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Product Description
Every ton of powder you grind carries an electric bill, a labor cost, and a depreciation line. If your current pulverizer is a single disc machine, those costs are roughly 35–50% higher than they need to be.
Dual Disc series from Chenxing Machinery redefines the economics of plastic powder production. By equipping each machine with two grinding discs — a primary coarse disc followed by a fine finishing disc — achieves the same throughput in a single pass that a conventional single disc disc grinding pulverizer achieves in two separate runs. The result: double the output per kilowatt-hour, and a direct path to lower cost-per-ton grinding.
What does this mean for your operation?
Electricity consumption drops 35–50% for the same output, because one machine does the work that two used to do.
Throughput doubles compared to an equivalently sized single disc unit — your 800 kg/h line becomes a 1600 kg/h line without expanding your factory footprint.
Disc service life extends significantly, since the workload is distributed across two discs instead of concentrated on one.
If you are paying more than you should per ton of ground powder, the CX-Pro pays for itself on the electric bill alone — typically within 12–18 months.
The CX-Pro operates on a closed-loop continuous grinding principle that eliminates manual intervention and maximizes uptime.
Step 1 — Feeding: Raw material enters a cyclone silo, then passes through a vibrating feeder that meters granules evenly into the grinding chamber. The screw feeder ensures consistent material flow — no bridging, no surging.
Step 2 — Primary Grinding: Inside the grinding chamber, the first set of discs — a high-speed rotating disc against a stationary disc — shears the material through centrifugal force. This primary pass breaks down larger granules into coarse powder.
Step 3 — Fine Grinding: Material is immediately conveyed to the second disc pair, where it undergoes fine grinding to target mesh size. The two-stage progression means each disc operates within its optimal particle size range, minimizing energy waste.
Step 4 — Collection: A high-pressure blower draws powder from the grinding chamber through a cyclone collection system. An air-lock rotary valve controls discharge without breaking the negative-pressure seal.
Step 5 — Screening & Auto-Regrinding: Powder passes through a vibrating screen at the specified mesh. On-spec powder exits to packaging. Oversize particles are automatically conveyed back to the grinding chamber — zero manual sieving, zero operator decision points.
What This Means for Your Operation
The entire sequence runs under PLC + HMI control. An operator loads material at one end and collects finished powder at the other. There are no intermediate manual transfers, no guesswork on regrind timing, and no production halts for cooling. The dual air + water cooling system maintains safe operating temperatures even during uninterrupted 24-hour shifts.
| Model | Dimension L×W×H (mm) | Disc Diameter (mm) | Main Motor Power (kW) | Vibrating Sieve Dia./Power (mm/kW) | Blower Power (kW) | Capacity (kg/h) |
|---|---|---|---|---|---|---|
| -500Pro | 2290×1630×4500 | 510 | 55×2 | 1200 / 1.1 | 11 | 600–1000 |
| -600Pro | 2490×1680×4600 | 610 | 75×2 | 1500 / 1.5 | 15 | 800–1600 |
| -800Pro | 2890×1780×4800 | 810 | 110×2 | 1800 / 2.2 | 18.5 | 1600–2000 |
Note on capacities: Actual throughput varies by material type, target mesh size, and ambient conditions. The ranges above represent typical production values for PE/PP at 40–80 mesh. For material-specific guidance, see the throughput guide below.
Each CX-Pro system is delivered as a complete, pre-integrated grinding line. Every component below is included in the standard package — no separate sourcing required.
Raw material (granules, regrind flake, or edge trim) enters the cyclone silo, which doubles as a buffer reservoir. A variable-frequency vibrating feeder meters material into the grinding chamber at a precisely controlled rate. Unlike gravity-fed systems, the vibrating feeder eliminates surge loading — the discs always see a consistent material bed, which stabilizes motor load and extends disc life.
The heart of the CX-Pro. Two disc pairs operate in series within a single compact housing. The primary disc pair handles coarse reduction; the fine disc pair finishes to target mesh. Both discs are driven by independent main motors with direct coupling — no belts, no pulleys, no transmission losses. Disc gap is adjustable via the user-friendly access door, allowing rapid changeover between different powder specifications.
