GB2518342A

GB2518342A - A plastics processing apparatus and method

Info

Publication number: GB2518342A
Application number: GB1309693.8A
Authority: GB
Inventors: Alexander Joseph Pluke
Original assignee: Plastic Economy Ltd
Current assignee: Plastic Economy Ltd
Priority date: 2013-05-30
Filing date: 2013-05-30
Publication date: 2015-03-25
Also published as: GB201309693D0; WO2014191735A3; WO2014191735A2

Abstract

A plastics processing apparatus 10 has a hopper 12 for receiving a plastics material, a barrel 14 having one or more screws 16 disposed co-axially with the barrel 14, a breaker plate 18, disposed on a distal end of the barrel 14, having one or more output apertures, a heater 20 and a motor 24 for driving the, or each, screw 16. The heater 20 provides heated fluid to the hopper 12 and/or barrel 14. The heated fluid is heated from heat derived from the exhaust of the 24 motor. The motor 24 may be a steam motor driven by steam from a biogas fueled boiler. Solar heating may also be used to preheat a working fluid.

Description

A plastics processing apparatus and method The present invention relates to a plastics processing apparatus and method, such as, for example, a plastics extruder or injection moulding apparatus and method, and particularly to an environmentally friendly plastics processing apparatus and method, such as, for example, an apparatus and method which requires less fossil fuels for the processing of the plastics materials.

A typical plastics processing apparatus uses a significant quantity of energy in running motors, drives, cooling systems, drying systems and heaters. This results in a significant cost both as a financial cost, with increasing energy charges, and an environmental cost, with the use of fossil fuels and the pollution into the environment. Furthermore, known plastics processing apparatus require a consistent electrical supply which therefore practically prevents the processing of plastics in countries and regions in which there is no electrical supply or in which there is only an inconsistent electrical supply available.

Moreover, the use of electricity undesirably involves multiple energy conversion losses.

It is therefore desirable in the industry for there to be a more cost effective and environmentally friendly means for processing plastics material. It is also desirable in the industry for there to be a means of processing plastics which is not reliant on electricity and one in which energy conversion losses are minimised.

It is an object of the present invention to provide a cost effective and environmentally friendly plastics processing apparatus and method.

It is also an object of the present invention to provide a plastics processing apparatus and method which is not dependent on electricity for heating and driving a motor.

According to a first aspect of the present invention there is provided a plastics processing apparatus comprising a hopper for receiving a plastics material, a barrel having one or more screws disposed co-axially with the barrel, a breaker plate, disposed on a distal end of the barrel, having one or more output apertures, a heater and a motor for driving the, or each, screw, characterised in that the heater provides heated fluid wherein the heated fluid is heated from heat derived from the exhaust of the driven motor.

The heater is advantageously suitable for heating plastics materials.

The motor is advantageously a steam driven motor.

The plastics heater may comprise a heating jacket having an internal void for receiving the heated fluid.

The heating jacket may be disposed about the outer circumference of at least one of the hopper and the barrel.

Additionally, or alternatively, the plastics heater may comprise one or more conduits for receiving the heated fluid.

The one or more conduits may be adapted to extend around the outer circumference of at least one of the hopper and the barrel.

The apparatus advantageously further comprises a boiler operable to heat a feed fluid via a heat exchanger to thereby provide steam for driving the motor.

The boiler is advantageously a bio-fuel boiler.

The boiler advantageously comprises a steam vent operable to open to release steam below a predetermined temperature and/or pressure into a feed fluid conduit and close to divert steam above a predetermined temperature/pressure towards the motor.

The motor may comprise a gearing mechanism operable to determine power transmitted to the screw.

The apparatus advantageously further comprises a steam modulator operable to modulate at least one of the temperature and pressure exhausted from the motor.

The apparatus as claimed in any of the preceding claims, further comprising a power generator.

The power generator is preferably a dynamo.

The apparatus advantageously further comprises a preheat module positioned and operable to preheat a working fluid.

