reusable regrind can reduce virgin resin consumption.Improved workflow
Centralised scrap handling reduces clutter around machinery.
Lower disposal costs
Less waste sent off-site.
Better sustainability outcomes
Material recovery supports recycling and circular manufacturing goals.
Are Plastic Size Reduction Systems Worth It?
In many cases, yes.
Especially for manufacturers generating consistent production scrap.
The return often comes from:
- reduced waste handling
- material reuse
- improved process efficiency
- reduced disposal costs
For larger operations, integrated systems may also improve automation and production flow.
For more detail, read: How Manufacturers Reuse Plastic Scrap In-House
Frequently Asked Questions
What is a plastic granulator?
A granulator reduces plastic into smaller, uniform particles suitable for reuse or recycling.
What is a plastic shredder?
A shredder breaks larger plastic material into smaller pieces before further processing.
What materials can Zerma systems process?
Systems can process:
- PET bottles
- drums
- pipes
- film
- purgings
- rigid plastics
- production scrap
Can manufacturers reuse plastic regrind?
Yes, many manufacturers reintroduce regrind into production depending on material and quality requirements.
What is the difference between slow-speed and central granulators?
Slow-speed granulators are often used beside processing machines, while central granulators handle higher volumes in larger systems.
Where can businesses buy plastic shredders and granulators in Australia?
Businesses source ZERMA equipment through Telford Smith, which provides supply, project engineering, integration, and local support.
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