The CX-Pro is the only SMP disc plastic pulverizer in its class to offer dual cooling as standard. An air cooling circuit removes heat from the grinding chamber exterior, while a water cooling circuit circulates through internal channels, directly cooling the discs and bearing housings. The combined effect: grinding zone temperature stays 15–25°C below single-cooling competitors during extended runs. For operations in hot climates, an optional ventilation cooler boosts total cooling efficiency by an additional 30%. Consider pairing with a dedicated SML water-cooled chiller or SML air-cooled chiller for maximum thermal stability.
Finished powder exits the cyclone via an air-lock rotary valve and drops onto a ZSQ linear vibrating screen. The screen is fitted with mesh matched to your target powder specification. On-spec material passes through and is collected. Oversize particles ride the screen deck into a pneumatic return line that feeds directly back to the grinding chamber inlet. The entire loop runs automatically under PLC logic — no operator sorts, scoops, or re-feeds material.
The entire material path — from silo to screen discharge — operates under negative pressure. A dust collection unit captures airborne fines at every transfer point and returns them to the product stream. Air-lock valves at the cyclone discharge and dust collector discharge maintain the negative-pressure seal. The result: a truly dust-free production environment that meets increasingly stringent workplace air quality standards.
A centralized PLC with touchscreen HMI controls every function: feeder speed, disc motor load, blower RPM, cooling circuit status, screen vibration amplitude, and auto-regrinding valve position. Recipe storage allows one-touch recall of parameter sets for different materials. An optional mobile internet module enables real-time remote monitoring — check production status, motor temperature, and output rate from your smartphone, anywhere.
Feature: Two disc pairs — coarse primary and fine secondary — within a single grinding chamber. Material progresses from granule to finished powder without leaving the machine.
Advantage: Compared to single disc mills, which require either a second pass or a coarser target grind, the dual disc design achieves target mesh in a single continuous flow. This eliminates the throughput bottleneck common in single disc operations when targeting fine powder (60–100 mesh).
Benefit: Double the output of a same-frame single disc machine. A CX-800Pro delivers 1600–2000 kg/h — output that would require two conventional 800 mm single disc mills and twice the floor space.
Feature: Each main motor connects to its disc spindle through a rigid shaft coupling. No V-belts, no tensioners, no pulleys.
Advantage: Belt-driven transmissions lose 15–20% of input power to friction, heat, and slippage. Direct coupling transfers nearly 100% of motor torque to the disc. Additionally, belt systems require periodic tension adjustment and replacement — direct coupling is maintenance-free.
Benefit: 20% more usable grinding power from the same motor rating. Zero belt replacement costs over the machine's service life. No production downtime for belt changes.
Feature: PMSM motors with rare-earth rotor magnets, eliminating rotor copper losses inherent in induction motors.
Advantage: Induction motors — even premium IE3/IE4 units — lose efficiency at partial load, which is where pulverizers spend a significant portion of operating hours during material changeovers and ramp-up. PMSM motors maintain near-peak efficiency from 25% to 100% load. They also deliver higher power density — more torque from a smaller frame.
Benefit: 5–15% lower electricity consumption compared to a same-rated asynchronous motor, translating to thousands of dollars in annual savings for continuous-operation plants. Smaller motor footprint reduces overall machine size and factory space requirements.
Feature: A closed-loop circuit where oversize powder from the vibrating screen is pneumatically returned to the grinding chamber inlet, controlled by PLC logic.
Advantage: Traditional grinding lines require an operator to collect oversize from the screen, manually transport it back to the feed hopper, and re-introduce it. This is labor-intensive, inconsistent, and creates contamination risk from handling.
Benefit: At least 0.5 FTE labor reduction per shift. Consistent powder quality because regrind ratio is PLC-controlled, not operator-dependent. Hands-free operation means the operator focuses on upstream and downstream tasks instead of babysitting the screen.