The preheat module advantageously comprises one or more solar heat tubes and a heat exchanger.

The solar heat tubes may comprise the working fluid and are arranged in a sealed cyclic system.

The solar heat tubes are advantageously evacuated of air.

The one or more solar heat tubes are advantageously operable to transfer thermal energy between the working fluid and the feed fluid prior to the feed fluid being fed into the boiler.

The apparatus advantageously further comprises means to increase solar gain incident on the heat tubes.

The heat exchanger advantageously comprises an exhaust input extending from the boiler.

The apparatus advantageously further comprises a feed valve operable in a first mode to prevent the feed fluid being fed into the motor below a predetermined temperature and in a second mode to allow the feed fluid to be fed into the motor above a predetermined temperature.

The apparatus advantageously further comprises a plastics pre-processing module.

The pre-processing module may comprise at least one grinder operable to grind plastics material into a more de-bulked or homogenised state.

IS The pre-processing module may comprise a plastics shredder operable to shred plastics material.

The pre-processing module may further comprise plastics cleaning means operable to clean plastics material prior to processing.

The plastics cleaning means may comprise a steam cleaner.

The plastics cleaning means may comprise a condenser for removing undesired washing fluid.

The pre-processing module may further comprise plastics sorting means operable to extract plastics material from used items made from plastics material.

The pre-processing module may further comprise plastics drying means.

The apparatus may further comprise conveying means operable to transport plastics material through the processing apparatus.

The apparatus may further comprise means for cooling processed plastics material.

Also according to the present invention there is provided a method of processing plastics material comprising: (a) providing a hopper, a barrel having at least one screw disposed co-axially therewith, a breaker plate, disposed on a distal end of the barrel, wherein the barrel comprises one or more output apertures; and (b) providing a heater and a motor for driving the, or each, screw; characterised in that the method further comprises the following step: (c) providing a heated fluid to the heater whereby the heat which heats the heated fluid is derived from the exhaust of the driven motor.

The heater is advantageously suitable for heating plastics material.

The motor is advantageously a steam driven motor.

The heater may comprise a heating jacket having an internal void for receiving the heated fluid.

The heating jacket is disposed about the outer circumference of at least one of the hopper and the barrel.

The heater may comprise one or more conduits for receiving the heated fluid.

The one or more conduits are advantageously adapted to extend around the outer circumference of at least one of the hopper and the barrel.

The method advantageously further comprises the step of providing a boiler and heating feed fluid via a heat exchanger to thereby provide steam for driving the motor.

The boiler is advantageously a bio-fuel boiler.

The boiler advantageously comprises a steam vent and the steam vent is opened to release steam below a predetermined temperature and/or pressure into a feed fluid conduit and closed to dived steam above a predetermined temperature/pressure towards the motor.

The method advantageously further comprises the step of providing a steam modulator and modulating at least one of the temperature and pressure of the steam exhausted from the motor.

The method may further comprise the step of providing a power generator whereby the power generator is preferably a dynamo.

The method advantageously further comprises the step of providing a preheat module and preheating a working fluid.

The solar heat tubes advantageously comprise the working fluid and are arranged in a sealed cyclic system.

The solar heat tubes are advantageously evacuated of air.

The method advantageously further comprises the step of transferring thermal energy between the working fluid and the feed fluid, through the solar heat tubes, prior to the feed fluid being fed into the boiler.

The method advantageously further comprises the step of providing means to increase solar gain incident on the heat tubes.

The method advantageously further comprises the step of providing the heat exchanger with an exhaust input which extends from the boiler.

The method advantageously further comprises the step of providing a feed valve and operating the feed valve in a first mode to prevent the feed fluid being fed into the motor below a predetermined temperature and in a second mode to allow the feed fluid to be fed into the motor above a predetermined temperature.

The method may further comprise the step of providing a plastics pre-processing module.

The pre-processing module may comprise at least one grinder and comprise the step of grinding plastics material into a more de-bulked or homogenised state.

The pre-processing module is provided with a plastics shredder and further comprises the step of shredding plastics material.

The pre-processing module may be provided with plastics cleaning means and further comprise the step of cleaning the plastics material prior to processing.

The plastics material is advantageously cleaned using steam.

The plastics cleaning means is advantageously provided with a condenser and advantageously further comprises the step of condensing undesirable washing fluid.

The pre-processing module may be provided with a plastics sorting means and may further comprise the step of extracting plastics material from items made from plastics material.

The pre-processing module may be provided with plastics drying means and may further comprise the step of drying plastics material.

The method may further comprise the step of providing conveying means and conveying plastics material through the processing apparatus.

The method advantageously comprises the step of heating at least one of the hopper and barrel to a predetermined temperature.

The method may further comprise the step of driving the screw in rotation, whereby the speed of rotation is controlled by a controller, which may be, for example, and electronic or mechanical controller.

The method may further comprise the step of feeding pre-processed plastics material into the hopper and feeding the plastics material from the hopper into the barrel at a controlled rate.

The method may further comprise the step of providing a die or mould in fluid communication with the breaker plate and receiving fluid plastics material into the die or mould via the output apertures of the breaker plate.

The method may further comprise the step of providing cutting means and cutting the outputted plastics material into predetermined shapes and/or dimensions.

The method may further comprise the step of providing means for cooling processed plastics material and cooling the processed plastics material.

The present invention will now be described in further detail with reference to the accompanying drawings, in which: Figure 1 is a schematic drawing showing a longitudinal section through a plastics processing apparatus according to the present invention; Figure 2 is a schematic drawing showing the plastics processing system.

Referring to Figure 1, a plastics processing apparatus 10 has a hopper 12, a barrel 14, a screw 16, a breaker plate 18, a first heater 20 and a second heater 22 and a motor 24. In an alternative embodiment the apparatus may comprise a plurality of screws.

The hopper 12 is operable to receive plastics material which has been pre-processed to provide suitable material for processing. The pre-processed material may be, for example, re-cycled from articles containing plastics materials.

The hopper 12 is of an inverted frusto-conical shape having a larger upper opening 26, through which, in use, the plastics material is received, and a narrower lower opening 28, through which, in use, the plastics material leaves the hopper 12 under the force of gravity.

The hopper 12 has an inner wall 30 and an outer wall 32. The first heater 20 is disposed within the inner wall 30 such as to provide thermal energy into the inside of the hopper 12 to thereby heat the plastics material.

The first heater 20 is formed from a coiled heating conduit 34, having an input 36 and an output 38. The coiled heating conduit 34 is disposed within or embedded in the inner wall 30 such that, in use, it emits thermal energy into the internal volume of the hopper 12. In an alternative embodiment there may be a plurality of coiled heating conduits or a heating jacket (not shown) suitably disposed to emit thermal energy into the internal volume of the hopper 12.

The outer wall 32 is formed, at least partially, from an insulating material.

The hopper 12 feeds into the barrel 14 through the lower opening 28. The barrel 14 is an elongate cylindrical member having a bore 40 formed by an outer wall 42. In an alternative embodiment it may have a rectangular cross section.

The barrel 14 has a proximate end 44 and a distal end 46. The hopper 12 is disposed at the proximate end 44 such that, in use, the hopper 12 loads the barrel 14 with plastics material via the lower opening 28 in a direction substantially transverse to the longitudinal axis of the barrel 14.

The breaker plate 18 is disposed at the distal end 46 of the barrel 14 and has an aperture 48, through which, in use, processed plastics material is outputted.

The screw 16 is disposed within the barrel 14 such that it lies co-axially therewith and, in use, is operable to rotate about the longitudinal axis of the barrel 14.

The screw 16 is mechanically connected to the motor 24 via a mechanical driving linkage 50 which extends through the periphery of the proximate end 44 of the barrel 14 and the motor 24 is operable to drive the screw 16 in rotation.

