It is not just about equipment specs these days, but also about finding an entire system to get the job done and, in the end, more material recycled and processed. Upfront engineering is essential to maximize production, along with reduced downtime and cost savings.
By Heather Caliendo
The recycling industry continues to evolvewith market demand. Across the industry, manufacturers and recyclers are becoming more sophisticated about size reduction equipment while also more aware of the value of reusing off-spec parts and other product waste.
There are several key reasons for this shift, including a bigger focus on automation, reducing contamination issues, plus energy costs driving demand for efficient material flow. In some areas, regulatory pressure is also driving the push for higher recovery rates.
As a result, manufacturers and recyclers are more systems oriented as well. And for many projects, the granulator is the one to get the job done. It then becomes a question of how to maximize its performance.
After all, one size does not fit all. Especially when it comes to finding a size reduction equipment to suit your application needs. Whether it is small or large injection or blow-molded parts, thermoform materials, pipes, bottles etc., it is crucial to get the right machine that will ensure the material can be turned into a manageable size for downstream processing.
Now, many processors and recyclers are seeking high performance granulators as part of a complete package. This may include custom-built equipment sized to fit a specific footprint, integrated control panels with enhanced safety features, and conveyors designed to monitor the feed flow on the granulator as well as reduce noise on the shop floor. Systems may also incorporate metal detectors, fines separators, and high levels of automation. All of this is designed to maximize throughput and longevity for customers.
Images courtesy of Rotogran.
Why Customization Matters
Recycling is moving toward full systems-oriented solutions. Customers are looking for high-efficiency systems that deliver durability, zero downtime, and consistent performance. This involves the complete package built around the granulator.
Not every project has the same demands. For instance, post-consumer and post-industrial material feature very different streams with specific needs. This is why customization is very important, especially when it comes to recycling and handling a wide range of scrap material. Custom-built granulators and systems help recyclers and manufacturers聽keep materials in use longer, reduce waste, and close the loop聽on production.
There is also space to consider. So custom-built options can be designed to ensure the granulator is sized to fit a specific space within existing facilities. This is particularly important for operations working with limited floor space or those retrofitting equipment into established production lines.
A key strength of a reliable OEM is the front-end application engineering, where they evaluate the machine to see where it can improve to maximize throughput.
Key Considerations
Many manufacturers are recycling a wider assortment of products, which calls for equipment that can handle higher throughput and improved wear resistance. The goal is to ensure recyclers and processors can maximize output while minimizing downtime.
It is important that the blade configuration, screen size, and the cutting chamber match the material鈥檚 size and density. Many mixed streams require interchangeable screen sizes. An industry-wide standard is the design for quick and easy access to the cutting chamber for cleaning or blade changes.
The combination of offering custom equipment plus installation and training to meet your scheduling expectations is vital. Training should include equipment overviews, operational and maintenance issues and more based on your project鈥檚 needs. Make sure you work with an OEM who is listening to what the customers are saying and learning if they are experiencing any difficulties.
Choosing the Right System
It is not just about equipment specs these days, but also about finding an entire system to get the job done and, in the end, more material recycled and processed. Upfront engineering is essential to better material quality maximize production, along with reduced downtime and cost savings.
Every project is unique and the ability to customize such high-power equipment is crucial in answering the customers鈥� demands. This systems-based approach supports a more efficient, resilient and sustainable recycling ecosystem.
In the end, it all comes down to communication between the customer and the OEM. It is not only about finding the right equipment, but the key is finding the right people with the right experience. And together, they can put together the complete package.
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Case Study: Real-World Example
Goodwill Industries, Ontario Great Lakes (OGL), headquartered in London, ON, is committed to environmental stewardship, repurposing millions of pounds of goods each year in collaboration with the communities they serve.
In 2025, Goodwill Industries (OGL) collected more than 69 million pounds of donated goods, with just over 45 million pounds sold for reuse, and another 14 million pounds to recycling, repurposing approximately 86 percent of all goods received.
However, Goodwill is developing innovative circularity solutions for goods received that have lacked a sustainable solution 鈥� like commercial and industrial Tupperware and plastics. Since there wasn鈥檛 an aftermarket solution in place, Goodwill needed to create one and partnered with Rotogran.
The solution included a granulator, feed conveyor and evacuation system, all integrated into a line expected to keep industrial plastics in circulation, longer.
Rotogran is highly respected within the industry, and since partnering, Goodwill says their customer service has been second to none. 鈥淚t鈥檚 incredibly personal with their eagerness to check in,鈥� says John Quigley, Circularity and Sustainability Specialist at Goodwill. 鈥淭hey are fantastic at communicating, troubleshooting and just in general follow up to see how things are going. They have an incredible response to help find solutions.鈥�
Goodwill Industries OGL also partnered with GreenWell Plastics, a Canadian remanufacturer, that is converting Goodwill鈥檚 granulated plastic into dynamic lumber, outdoor furniture and more.
Heather Caliendo is the communications manager for Rotogran International, a Canadian manufacturer of size reduction equipment for the plastics and recycling industry, custom designing and building granulators, fines separators, evacuation systems, and feed conveyors with metal separators.
Located in Bolton, ON, Rotogran聽focuses on offering the complete package for processors and recyclers. The single pass, high-capacity granulators are capable of reprocessing plastic scrap into valuable regrind regardless of its original shape or size. For more information, visit .