The system shown in the video above is undergoing factory testing before shipment to our customer in Costa Rica. This compact all-in-one unit combines a shredder and a granulator in a single frame, purpose-built for PP jumbo bags (FIBC). It is rated at 500 kg/hr and can reach up to 600 kg/hr with consistent feeding.
Traditionally, shredding and granulating required two separate machines with conveyor belts running between them. This integrated design eliminates the transfer stage entirely, cutting the floor space required, reducing the number of operators needed, and lowering overall manufacturing costs.
Why Combine Shredding and Granulating in One Machine
Jumbo bags are bulky with very low bulk density, which makes them awkward and expensive to convey between separate machines. Every transfer point is a potential jam point and needs an operator’s attention. Combining both stages means a single infeed, a single control point, and a much smaller footprint. For plants running around 500 kg/hr, integration removes a conveyor, an extra drive motor, and the floor space that used to sit between two machines. Fewer drives also means fewer maintenance points over the life of the equipment.
There is also a workflow advantage that shows up on the plant floor. With two separate machines, one operator typically watches the shredder discharge while another manages the granulator infeed, constantly adjusting to keep the two stages balanced. In the all-in-one system, a single operator monitors one infeed and one control panel. Startups and shutdowns are simpler too: one start sequence brings up the whole reduction stage, instead of choreographing two machines and the conveyor between them.
How the 500 kg/hr System Handles PP Jumbo Bags
In the first stage, the shredder reduces whole jumbo bags, including their stitched seams, into coarse pieces. In the second stage, the granulator cuts those pieces into uniform regrind that is ready for washing or extrusion. Woven PP cuts cleanly rather than tearing, which keeps dust generation down and particle size consistent. Real throughput depends on feed consistency: steadily fed, pre-opened bags will hit the 500 to 600 kg/hr range, while tightly baled or tangled feed will run slower because the shredder has to work through dense clumps.
Dust control deserves a mention because jumbo bag recycling generates fine PP fibers at both cutting stages. A simple dust extraction hood over the discharge, vented to a filter or cyclone, keeps the work area clean and recovers fines that would otherwise be lost. Good housekeeping around the machine also matters: regrind spilled on the floor gets tracked into bearings and electrical cabinets over time.
Working Principle
Bags enter the shredder chamber, where the rotor reduces them to coarse flakes. The material passes directly into the granulator chamber, where rotating and stationary knives cut it against a screen. On-size particles pass through the screen while oversize material stays in the cutting chamber until it is reduced. A single coordinated control system runs both stages, so the granulator is never starved or flooded by the shredder output.
Because both stages share one control system, interlocks protect the machine automatically. If the granulator chamber overloads, the shredder feed pauses until the chamber clears; if a jam is detected, the system stops in a safe sequence rather than letting one stage grind against a stalled load. This coordination is difficult to achieve with two standalone machines from different suppliers, where the conveyor between them has no awareness of either machine’s load.
When to Choose Separate Machines Instead
Integration is ideal at the 500 kg/hr scale, but higher capacities call for separate machines. Dedicated units let you size each stage independently, service one machine while the other stands by, and tune rotor speeds separately for difficult materials. If your target is well above 600 kg/hr, or you run multiple materials that need different screen sizes, a two-machine setup with a conveyor between them gives more flexibility. For complete downstream processing, the regrind from either configuration can feed a woven bag washing line or a rigid plastic recycling line.
Operating Notes for Jumbo Bag Recycling
Check incoming bags for metal clips, hooks, or stones before feeding, since tramp material damages knives quickly. Opening bales before feeding gives steadier throughput than dropping in whole compressed bales. Inspect knives and screens on a regular schedule, because woven PP is mildly abrasive over long runs. Keep the discharge area clear so regrind flows freely to the next stage, whether that is a film shredding and densifying line or a centrifugal dryer ahead of washing.
It is also worth keeping a basic spare parts stock on site: a spare set of knives, one granulator screen in your standard size, and the fastener kit for the blade holders. These are wear items with predictable replacement cycles, and having them on the shelf turns a scheduled knife change into a half-day task instead of a week of downtime waiting for parts. ASG can recommend the initial spares package based on your planned operating hours.
Frequently Asked Questions
What materials is this all-in-one system designed for?
It is purpose-built for PP jumbo bags (FIBC). Suitability for other bulky materials depends on wall thickness, contamination level, and target output size, so share your material details with ASG before deciding.
What is the real throughput of the system?
The system is rated at 500 kg/hr and can reach up to 600 kg/hr with consistent, pre-opened bag feeding. Baled or tangled feed will run below the rated capacity.
What if I need more than 600 kg/hr?
For higher capacities, ASG recommends separate shredder and granulator machines. Dedicated units can be sized independently and serviced without stopping the entire reduction stage.
How does the integrated design save costs?
It eliminates the conveyor between two machines, reduces the floor space required, needs fewer operators, and has fewer drive motors to maintain, all of which lower manufacturing costs.
Can it handle jumbo bags with inner liners?
Liners change how the material behaves in the cutting chamber, so tell ASG whether your bags include PE liners. The shredder and screen configuration may need to be adjusted for liner-heavy feed.
What particle size does the granulator produce?
The final particle size is set by the granulator screen, which can be selected to match your downstream process, whether that is washing, extrusion, or pelletizing.
Is each system tested before shipment?
Yes. Every system is factory-tested, as shown in the video above, before it is shipped to the customer. The Costa Rica unit shown here completed its test run prior to dispatch.
What routine maintenance does it need?
Regular knife inspection and screen checks are the main items, plus standard lubrication per the manual. Keeping tramp metal out of the feed is the single best way to extend knife life.
How many operators does the system need?
Fewer than a conventional two-machine setup with a conveyor between them, since there is only one infeed point and one control system to manage.
Can I see the system running before ordering?
The video above shows the Costa Rica system during factory testing. Contact ASG through the form below to discuss your material and arrange a detailed technical review.
Get a Quote for Your Jumbo Bag Project
To learn more about this all-in-one shredder and granulator system, send us your material details using the form below: