Product Descriptions
Wanner Xtra Series Granulation Machines
Screenless, Quiet, and Controlled Size-Reduction Technology for Brittle and Glass-Fiber-Reinforced Plastics
The Wanner Xtra Series granulation machines are screenless, toothed-cylinder granulators specifically developed for processing brittle, hard, and glass-fiber (GF) reinforced plastics. The Xtra Series is designed for safe in-line operation next to injection molding machines, particularly in applications where conventional knife granulators are insufficient or where high noise levels, excessive dust formation, and inconsistent granulate quality occur.
This series is based on Wanner's low-speed, high-torque, and controlled crushing principle. Thanks to screenless granulation, the granule size is defined by the geometry of the toothed cylinders, resulting in almost dust-free, homogeneous, and uniformly shaped regrind.
Working Principle of the Xtra Series
In Wanner Xtra Series machines, star-shaped primary crushers operate together with toothed cylinders instead of the conventional rotor-knife-screen structure. Large and brittle sprues or parts are first reduced in a controlled manner by the primary crushers. The material is then guided over the toothed cylinders, where it is reduced to the final granule size.
The granule size is determined by the tooth width of the toothed cylinders, with standard options of 4 mm or 5 mm. This design provides several key advantages:
The risk of screen clogging is completely eliminated
Excessive fine dust formation in glass-fiber-reinforced materials is prevented
Granule size remains stable and highly repeatable
Xtra Series machines operate at very low rotor speeds of approximately 30-32 rpm. This significantly reduces noise levels while ensuring gentle, impact-free processing of the material.
Xtra Series Models and Technical Specifications
The Wanner Xtra Series consists of three main models designed to meet different production volumes and sprue sizes.
Xtra 1 Model
Compact solution for small and medium-sized brittle sprues
Crushing chamber opening: 260 × 170 mm
Number of primary crushers: 1
Rotor speed: approximately 32 rpm
Cutting module (granule size): 4-5 mm
Motor power: 1.1 kW
Machine weight: approximately 200 kg
The Xtra 1 model is ideal for the quiet and stable grinding of small glass-fiber-reinforced sprues and hard, brittle parts directly next to the injection molding machine.
Xtra 2 Model
Balanced performance for medium-scale applications
Crushing chamber opening: 260 × 260 mm
Number of primary crushers: 2
Rotor speed: approximately 32 rpm
Cutting module (granule size): 4-5 mm
Motor power: 1.5 kW
Machine weight: approximately 220 kg
The Xtra 2 is the most widely used Xtra model in injection molding lines and is ideally suited for integration with robotic feeding systems and sprue pickers.
Xtra 3 Model
High-capacity solution for large and bulky brittle sprues
Crushing chamber opening: 260 × 350 mm
Number of primary crushers: 3
Rotor speed: approximately 32 rpm
Cutting module (granule size): 4-5 mm
Motor power: 2.2 kW
Machine weight: approximately 250 kg
The Xtra 3 model has been developed specifically for the safe processing of large, thick, and bulky glass-fiber-reinforced sprues.
Low Noise Operation and Operator Comfort
One of the most distinctive advantages of the Xtra Series granulators is their extremely low noise level. Thanks to the low rotor speed and toothed-cylinder crushing principle, they operate far more quietly than conventional knife granulators.
As a result:
The need for additional sound enclosures is eliminated in most applications
Operator comfort in injection molding areas is significantly improved
Occupational safety and ergonomics are enhanced
The screenless design also reduces vibration levels, contributing positively to machine service life.
Energy Efficiency and Intelligent Control Systems
The Wanner Xtra Series can optionally be equipped with Green Line and IQ Line energy-saving control systems.
Green Line Control System
The machine operates only when required thanks to an automatic start-stop function
Idle running times are eliminated
Energy savings of up to 70 percent can be achieved in typical injection molding applications
IQ Line Control System
Frequency inverter-based design allows precise adjustment of rotor speed
When the speed is reduced, energy consumption decreases almost proportionally
Energy usage, operating times, and maintenance data can be digitally monitored via the OPC-UA interface
Provides full Industry 4.0 compatibility
Modular Design and Application Flexibility
Xtra Series granulators can be supplied in numerous configurations, including standard hoppers, robot-fed hoppers, sandwich sheet-metal hoppers, high stands, bag-filling systems, mobile suction-box stands, and optional dust extraction units.
In addition, customer-specific solutions are available, such as:
Compression feeding systems for large sprues
Special hopper designs for separation systems
Customized feed hoppers for injection molding machines from manufacturers such as Arburg, Engel, and Sumitomo Demag
Ease of Maintenance and Long Service Life
Xtra Series machines offer exceptionally easy maintenance thanks to their tool-free, fully openable crushing chamber. The crushing chamber opens completely, allowing free access to the toothed cylinders. Areas that could cause material accumulation are minimized.
This design results in:
Shorter cleaning and maintenance times
Faster material changeovers
Increased machine uptime
The robust geared motor drive and wear-resistant components ensure that the Xtra Series delivers stable performance over many years.
Conclusion
Wanner Xtra Series granulation machines provide a screenless, quiet, low-dust, and energy-efficient recycling solution for brittle and glass-fiber-reinforced plastics. With a design optimized for in-line use next to injection molding machines, modular configuration options, and long service life, the Xtra Series is an ideal investment for manufacturers seeking high quality and low operating costs.
