Even though the sorting process seems like magic because it happens so quickly, the technology behind it is actually quite simple.  In fact, you have probably been exposed to the same magic we use to sort plastic resin when you were a kid.

Do you remember the spy decoder that used to come in Cracker Jack boxes?  This was a red tinted gel that when you put it over a random looking pattern of colors would let you see a hidden message.  The way it worked was by filtering out all of a certain color that was ‘blocking’ your ability to read the message.  Once all the red was blocked, the message was clear.

Funny how much we learn as a child just by playing and having fun.  Sticking with the lessons we learned in kindergarten, we still use the same ‘trick’ to sort plastic resin.

We make everything we want to keep (all your good resin) ‘disappear’ and all the junk you want removed to really stand out.  In this way, the sensors on our equipment are tricked into seeing what we want them to see.  Just like you were tricked as child into thinking that random image was just a bunch of different colors.  That is unless you had the secret decoder.

We make the defects more visible using different colored lighting and filters.

Perhaps that is a good way to think about what we do for our clients.  We use the same Hollywood trick of employing different colored lights and filters to achieve our goal.  The same goal the director of every great movie is trying to achieve.  To finish the story with everything getting sorted out in the end.

Check it out… http://www.ptonline.com/articles/mobile-drying-project-required-in-the-box-thinking

Check us out –  +PolyClean

Several years ago, a client we work with approached us with a problem. Their material was out of spec in terms of moisture.  Their customers were complaining about the issue and our client was searching for a solution. A solution to a plastic problem that did not require a capital investment on their part.

We discussed building a truck specifically for drying their materials. Other clients had asked us about this kind of service before so we knew there was a need in the market. What we did not know (and still don’t to some degree) is how big the potential for this kind of service would be. And since this was a sizable investment for us, we needed at least one client willing to ‘guarantee’ enough material annually to justify the outlay. In 2011, our client couldn’t ignore the problem any longer and asked us to build the truck. To create a solution to solve their problem.

One of two 500 CFM dryers prior to installation

Our clients know that we build all of our own trucks.  The trucks are fairly complex. We deal with 460 volt three phase power, air compressors with dryers, vacuum convey systems, and the sorting or cleaning technology that is at the heart of the truck.  In most cases the main machine will be some sort of optical separator but we also have dedicated metal removing equipment, mobile screeners, and de-dusters.

Thinking Inside the Box…

Mobile drying offered a unique set of problems.  Mostly because we were looking to get a minimum of 1000 pounds per hour in capacity with a 6 hour dry time. The trucks we use have limited space so we couldn’t use a drying hopper that was too big (i.e. 6000 pounds) because it simply would not fit. Knowing what we wanted to achieve as well as  our knowledge limitations, we turned to an expert in the world of drying…a company called Dri-Air (dri-air.com).

One dryer installed with the six, 1000 pound hoppers clearly visible in the front.

The owner of the company, Charlie Sears, and his team of experts, listened to what we wanted and helped us design the perfect system.  They also helped us install the equipment at their facility which was a huge plus for the project. Their people got to see a system installation and we had the experts holding our hands through the process.

Dri-air is a great partner for us in helping us solve our clients plastic problems.  Due to the demand we have already seen for the truck, we are planning for the second drying truck to be built this year.  If you have a drying problem that needs solving, we are happy to announce we have a solution.  Give us a call and let’s discuss your needs.

The truck is just about ready to go (we are tweaking some of the software).  Our client has materials that need to be dried right now so our first run will be a bit of a trial by fire.  But we are confident that the truck will work as designed.

In a future post, I will discuss the innovative convey system that was developed for this truck to regulate the flow of materials through the process.  It’s pretty cool.

The big news for early 2012 will be the completion of our mobile drying truck.  It is one of our most ambitious projects ever and came about from a request from an amazing client that we love working with.  More details to come but Bill Hussey and I are really looking forward to showcasing this to the world.

If you ever have any issues with materials that need to be dried, give us a call and we’ll fill you in on the details.

And happy New Year…we look forward to solving your plastic problems in 2012 and beyond.