Feature: Separate air and water cooling circuits. Air cooling handles the grinding chamber exterior; water cooling runs through internal channels around disc hubs and bearing housings.
Advantage: Single-cooling systems (air only or water only) struggle during extended runs — temperatures creep up, powder quality degrades, and the operator must pause production to let the machine cool. The CX-Pro's dual circuit maintains steady-state temperature regardless of shift length.
Benefit: Uninterrupted 24/7 operation with no heat-related shutdowns. Consistent powder quality from the first kilogram to the last. This is the difference between a machine that "can grind" and a machine that "can produce."
Feature: Complete enclosure of the material path from silo to screen discharge, with negative-pressure dust collection at all transfer points and air-lock discharge valves.
Advantage: Open or partially enclosed grinders release airborne fines into the factory — a respiratory hazard, a housekeeping burden, and a fire/explosion risk in certain materials. The CX-Pro contains all dust at source.
Benefit: Compliance with workplace air quality regulations. Reduced housekeeping labor. Lower contamination risk for color-sensitive applications like masterbatch grinding. Safer working conditions, particularly when processing PVC or other materials with regulatory exposure limits.
Feature: A dedicated oil pump circulates lubricating oil through the main bearing housings, simultaneously cooling and lubricating.
Advantage: Grease-packed bearings — the standard in most pulverizers — degrade predictably under the combination of high speed, high load, and elevated temperature inside a grinding chamber. Forced oil circulation actively removes heat and continuously replenishes the lubricant film.
Benefit: Main bearing service life extended by 50–100% compared to grease-lubricated equivalents. Fewer bearing replacements mean less downtime, lower spare parts cost, and more predictable maintenance scheduling.
Feature: Full-access side doors on the grinding chamber cabinet. All service points — disc gap adjustment, blade replacement, bearing inspection — are reachable without disassembling surrounding equipment.
Advantage: Conventional pulverizers often require partial disassembly of feed systems or guarding to access the discs. A routine blade change can consume half a shift. The CX-Pro's open-door design exposes the entire disc assembly immediately.
Benefit: Disc and blade changes completed in under 30 minutes. Reduced maintenance labor cost. More production uptime per year.
Feature: An add-on forced-air ventilation cooler module that supplements the standard dual cooling circuit.
Advantage: In hot climates or high-ambient-temperature factories, even dual cooling can approach its thermal ceiling during peak summer months. The ventilation cooler adds headroom.
Benefit: Maintains full production rate year-round, even when ambient temperatures exceed 40°C. Critical for tropical and desert-region plants.
Feature: IoT module with mobile app connectivity for real-time monitoring of motor load, disc temperature, output rate, and alarm status.
Advantage: Plant managers cannot be on the factory floor 24/7. Remote monitoring provides anywhere, anytime visibility into machine status and production metrics.
Benefit: Faster response to production anomalies. Data-driven shift performance comparison. One manager can oversee multiple lines across different locations.
The CX-Pro handles a wide range of thermoplastics and compounds. Below is a practical guide based on field data from installed machines.
