Air-cooled Die Face Hot Cutting System

The air-cooled die face hot cutting system is an efficient, waterless plastic granulation solution designed specifically for high-yield, heat sensitive materials and high filling formulations. This system integrates granulation, cooling, and transportation into a continuous closed-loop process. Compared with traditional water drawing or underwater granulation methods, it has the advantages of small footprint, low energy consumption, and high degree of automation, especially suitable for granulation production of engineering plastics, modified materials, and recycled materials.

·Integrated air-cooled conveying: Utilizing high-speed closed-loop airflow to instantly cool and solidify molten polymer droplets on the mold surface, completely eliminating the water cooling process and avoiding the risk of material hydrolysis.
·Hydraulic self-adjusting die surface cutter: equipped with a precision hydraulic drive device, the cutter maintains constant pressure contact with the die surface, ensuring uniform particle size and extending the service life of the blade.
·High wear-resistant alloy die head: The die head is made of special alloy steel and has precise heating channels to ensure uniform temperature and stable discharge of the melt in the mold hole area.
·Closed loop pneumatic conveying system: integrating cyclone separator and centrifugal fan, directly conveying finished particles to the storage bin, and recovering waste heat to achieve energy-saving production.
·Quick color/material change design: The mold head adopts a quick opening structure, and the cutting blade assembly can be quickly disassembled. Material switching can be completed without disassembling the pipeline, greatly reducing downtime.

Noted: Details depend on your requirements and need.

Why choose the air-cooled die face hot cutting system instead of other cutting methods?

Compared to traditional water drawn strip cutting, the air-cooled die face hot cutting system does not require a long water tank or a water removal fan, completely solving problems such as strip breakage and roller wrapping, especially for soft and viscous materials, with more stable processing performance.

Compared with water ring cutting or underwater cutting, the "waterless drying" feature of this system avoids the risk of material hydrolysis caused by contact with water, eliminates the need for back-end equipment such as dehydrators and dryers, and reduces comprehensive energy consumption by about 30%. At the same time, the finished particles are regular spherical or hemispherical in shape, with good fluidity, and can be directly packaged or entered into downstream processes without further processing.

This plastic granulation system is widely used in the following high-performance mixing and recycling scenarios:
·Modified granulation: masterbatch production, high filling modification (calcium carbonate, talc powder), fiberglass reinforced plastics.
·Engineering plastics: materials sensitive to moisture such as nylon (PA6, PA66), polycarbonate (PC), PBT, etc.
·Recycling: Water free granulation of soft PVC, TPU, EVA and other materials after industrial recycling (PIR).
·Hot melt adhesive: special materials such as pressure-sensitive adhesives and wax based adhesives that are not suitable for contact with aqueous media.

Nanjing Kelongwell Chemical Machinery Co., Ltd. provides fully customized services for air-cooled die face hot cutting systems:
·Mold head customization: According to the extruder output and material flowability, mold heads with different aperture sizes, hole numbers, and heating zone layouts can be customized.
·Blade material selection: For high wear fillers, ceramic coating or hard alloy blade options are available.
·Whole line integration: It can be matched with twin-screw extruders and upstream batching systems, providing unified PLC control to achieve one click start stop and interlock protection.

Q1: What is the main difference between the air-cooled die face hot cutting system and the underwater cutting system?
A: Underwater particle cutting relies on water as the cutting and cooling medium, while this system uses high-speed circulating air for cooling. This difference makes air-cooled die surface heat cutting particularly suitable for moisture absorbing materials such as nylon and PET, or formulas containing foaming agents and high filling, which can avoid particle water absorption, eliminate the need for subsequent drying processes, and the finished particles can be packaged without dehydration.

Q2: Can the air-cooled die face hot cutting system handle high filling materials with up to 80% calcium carbonate filling? How is the wear of the blade?
A: Okay. The system is specifically designed for high wear applications, with the die head made of wear-resistant alloy and optional high hardness wear-resistant blades. The hydraulic driven self-adjusting cutter maintains a constant contact force between the blade and the mold surface, effectively delaying blade wear and extending service life even when handling high filling materials.

Q3: Compared to water drawn strip cutting, what are the advantages of air-cooled die face hot cutting system?
A: The cutting of water drawn strips requires a long water tank and air drying section, occupies a large area, and the strips are prone to breakage, causing the production line to shut down. The air-cooled die face hot cutting system adopts closed-loop air-cooled conveying, with a compact structure and high degree of automation. Especially for soft and viscous materials, it avoids the problem of adhesion and winding of the pulling strip, achieving higher operational stability and single machine output.

Q4: How to achieve rapid color or material change?
A: The mold head of this system adopts a quick opening structure, and the cutting blade assembly can easily swing outward without disassembling the pipeline to clean the mold surface. Due to the lack of a sink and drying system, only the mold head and cutting blade cavity need to be cleaned during color change, which can usually be completed within 20-30 minutes, much faster than the color change time of underwater cutting systems, significantly reducing material waste.

Q5: Is the air-cooled die face hot cutting system suitable for plastic recycling granulation?
A: Very suitable. This plastic granulation system is widely used for granulation of industrial post recycling (PIR) materials. The melting point of recycled materials fluctuates greatly, and the air-cooled die face hot cutting system has strong adaptability to changes in the melt, avoiding thermal stress problems caused by the rapid cooling of recycled materials in contact with water. The obtained particles are uniform and have high cleanliness, and can be directly used for re extrusion or injection molding.