The second heater 22 is formed from a second coiled heating conduit 52, having an input 54 and an output 56. The coiled heating conduit 52 is disposed on, within or embedded in, the outer wall 42 such that, in use, it emits thermal energy into the internal volume of the barrel 14. In an alternative embodiment there may be a plurality of coiled heating conduits or a heating jacket (not shown) suitably disposed to emit thermal energy into the internal volume of the barrel 14.

The motor 24 is a steam driven motor which has a steam exhaust outlet 58.

The steam exhaust outlet 58 is fluidly connected via a first feed heater pipe to connect to the first heater input 36 such that, in use, exhausted steam is used to provide the heat for the first heater 20.

Similarly, the steam exhaust outlet 58 is fluidly connected via a second heater pipe 62 to the second heater input 54 such that, in use, exhausted steam is used to provide the heat for the second heater 52.

In use, used steam is recycled back to the motor 24 via a first return conduit 64 extending from the first heater output 38 and from the second heater output 56, to a return inlet 66. Prior to being fed to the motor 24, the used steam is re-heated to a predetermined temperature suitable for driving the motor.

Referring also to figure 2, a boiler 68 heats water to a predetermined superheated temperature, which is suitable for the steam driven motor (24).

The superheated steam is fed to the motor 24 via a steam inlet 70.

The boiler 68 is preferably powered by biogas. However, it will be appreciated that other fuels may be used.

The boiler 68 has a steam vent operable to open to release steam below a predetermined temperature and/or pressure into a feed fluid conduit and close to divert steam above a predetermined temperature and/or pressure into the steam inlet 70.

Water is fed into the boiler from a reservoir 72.

A steam modulator 74 is preferably used between the exhaust outlet 58 and the first heater inlet 36 and the second heater inlet 54 and is operable to modulate at least one of the temperature and pressure exhausted from the motor via the exhaust outlet 58.

The steam driven motor 24 preferably has a power generator (not shown) such as a dynamo.

A preheat module 76 is positioned between the reservoir 72 and the boiler 68. The preheat module 74 has one or more solar panels or heat tubes operable to preheat a working fluid. The working fluid is then passed through a heat exchanger with the water feed to the boiler, such that heat is transferred from the preheat module to preheat the water fed into the boiler 68.

In use, water is fed from the reservoir 72 to the boiler 68, via the preheat module 76. The boiler 68 heats the preheated water to produce superheated steam. The superheated steam drives the motor 24, wherein the motor drives the screw 16.

The speed of rotation of the screw is controlled by sensors which feedback to a speed variator 78, which may be a gearbox mechanism.

Steam which is exhausted from the motor, via exhaust outlet 58, is fed into the first heater 20 to provide heat in the internal volume of the hopper 12 and is fed into the second heater 22 to provide heat in the internal volume of the barrel 14.

Steam, exhausted from the first and second heaters, may be fed back to the boiler 68 or the motor 24 to be recycled. If fed directly to the motor 24, a means of pre-heating the exhausted steam is required prior to recycling the exhausted steam into the motor 24. Alternatively, the exhausted steam can be recycled to a reservoir 72 which stores the feed water. Recycling the steam in this way provides for a means of heating the water prior to feeding it into the boiler and thereby reduces the energy required to produce superheated steam.

Upon reaching a predetermined temperature suitable for melting the relevant plastics material, plastics material is fed into the hopper 12 through the upper opening 26. The plastics material may be plastic items for recycling. The heat in the internal volume of the hopper 12 pre-heats the plastics material which, under gravity, is fed into the barrel 14 via the lower opening 28.

As the screw 16 is being driven, the plastics material is fed along the length of the barrel 14 towards the breaker plate 18. As the plastics material travels along the barrel, the second heater 22 heats the plastics material and, with the addition of heat caused by friction, transforms the plastics material into a fluid. Upon reaching the breaker plate 18, the fluid plastics material is extruded through the aperture 48 and may be cut into strips of processed plastics material.

If required, a die or mould (not shown) may be positioned adjacent to the aperture to form the plastics material into a predetermined shape or item.