| Material | Typical Mesh Range | Recommended Model | Expected Throughput (kg/h) | Notes |
|---|---|---|---|---|
| LDPE / LLDPE | 40–80 | -600Pro | 900–1400 | Excellent grindability; highest throughput material |
| HDPE | 40–80 | -600Pro | 800–1300 | Slightly harder than LDPE; expect ~10% lower throughput |
| PP | 40–100 | CX-600Pro | 800–1400 | Good grindability; fine powder (80+ mesh) favors CX-800Pro |
| PVC (soft) | 40–80 | CX-600Pro | 700–1200 | Dust collection essential; pair with PVC pelletizing line for integrated recycling |
| PVC (rigid) | 60–100 | CX-800Pro | 600–1000 | Hard material; benefits from larger disc diameter and dual cooling |
| PET | 40–80 | CX-600Pro | 600–1000 | Brittle; grinds quickly but requires careful temperature control |
| PA6 / PA66 | 40–80 | CX-800Pro | 500–900 | Tough material; larger motor power recommended |
| TPU | 40–60 | CX-600Pro | 500–800 | Elastic; keep feed rate steady to avoid disc glazing |
| EVA | 40–60 | CX-500Pro | 400–700 | Soft; lower power requirement |
| ABS / PS | 40–80 | CX-600Pro | 700–1200 | Good grindability; brittle fracture aids throughput |
| Masterbatch | 20–60 | CX-500Pro | 400–800 | Color change requires thorough cleaning; access door design speeds this |
| Nylon (PA) | 40–80 | CX-800Pro | 500–900 | See PA6/PA66 notes |
| PU | 40–60 | CX-600Pro | 500–800 | Monitor temperature closely |
Application scope: The CX-Pro excels in plastic granule and scrap-to-powder conversion; medium-hardness, impact-resistant, and brittle material precision grinding; PVC pipe/profile waste recycling for closed-loop production; WPC/SPC floor raw material preparation; and masterbatch/powder coating grinding. For granulation upstream, pair with a plastic pelletizer. For size reduction of larger scrap before grinding, add a plastic crusher.
| Criterion | -Pro Dual Disc | Conventional Single Disc | Advantage |
|---|---|---|---|
| Energy per ton | 35–50% lower | Baseline | Electricity bill cut by one-third to one-half |
| Throughput (same frame size) | Double | Baseline | Same floor space, twice the output |
| Transmission type | Direct-drive coupling | Belt drive (majority) | ~20% efficiency gain; zero belt maintenance |
| Motor technology | PMSM (permanent magnet) | Induction (asynchronous) | 5–15% additional energy savings |
| Cooling system | Air + Water dual circuit | Air only, or water only | True 24/7 continuous operation capability |
| Regrinding | Automatic closed-loop | Manual (operator scoops oversize) | 0.5 FTE labor reduction per shift |
| Dust containment | Fully enclosed, negative pressure | Partial or open discharge | Cleaner workplace; regulatory compliance |
| Disc service life | Extended (load distributed) | Shorter (concentrated load) | Lower spare parts cost per ton |
| Bearing lubrication | Forced oil circulation | Grease-packed | 50–100% longer bearing life |
| Access for maintenance | Full side-door access | Partial disassembly required | Blade change in 30 minutes vs. half a shift |
| Remote monitoring | Optional IoT module | Not available | Multi-line visibility from anywhere |
Bottom line: For a plant grinding 1,000 kg/h, the energy savings alone can exceed 30,000 per year depending on local electricity rates. Add labor savings from auto-regrinding, reduced spare parts from extended disc and bearing life, and increased output from higher throughput — the total cost-per-ton advantage typically ranges from 30–45%.
The CX-Pro is not just a better pulverizer. It is a fundamentally different economic proposition.
Field data from CX-Pro installations shows 35–50% lower energy consumption per ton of finished powder versus conventional single disc mills of the same frame size. This is driven by three factors: the dual disc design (fewer passes needed for target fineness), direct-drive transmission (no belt losses), and PMSM motor technology (5–15% more efficient than induction motors, especially at partial load). For a plant processing 800 kg/h over two 8-hour shifts, this translates to 25,000 in annual electricity savings depending on local kilowatt-hour rates.
Most customers recover the price difference between a CX-Pro and a conventional single disc mill within 12–18 months from energy savings alone. When factoring in labor reduction (auto-regrinding eliminates manual oversize handling), reduced spare parts consumption (longer disc and bearing life), and increased throughput (double the output from the same footprint), payback periods as short as 8–12 months are common in high-utilization operations.
Yes. The dual cooling system — air cooling for the chamber exterior, water cooling for internal disc hubs and bearing housings — maintains steady-state operating temperature regardless of shift duration. This is a key differentiator from single-cooling systems that experience thermal creep during extended runs. Many CX-Pro customers operate three-shift schedules without heat-related shutdowns. For plants in hot climates (ambient >40°C), the optional ventilation cooler adds an additional 30% cooling headroom.
