Capture before contamination
Collect compatible sprues and rejected parts at the machine or through a defined central stream.
Control: resin identity, color and foreign material
Granulating and Recycling System
Granulating and Recycling System
Topstar’s Granulator series includes low-speed soundproof, middle-speed, powerful, and powerful soundproof granulator machines. Mainly used for crushing nozzle materials at the injection molding machine side. It is suitable for recycling all kinds of hard and brittle plastic nozzles. It is especially suitable for crushing and recycling hard nozzle materials such as PC, nylon, and ABS. It adopts a screen-less design, and the crushed particles are even, and the dust content is low. Very rarely, the feed hopper adopts a double-layer sound-insulation design; the inner layer is made of stainless steel, and it has a visual material window.
Products
Granulating and Recycling System
Products
Granulating and Recycling System
- High Performance
- Reliability
- Durability
- Universally Applicable
Powerful Sound-Proof Granulator – TGQ
The TGQ series powerful sound-proof granulator features a double-layered hopper design to minimize noise while delivering exceptional safety, environmental performance, energy efficiency, and durability. It boasts a well-engineered structure and user-friendly operation, with a hinged design that facilitates easy maintenance and servicing. The fully enclosed silent design ensures noise levels remain below 85 dB at a distance of one meter, fostering a favorable working environment. 1. Efficient Internal Cooling — Dissipates motor heat and extends equipment service life. 2. Flexible Recycling — Supports both centralized and machine-side crushing. 3. Easy Maintenance — Hinged structure provides quick access for cleaning and servicing. 4. Multiple Safety Protections — Includes motor overload protection, emergency stop, and phase sequence control. 5. Stainless Steel Storage Bin — Easy to clean, with an optional suction-port design.
Powerful Granulator – TGP
The TGP series powerful granulator is specifically designed for the size reduction and recycling of various types of hard plastics. It features an optimized rotor design available in three configurations: flat blade, claw blade, and straight blade. The claw-style blade design effectively distributes cutting forces and enhances the shearing power of individual blades; it is particularly well-suited for processing thick-walled products, large plastic scrap, and hard material lumps, offering increased cutting efficiency while effectively minimizing blade wear. 1. Powerful Crushing Performance — Ideal for hard plastics, thick parts, and large plastic scraps. 2. 3 Blade Options — Flat, claw, and straight blades for different crushing requirements. 3. High-Shear Claw Blade — Distributes cutting force for stronger crushing and reduced blade wear. 4. Durable Alloy Blades — Provides excellent wear resistance and long service life. 5. Flexible Screen Sizes — Standard 8 mm / 10 mm mesh with custom sizes available. 6. Contamination-Free Option — Stainless steel hopper and screen available for transparent and white materials.
Middle Speed Granulator – TGM
The medium speed granulator is suitable for crushing and recycling sprue materials. It is specifically designed to crush both more rigid engineering plastics and softer general-purpose plastics. The moderate rotation speed minimizes dust and noise and reduces tool wear. Both the moving and stationary blades are made of Cr12MOV, ensuring a long service life. 1. Versatile Plastic Recycling — Suitable for engineering and general-purpose plastics. 2. Low-Maintenance Operation — Simple operation with reliable crushing performance. 3. Multiple Safety Protections — Enhance operator safety and equipment reliability. 4. Application Scenarios — Suitable for granulating soft sprue/runner scrap such as PE and PP, as well as tough sprue/runner scrap such as PC and ABS.
Low Speed Sound-Proof Granulator – TGL
The TGL series Low Speed Sound-Proof Granulators are designed for the in-line grinding and recycling of defective parts and rejects made from various hard, brittle plastics. It is particularly well-suited for processing hard sprue and runner scrap from materials such as PC, Nylon, and ABS. This screenless granulator features durable cutters made from high-quality SKD-11 steel (optional) and supports "30-second immediate recycling," minimizing material degradation from moisture absorption or oxidation. Operating at a low speed of 20–28 rpm, the unit is energy-efficient and eliminates noise pollution, making it ideal for recycling hard scrap materials like PC, PBT, ABS, and Nylon. 1. Screenless Design — Simplifies structure and improves recycling efficiency. 2. 20–28 RPM Low-Speed Operation — Reduces noise and energy consumption. 3. 30-Second Immediate Recycling — Minimizes moisture and oxidation damage to sprue materials. 4. Lubrication-Free Gear Drive — Saves maintenance and installation space.