In an alternative embodiment, the steam exhaust from the driven motor 24 heats a working fluid via a heat exchanger (not shown). The heat exchanger may additionally comprise, for example, solar heating means.

The working fluid may be, for example, an oil that is fed at a predetermined temperature to the first and second heaters 20 and 22. The steam exhausted from the motor is modulated to a predetermined temperature and/or pressure.

The steam exhausted from the working fluid heat exchanger can be recycled to the beginning of the system process whereby the heat can be used to increase the temperature of the water which, for example, is stored in the reservoir.

In an alternative embodiment, the motor 24 is a combustion engine which is used to drive the screw (16) and a working fluid, such as, for example, oil is heated and fed into the first and second heaters 20 and 22.

The combustion engine (motor 24) would preferably be fuelled by biogas and operable to drive the, or each, screw (16).

The exhausted gas from the combustion engine motor is used to heat a working fluid via a working fluid heat exchanger. The working fluid is, for example, a suitable oil. The heated working fluid is fed into the first and second heaters.

The working fluid heat exchanger may comprise solar heating means such as, for example, solar collectors and/or tubes which at least contribute to heating the working fluid.

Alternatively, or additionally, the working fluid may be heated using a biogas burner. The biogas burner's flame can be controlled to provide a desired temperature of working fluid which, in turn, determines the heat emitted from the first and second heaters 20 and 22. The biogas burner heats the working fluid prior to the working fluid being heated by the exhaust of the motor 24.

Accordingly, the working fluid is pre-heated by the biogas burner and then heated further to a predetermined desired temperature by the exhaust of the motor, before being fed into the first and second heaters 20 and 22.

Pumps and valves are used to control and provide an even distribution of Different working fluids and exhaust gases may be kept discrete from each other by using heat exchangers. For example, the working fluid from the solar collectors can be separated by a heat-exchanger from the working fluid that is exposed to the motor exhaust gas. Further, the motor exhaust gas can be separated by a heat exchanger from the working fluid of the burner.

The apparatus and method, according to the present invention, minimises energy conversion losses by directly using thermal and kinetic energy from the energy sources.

That is to say, instead of using heat and kinetic energy to generate electricity, and then using that electricity to generate heat and electricity; the apparatus and method of the present invention uses utilises energy directly from the energy sources and thereby significantly reduces energy conversion losses, which would otherwise typically be between 20-60%.

