plastic granulator machine

At The Mark-Costello Co., we take a deeply consultative approach to designing granulation systems that reflect the individual operating conditions of each facility. Unlike generic machinery that forces users to conform their workflow to the equipment, our solutions are designed around how our clients already work. From automotive manufacturing plants dealing with thick molded parts to pharmaceutical operations processing medical-grade resin waste, we recognize that plastic scrap comes in a wide range of shapes, densities, and compositions. Each of these variables influences how plastic should be cut, conveyed, and collected—so we never recommend a machine without first understanding the full picture. Our engineering team evaluates everything from material flow rates and contamination levels to noise limitations, floor space availability, and end-use granule specifications. The result is a highly engineered, purpose-built solution that integrates into your facility without compromising efficiency, safety, or product integrity.

A central factor in any granulation setup is the physical behavior of the plastic itself. Different materials respond uniquely when subjected to mechanical stress. High-density polyethylene (HDPE), for example, is rugged but can deform plastically, making it prone to jamming in improperly configured chambers. Polypropylene (PP), often found in molded parts and industrial containers, tends to fragment cleanly but may vary in brittleness depending on the temperature and processing history. More rigid plastics like polyvinyl chloride (PVC) and polyethylene terephthalate (PET) bring their own set of challenges, particularly around heat sensitivity and the risk of degradation during processing. These materials can become brittle or give off fumes if processed at improper speeds or under excessive friction. Our machines are fine-tuned with variable rotor speeds, customizable cutting geometries, and screen configurations that allow for the safe and efficient handling of each material type. This attention to technical detail ensures that the granules produced are uniform, contamination-free, and ready for reintroduction into the manufacturing cycle or resale markets.

Beyond the cutting chamber, The Mark-Costello Co. offers a suite of integrated accessory systems that enhance throughput, reduce manual handling, and improve the overall cleanliness of the process. For high-volume operations, we provide automatic feed conveyors that meter scrap into the granulator at a consistent rate, preventing overloading and preserving blade integrity. To minimize airborne dust and polymer fines, we incorporate cyclone separators and filtration units that maintain a clean working environment—particularly important in food packaging and medical supply industries where contamination cannot be tolerated. We also design output collection systems that include bulk bin drop zones, sealed bagging stations, or feed-back loops for reintegration into process hoppers. For facilities with multiple molding or extrusion stations, our centralized recovery systems allow scrap from various production lines to be collected and granulated at a single location. This modular approach not only improves efficiency but also helps standardize material handling practices across departments.

Our focus on serviceability is just as strong as our focus on performance. Many of our clients operate 24/7 or under high-pressure production timelines, where unexpected downtime can cause costly disruptions. That’s why every system we build includes maintenance-friendly features like quick-release access doors, segmented and reversible rotor knives, and easy-to-swap screens. These thoughtful design elements reduce the time and labor required to perform routine maintenance or address wear-and-tear. Our comprehensive support extends well beyond installation; we provide in-depth operator training sessions, digital and printed manuals, and access to our nationwide service technicians who are available for troubleshooting, repairs, and preventive care. For businesses seeking to transition into more sustainable operations or achieve closed-loop recycling within their production environments, our systems provide a reliable foundation. Whether your goal is to process lightweight films, thick-wall purgings, or a mixture of materials with variable densities and hardness, our solutions give you the control, flexibility, and resilience to handle the job with confidence.