TGL Low Speed20–28 RPM
TGM Middle Speed140–150 RPM
TGL Return CycleAbout 30 Seconds
TGQ Sound-Proof Design<85 dB at 1 m
Published figures apply to the stated Topstar series. Final performance varies with model, resin, scrap geometry and operating conditions.
The Recovery Control Chain
Regrind quality is created across the entire return path.
A plastic granulator reduces particle size, but successful recycling also depends on clean collection, controlled temperature, material separation and accurate reintroduction.
Cut without excessive heat or dust
Match rotational speed, cutter geometry and chamber capacity to the form and toughness of the scrap.
Control: speed, blade type, feed rate and cooling
Manage particle size
Screenless and screened systems create different particle paths; neither is universally correct.
Control: granule distribution, fines and oversized pieces
Return at an approved ratio
Convey and meter regrind according to process approval instead of returning an uncontrolled quantity.
Control: storage, conveying, dosing and recipe traceability
Four Granulator Architectures
Select by scrap behavior, recovery location and required cutting force.
The four Topstar granulator platforms address different combinations of hard or soft plastics, machine-side recovery, large scrap, throughput, dust control and workshop noise.
Screenless / Machine-Side
TGL Low-Speed Sound-Proof Granulator
For hard, brittle sprues such as PC, PBT, ABS and nylon when low speed, low dust and immediate recovery matter.
20–28 RPM · Screenless
View TGL platform →
Balanced Speed / Mixed Plastics
TGM Middle-Speed Granulator
For soft general-purpose plastics and tougher engineering plastic sprues where moderate speed limits dust, heat and cutter wear.
140–150 RPM · Cr12MOV Blades
View TGM platform →
High Cutting Force / Large Scrap
TGP Powerful Granulator
For thick products, large hard-plastic scrap and material blocks, with flat, claw or straight blade configurations.
3 Blade Options · Screened Output
View TGP platform →
Enclosed / Central or Machine-Side
TGQ Powerful Sound-Proof Granulator
For higher-capacity crushing where enclosure, dust containment, motor cooling and workshop noise control are priorities.
<85 dB at 1 m · Enclosed
View TGQ platform →
Granulator Selection Matrix
Start with the scrap—not the horsepower.
Motor power and chamber size follow the application. First define material toughness, scrap dimensions, recovery location, required particle size and the permitted dust and noise level.
| Platform | Typical Scrap | Cutting Strategy | Primary Advantage | Typical Position |
|---|---|---|---|---|
| TGL Low Speed | Hard, brittle sprues and small rejected parts | 20–28 RPM, screenless, gear drive | Low dust, low noise and immediate return | Beside the press |
| TGM Middle Speed | Soft general plastics and rigid engineering sprues | 140–150 RPM with replaceable screen | Balanced cutting, dust and blade wear | Machine-side recycling |
| TGP Powerful | Thick products, large scrap and hard blocks | Flat, claw or straight blade with screen | Higher shearing force and flexible blade choice | Batch or central area |
| TGQ Sound-Proof | Rejected parts requiring enclosed high-capacity crushing | Powerful crushing in a fully enclosed cabinet | Noise reduction, dust containment and cooling | Central or beside press |
Final model selection also requires maximum scrap dimensions, hourly mass, bulk density, desired granule size, power supply and installation constraints.
Inside the Cutting System
Uniform regrind depends on more than blade sharpness.
The chamber, rotor, stationary knives, screen or screenless path, motor protection and cleanout access must work as one cutting system.
Cut → Classify → DischargeEach stage affects dust, particle distribution and cleaning time.
Blade geometry matches scrap geometry
Flat, claw and straight blades distribute cutting force differently. Thick sections and hard blocks need a different attack than small brittle sprues.
Rotational speed controls heat, noise and fines
Lower speed can protect brittle engineering scrap from excessive powder; moderate speed broadens material flexibility; powerful systems address larger loads.
Screen strategy controls the discharge path
Screenless TGL models simplify immediate machine-side recycling. TGM, TGP and TGQ screen options help define granule size for other applications.