Claims

CLAIMS1. A plastics processing apparatus comprising a hopper for receiving a plastics material, a barrel having one or more screws disposed co-axially with the barrel, a breaker plate, disposed on a distal end of the barrel, having one or more output apertures, a heater and a motor for driving the, or each, screw, characterised in that the heater provides heated fluid wherein the heated fluid is heated from heat derived from the exhaust of the driven motor.
2. A plastics processing apparatus as claimed in claim 1, wherein the heater is suitable for heating plastics materials.
3. A plastics processing apparatus as claimed in claim 1 or 2, wherein the motor is a steam driven motor.
4. Apparatus as claimed in any preceding claim, wherein the heater comprises a heating jacket having an internal void for receiving the heated fluid.
5. Apparatus as claimed in claim 4, wherein the heating jacket is disposed about the outer circumference of at least one of the hopper and the barrel.
6. Apparatus as claimed in claims 1 to 3, wherein the plastics heater comprises one or more conduits for receiving the heated fluid.
7. Apparatus as claimed in claim 6, wherein the one or more conduits are adapted to extend around the outer circumference of at least one of the hopper and the barrel.
8. Apparatus as claimed in any preceding claims further comprising a boiler operable to heat a feed fluid via a heat exchanger to thereby provide steam for driving the motor.
9. Apparatus as claimed in claim 8, wherein the boiler is a bio-fuel boiler.
1 0.Apparatus as claimed in claim 8 or 9, wherein the boiler comprises a steam vent operable to open to release steam below a predetermined temperature and/or pressure into a feed fluid conduit and close to divert steam above a predetermined temperature/pressure towards the motor.
11.Apparatus as claimed in any of the preceding claims, wherein the motor comprises a gearing mechanism operable to determine power transmitted to the screw.
12. Apparatus as claimed in any of the preceding claims, further comprising a steam modulator operable to modulate at least one of the temperature and pressure exhausted from the motor.
13.Apparatus as claimed in any of the preceding claims, further comprising a power generator.
14.Apparatus as claimed in claim 13, wherein the power generator is a dynamo.
15.Apparatus as claimed in any of the preceding claims, further comprising a preheat module positioned and operable to preheat a
16.Apparatus as claimed in claim 15, wherein the preheat module comprises one or more solar heat tubes and a heat exchanger.
17.Apparatus as claimed in claim 16, wherein the solar heat tubes comprise the working fluid and are arranged in a sealed cyclic system.
18.Apparatus as claimed in claim 16 or 17, wherein the solar heat tubes are evacuated of air.
19.Apparatus as claimed in claim 16, wherein the one or more solar heat tubes are operable to transfer thermal energy between the working fluid and the feed fluid prior to the feed fluid being fed into the boiler.
20.Apparatus as claimed in claims 13 to 16, further comprising means to increase solar gain incident on the heat tubes.
21.Apparatus as claimed in claims 13 to 17, wherein the heat exchanger comprises an exhaust input extending from the boiler.
22.Apparatus as claimed in any preceding claim, further comprising a feed valve operable in a first mode to prevent the feed fluid being fed into the motor below a predetermined temperature and in a second mode to allow the feed fluid to be fed into the motor above a predetermined temperature.
23. Apparatus as claimed in any preceding claim further comprising a plastics pre-processing module.
24.Apparatus as claimed in claim 23, wherein the pre-processing module comprises at least one grinder operable to grind plastics material into a more de-bulked or homogenised state.
25.Apparatus as claimed in claim 23 or 24, wherein the pre-processing module comprises a plastics shredder operable to shred plastics material.
26.Apparatus as claimed in claims 23 to 25, wherein the pre-processing module further comprises plastics cleaning means operable to clean plastics material prior to processing.
27.Apparatus as claimed in claim 26, wherein the plastics cleaning means comprises a steam cleaner.
28.Apparatus as claimed in claim 26 or 27, wherein the plastics cleaning means comprises a condenser for removing undesired washing fluid.
29.Apparatus as claimed in claims 23 to 28, wherein the pre-processing module further comprises a plastics sorting means operable to extract plastics material from used items made from plastics material.IS
30.Apparatus as claimed in claims 23 to 29, wherein the pre-processing module further comprises plastics drying means.
31.Apparatus as claimed in any of the preceding claims, further comprising conveying means operable to transport plastics material through the processing apparatus.
32.A method of processing plastics material comprising: (a) providing a hopper, a barrel having at least one screw disposed co-axially therewith, a breaker plate, disposed on a distal end of the barrel, wherein the barrel comprises one or more output apertures; and (b) providing a heater and a motor for driving the, or each, screw; characterised in that the method further comprises the following step: (c) providing a heated fluid to the heater whereby the source of the heat which heats the heated fluid is derived from the exhaust of the driven motor.
33.A method as claimed in claim 32, whereby the heater is suitable for heating plastics material.
34.A method as claimed in claim 32 or 33, whereby the motor is a steam driven motor.
