Machine Specifications
Technical specs, operating parameters, safety notes, and maintenance schedules for every machine in the travelling production facility.
Shredder
The shredder is the first stage of the plastic recycling pipeline. It takes sorted HDPE plastic and reduces it to small flakes ready for the heat press.
| Parameter | Value |
|---|---|
| Input Material | Sorted HDPE (#2) plastic |
| Output | Plastic flakes (uniform size) |
| Power | 3-phase electric |
| Feed Method | Manual — hand-fed through hopper |
Operating Notes
- Feed plastic steadily — do not overload the hopper
- Listen for changes in motor sound that indicate a jam
- Clear jams only when machine is powered off and locked out
- Check output flake size regularly for consistency
Safety
- Hearing protection required at all times during operation
- Safety glasses and gloves mandatory
- Keep hands clear of the hopper opening
- Lockout/tagout before clearing any jam
- Long hair and loose clothing must be secured
Maintenance
- Daily: Clear residual plastic from blades and hopper
- Weekly: Inspect blade sharpness, check belt tension
- Monthly: Lubricate bearings, inspect electrical connections
- As needed: Blade sharpening or replacement
Heat Press
The heat press melts shredded HDPE flakes and presses them into solid sheets that become the recycled plastic legs of the Stretch Bed.
| Parameter | Value |
|---|---|
| Operating Temperature | 190°C |
| Pressure | ~5,000 PSI |
| Cycle Time | 2–3 hours per sheet |
| Input | Shredded HDPE flakes in steel frame |
| Output | Solid HDPE sheet |
| Power | 3-phase electric |
Operating Notes
- Distribute flakes evenly in the frame before pressing — uneven fill causes weak spots
- Preheat the press to target temperature before loading
- Monitor temperature gauges throughout the cycle
- Do not open the press during the cycle — heat loss causes inconsistent sheets
Safety
- Heat-resistant gloves required when handling frames and sheets
- Burns risk — surfaces reach 190°C
- Adequate ventilation required — HDPE fumes at temperature
- Keep fire extinguisher accessible at all times
- Never leave the press unattended during operation
Maintenance
- Daily: Clean press surfaces of residual plastic
- Weekly: Check hydraulic fluid levels, inspect seals
- Monthly: Calibrate temperature gauges, inspect heating elements
- Quarterly: Full hydraulic system inspection
Cooling Press / Rack
After hot-pressing, sheets must cool slowly and under pressure to prevent warping. The cooling rack holds sheets flat during the critical cooling period.
| Parameter | Value |
|---|---|
| Minimum Cool Time | 6 hours |
| Method | Weighted flat cooling under even pressure |
| Capacity | Multiple sheets simultaneously |
Operating Notes
- Transfer sheets to cooling rack immediately after pressing
- Apply weight evenly across the entire sheet surface
- Do not rush cooling — sheets removed early will warp
- 6 hours minimum; overnight is ideal
- Check for warping before moving to CNC stage
Common Issues
| Issue | Cause | Solution |
|---|---|---|
| Warped sheet | Insufficient cool time or uneven weight | Re-press and cool for longer with more even weight |
| Surface marks | Debris on cooling surface | Clean cooling surfaces before each use |
CNC Router
The CNC router cuts cooled HDPE sheets into precise leg components using pre-loaded templates. Accuracy here determines fit quality during bed assembly.
| Parameter | Value |
|---|---|
| Material | Cooled HDPE sheets |
| Templates | Pre-loaded cutting profiles for bed leg components |
| Dust Extraction | Required — connected extraction system |
| Hold-Down | Vacuum table or mechanical clamps |
Operating Notes
- Verify template selection before starting each cut run
- Ensure sheet is firmly held down — movement during cutting ruins the part
- Dust extraction must be running before starting the router
- Check first cut piece against template for dimensional accuracy
- Collect all offcuts for re-shredding (zero waste)
Safety
- Safety glasses and hearing protection required
- Dust extraction must be active — HDPE dust is a respiratory hazard
- Keep hands clear of the cutting area during operation
- Do not reach under the sheet while the router is running
- Emergency stop must be accessible at all times
Maintenance
- Daily: Clear dust and chips from table and guides
- Weekly: Inspect router bit sharpness, check extraction filters
- Monthly: Lubricate guide rails, verify template calibration
- As needed: Router bit replacement
Flip Table / Frames
The flip table is used for sheet preparation, trimming, and final quality inspection before parts move to assembly. Steel frames hold plastic during pressing.
| Parameter | Value |
|---|---|
| Purpose | Sheet preparation, trimming, inspection |
| Frames | Steel moulds that hold plastic during pressing |
| Capacity | One sheet at a time |
Operating Notes
- Clean frame surfaces before filling with shredded plastic
- Apply release agent to frame walls to prevent sticking
- Distribute plastic evenly — overfill slightly to account for compression
- Trim sheet edges flush after cooling
- Inspect finished sheets for voids, cracks, or uneven thickness
Frame Care
- After each use: Clean residual plastic from frame edges
- Weekly: Check frame for warping or damage
- As needed: Re-apply release agent coating