Clean material-contact parts protect appearance
Transparent and white materials may require stainless steel hoppers, screens or storage bins to reduce contamination from coatings and residual material.
Interlocks and overload protection manage risk
Door and hopper protection, emergency stopping, motor overload control and correct phase sequence support safer maintenance and operation.
Recovery Architecture
Return material beside the press—or consolidate it centrally.
The correct architecture depends on how quickly material should return, how many machines share the stream and how strictly the plant must separate resins and colors.
Machine-Side Immediate Recycling
Keep a known material stream close to one injection molding machine and shorten the time between sprue generation and return.
Molded SprueTGL / TGMLoader / MixerSame Machine
Best when material identity is stable and rapid return is approved.
Centralized Scrap Processing
Consolidate defined scrap streams for higher-capacity crushing, controlled storage and managed redistribution.
Sorted ScrapTGP / TGQClean StorageApproved Users
Best when throughput, enclosure and multi-machine coordination matter.
Regrind Quality Gate
Do not return regrind until five conditions are known.
Granulating does not restore damaged polymer. Burned, contaminated, mixed or thermally degraded scrap requires process approval before reuse.
Material Identity
Confirm resin grade, additives, color and whether mixed streams are prohibited.
Cleanliness
Exclude metal, oil, paper, dust and foreign polymers before the cutting chamber.
Granule Distribution
Check fines, oversized pieces and whether conveying remains stable.
Moisture and Heat History
Dry hygroscopic regrind when required and reject burned or heavily degraded material.
Approved Return Ratio
Use proportional valves, screw dosers or gravimetric blending when the recipe requires controlled regrind content.
Granulating & Recycling FAQ
Practical answers for selecting and integrating a plastic granulator.
Each answer remains in the page HTML and can be read by users, search engines and generative search systems.
What does a plastic granulator do in injection molding?
A plastic granulator cuts compatible sprues, runners, rejected parts or production scrap into smaller particles. The regrind may then be stored, conveyed and returned at an approved ratio, provided material identity and quality remain controlled.
How do low-speed and middle-speed granulators differ?
Topstar TGL units operate at 20–28 RPM and use a screenless path for low-dust machine-side recovery of hard, brittle sprues. TGM units operate around 140–150 RPM and accommodate both softer general-purpose plastics and tougher engineering plastic sprues.
When is a powerful granulator required?
A powerful granulator is appropriate when scrap includes thick-walled products, large hard-plastic pieces or blocks that require higher shearing force and a larger cutting chamber. Maximum dimensions and hourly mass must be checked before model selection.
What is the purpose of a sound-proof granulator?
A sound-proof granulator encloses the cutting system to reduce workshop noise and contain dust. Topstar TGQ models also use internal heat dispersion, safety protection and cleanable stainless storage options for enclosed operation.
Is screenless granulation always better?
No. A screenless design can simplify low-speed immediate recycling and reduce powder for suitable hard, brittle sprues. Screened systems are useful when the application needs a defined discharge size or processes larger and more varied scrap.
Can all granulated plastic be returned to production?
No. Reuse depends on resin compatibility, contamination, moisture, thermal history, product requirements and the approved regrind percentage. Mixed, burned or contaminated scrap should not be returned without process and quality approval.
Define the Recovery Duty
Send the scrap sample, dimensions and hourly load before choosing a granulator.
Topstar can evaluate material type, maximum scrap size, desired granule size, recovery location, noise limits, conveying method and regrind return ratio as one auxiliary-equipment system.
Required Input
Resin · Scrap photo · Maximum dimensions · kg/h · Particle target · Noise requirement · Return ratio
Training for Installation and Operation Correctly
Topstar Service
We have a comprehensive after-sales training system. To address potential issues and ensure optimal operation, we provide you with the necessary training resources for installing and operating the packaging machine.
- Instructions for Use – Installation Steps and Operating Precautions
- Video demonstration of installation and debugging
- On-site training – additional service fee required
Technical Support
Whether your business is located in Europe, North America, or the Middle East, we provide global services, and our experts are on call to provide technical support services through video calls or on-site assistance. Services include:
- First installation and debugging of equipment
- Daily debugging and maintenance
- Emergency fault assistance
- Equipment optimization services
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