35.A method as claimed in claims 32 to 34, whereby the heater comprises a heating jacket having an internal void for receiving the heated fluid.
36.A method as claimed in claim 35, whereby the heating jacket is disposed about the outer circumference of at least one of the hopper and the barrel.
37.A method as claimed in claims 32 to 34, whereby the heater comprises one or more conduits for receiving the heated fluid.
38.A method as claimed in claim 37, whereby the one or more conduits are adapted to extend around the outer circumference of at least one of the hopper and the barrel.
39.A method as claimed in claims 32 to 38, further comprising the step of providing a boiler and heating feed fluid via a heat exchanger to thereby provide steam for driving the motor.
40. A method as claimed in claim 39, whereby the boiler is a bio-fuel boiler.
41.A method as claimed in claim 39 or 40, whereby the boiler comprises a steam vent and the steam vent is opened to release steam below a predetermined temperature and/or pressure into a feed fluid conduit and closed to divert steam above a predetermined temperature/pressure towards the motor.
42.A method as claimed in claims 32 to 41, whereby the motor comprises a gearing mechanism operable to determine power transmitted to the screw.
43. A method as claimed in claims 32 to 42, further comprising providing a steam modulator and modulating at least one of the temperature and pressure of the steam exhausted from the motor.
44.A method as claimed in claims 32 to 43, further comprising providing a dynamo and generating electrical power from the dynamo.
45.A method as claimed in claims 32 to 44, further comprising providing a preheat module and preheating a working fluid.
46.A method as claimed in claim 45, whereby the preheat module comprises one or more solar heat tubes and a heat exchanger.
47.A method as claimed in claim 46, whereby the solar heat tubes comprise the working fluid and are arranged in a sealed cyclic system.
48.A method as claimed in claim 46 or 47, whereby the solar heat tubes are evacuated of air.
49.A method as claimed in claim 46, comprising transferring thermal energy between the working fluid and the feed fluid, through the solar heat tubes, prior to the feed fluid being fed into the boiler.
50.A method as claimed in claims 46 to 49, further comprising providing means to increase solar gain incident on the heat tubes.
51.A method as claimed in claims 46 to 50, comprising the step of providing the heat exchanger with an exhaust input which extends from the boiler.
52.A method as claimed in claims 32 to 51, further comprising the step of providing a feed valve and operating the feed valve in a first mode to prevent the feed fluid being fed into the motor below a predetermined temperature and in a second mode to allow the feed fluid to be fed into the motor above a predetermined temperature.
53.A method as claimed in claims 32 to 52, further comprising the step of providing a plastics pre-processing module.
54.A method as claimed in claim 53, whereby the pre-processing module comprises at least one grinder and comprising the step of grinding plastics material into a more de-bulked or homogenised state.
55.A method as claimed in claim 53 or 54, whereby the pre-processing module is provided with a plastics shredder and further comprising the step of shredding plastics material.
56.A method as claimed in claim 53 to 55, whereby the pre-processing module is provided with plastics cleaning means and further comprising the step of cleaning the plastics material prior to processing.
57.A method as claimed in claim 56, whereby the plastics material is cleaned using steam.
58.A method as claimed in claim 56 or 57 whereby the plastics cleaning means is provided with a condenser and further comprising the step of condensing undesirable washing fluid.
59.A method as claimed in claims 53 to 58, whereby the pre-processing module is provided with a plastics sorting means and further comprises the step of extracting plastics material from items made from plastics material.
60.A method as claimed in claims 53 to 59, whereby the pre-processing module is provided with plastics drying means and further comprising the step of drying plastics material.
61.A method as claimed in claims 32 to 60, further comprising the step of providing conveying means and conveying plastics material through the processing apparatus.
62.A method as claimed in claims 32 to 61, comprising the step of heating at least one of the hopper and barrel to a predetermined temperature.
63.A method as claimed in claims 32 to 62, comprising the step of driving the screw in rotation, whereby the speed of rotation is controlled by at least one of an electronic and mechanical controller.
64.A method as claimed in claims 32 to 63, comprising the step of feeding pre-processed plastics material into the hopper and feeding the plastics material from the hopper into the barrel at a controlled rate.
65. A method as claimed in claims 32 to 64, comprising the step of providing a die or mould in fluid communication with the breaker plate and receiving fluid plastics material into the die or mould via the output apertures of the breaker plate.
66.A method as claimed in claims 32 to 65, further comprising the step of providing cutting means and cutting the outputted plastics material into predetermined shapes and/or dimensions.
67.Apparatus as substantially described herein with reference to the accompanying drawings.
68. A method as substantially described herein with reference to the accompanying drawings.