In a conventional grinding line, the operator must collect oversize powder from the vibrating screen, carry it back to the feed hopper, and manually re-introduce it. This consumes 2–4 hours per shift depending on screen efficiency and target fineness. The CX-Pro's closed-loop auto-regrinding system returns oversize to the grinding chamber automatically under PLC control. The operator is freed for upstream and downstream tasks — effectively a 0.5 FTE labor reduction per shift. At typical factory labor rates, this saves 8,000 annually per machine.
The CX-Pro routinely achieves 60–100 mesh powder for SPC floor production and WPC applications. The dual disc design is particularly advantageous for fine-grinding applications because the workload is staged: the primary disc handles coarse reduction (extending its life), while the fine disc is dedicated to final sizing. Target mesh is set by the vibrating screen — simply install the appropriate screen mesh and the auto-regrinding system handles the rest. For SPC core layer powder at 80–100 mesh, the CX-800Pro is recommended for maximum throughput.
No — in fact, it is simpler. The CX-Pro's full side-door cabinet design provides immediate access to discs, blades, and bearings without disassembling surrounding equipment. A disc or blade change takes under 30 minutes. The direct-drive coupling eliminates belt tensioning, inspection, and replacement — a recurring maintenance task on belt-driven machines. The forced oil circulation system extends bearing life, reducing the frequency of bearing replacements. The only additional maintenance item is periodic coolant circuit inspection, which is a visual check. Overall, annual maintenance hours are typically 30–40% lower than for a belt-driven single disc mill.
Yes. The HMI recipe function stores complete parameter sets (feeder speed, disc gap, screen mesh, blower RPM) for each material. Switching from LDPE to PVC, for example, is a matter of selecting the PVC recipe on the touchscreen, changing the screen mesh, and performing a quick cleanout through the access doors — typically 15–20 minutes for the entire changeover. The open cabinet design makes cleanout fast and thorough, which is critical for color-sensitive applications like masterbatch grinding.
A belt-driven disc grinding pulverizer loses approximately 20% of motor power to belt friction and slippage before it reaches the disc. Over a year of continuous operation, this is tens of thousands of kilowatt-hours that generate heat — not powder. The CX-Pro's direct-drive coupling eliminates this entirely. Additionally, belt drives require periodic tensioning and eventual replacement (typically every 6–12 months in heavy use), adding labor and parts cost. Direct-drive is fit-and-forget.
Chenxing Machinery provides remote commissioning guidance as standard, with on-site engineer dispatch available for turnkey installations. Every machine ships with comprehensive documentation, wiring diagrams, and PLC program backup. Spare parts — discs, blades, screens, bearings — are stocked at our Zhangjiagang facility for same-day dispatch. For more complex integrated lines that include upstream sheet extrusion or pipe extrusion equipment, we offer full line commissioning services.
Taking the first step toward lower cost-per-ton grinding is straightforward:
Step 1 — Define Your Requirements: What material? What target mesh? What desired throughput? (Refer to the throughput guide above for initial sizing.)
Step 2 — Contact Nicole for a Quote: Reach out to our export team with your specifications. We will recommend the optimal CX-Pro model and provide a detailed quotation including shipping, commissioning, and optional modules.
Step 3 — Review the Complete Line Configuration: If your CX-Pro is part of a larger production line — such as an SPC floor production line, PVC pelletizing line, or sheet extrusion line — we provide integrated engineering support to ensure seamless upstream-downstream compatibility.
Step 4 — Commission and Start Saving: Installation, commissioning, and training support ensure your team is producing at full capacity from day one. Most customers report achieving nameplate throughput within the first week of production.
Contact Chenxing Machinery Today:
Contact Person: Nicole
Phone / WhatsApp: +8615951187228
Email: ceo@CXsljx.com
Company: Zhangjiagang Chenxing Machinery Co., Ltd.
Website: www.chenxingmachinery.com
