Primary reduction equipment,
or slow-speed high-torque shredders, are used to process a variety
of materials across of wide array of industries involved in reclamation
and destruction. Instead of shredding material in a conventional
manner, primary-reduction equipment breaks material into smaller
pieces using impaction. Already popular outside the United States
in countries where landfill space comes at a high cost, the domestic
trend is following suit, as landfill space becomes increasingly
more expensive stateside.
Greg Wright is sales director at Granutech Saturn Systems. The
firm has been in business over 40 years, sells products worldwide
and “offers several lines of shredders that provide solutions
for challenging applications.”
He went on to describe, “Saturn, our most versatile line, offers
low speed, high torque, 2 and 4 shaft rotary shear shredders
(11-50 rpm). The Roto-Grind model is a ram-fed, single rotor
grinder (80-115 rpm), and our Grizzly product is a massive, gravity-fed,
single-rotor grinder (321 rpm),” Wright reported.
He said that choosing the shredder most appropriate for a given
job involves several factors, including the material to be shredded,
the amount of contamination in that material, the production
rate required and the final product size.
“Oftentimes, multiple machines or stages will be integrated together
to achieve the required result. For example, a company might
use our two or four shaft shredder, followed by our Grizzly shredder
to achieve maximum cleanliness, or a smaller product size. Our
focus is typically on the larger side of processing equipment,
with most of what we build being greater than 150 hp. We also
build a lot of hydraulic-driven equipment for the advantages
it has over electric-drive in tough applications. These advantages
include instant and multiple reversals of the shafts, no need
for an external gearbox or clutch, and the ability to clip amperage
spikes with no need to constantly re-start electric motors,”
He added, “When more than just shredding is required, we’re also
able to integrate ancillary equipment such as our conveyors,
eddy current or density separators, metal detectors, cross belt
magnets and air/dust collection systems.”
Wright claimed that as people everywhere attempt to reduce the
amount of waste generated and find new uses for what was once
considered waste, the need for finer processing continues to
grow. Waste-to-energy, biomass reduction, and refuse derived
fuel applications are becoming more prevalent, and many of these
applications require a small final shred size. “Our Grizzly shredder
is very successful in these applications because it produces
a very small and consistent product size – the ideal end product
for fuel usage,” Wright said.
Hammel shredders do it differently. “Our shredders operate under
a ‘ripping and tearing’ principle instead of ‘cutting and shearing.’”
This is how Ralf Semler, regional manager, at Hammel New York
differentiates Hammel shredders from those made by other manufacturers.
“This difference makes our machines extremely tolerant to any
kind of material contamination, which can quickly dull or damage
a sharp cutting edge type of shredder. Because we are not concerned
with maintaining sharp edges and tight tolerances in the shredding
mill, our maintenance and operating costs are among the lowest
in the industry,” said Semler.
Hammel’s main product line offers slow-speed, high-torque primary
shredders, offered in several models: VB450, VB750, VB850 and
the VB950 – the “Red Giant.” When processing solid waste, the
throughput capacity of these machines range from 10 tons per
hour up to 200 tons per hour.
Hammel products are manufactured in Bad Salzungen, Germany where
approximately 250 shredders are produced annually. “Hammel invented
the first synchronized dual-shaft, slow-speed, high-torque shredder
for processing dirty stumps 30 years ago. Since then, our products
have evolved to handle applications such as processing MSW, C&D,
green waste, industrial waste, counterfeit or confiscated goods,
tires with or without rims and scrap metal items such as white
goods, appliances, aluminum, steel – even entire cars,” Semler
He said Hammel’s product line focuses mainly on machines that
offer superior volume reduction, ferrous metal reclamation or
preparation (sizing) of material for further processing. The
company also designs and builds entire turnkey recycling plants
and special equipment according to customer specifications.
According to Semler, “Our newest products include the MMS 150DK
Mobile Metal Screen and the MWA 1000E Mobile Eddy Current Separator.
When used along with our VB950 primary shredder, we can provide
a mobile plant that is designed to process scrap metal, appliances,
white goods, etc. Ferrous, nonferrous and fluff elements are
reduced to a six inch or less size, and all three items are then
divided into separate streams for final output. Our mobile primary
shredders are self-contained and require no set-up other than
hydraulically unfolding the discharge conveyor.
“Most of our shredders are remote controlled and track-mounted
but we also offer semi-stationary and stationary machines.” Semler
believes that domestic market demand for the type of shredder
design offered by Hammel will continue to grow. “Domestic interest
in minimizing landfill usage is increasing and volume reduction
equipment is the simple, straight-forward solution whether it
is used on a transfer station to recover ferrous metals and reduce
trucked-off material volume or right at the working face of the
landfill, to increase compaction, recover ferrous metals, and
prolong the lifespan of each cell,” Semler predicted.
In the opinion of Jason Bradley, Republic Machine’s Modular Split-a-Part,
Eagle and Pipe Single and Multiple-Shaft Shredder cutting systems
incorporate the best of the firm’s patented engineering innovations.
Bradley, vice president of sales, explained the innovations further,
“The modular construction of our shredders facilitate the best
accessibility, easiest cleanout and most efficient maintenance
in the industry today. Our Modular Split-a-Part machine features
cutter knife rotation and the bed knife reduces readjustment
time by half compared to a typical non-split machine. Our patented
Zoidal Cutting product is a non-wrapping precision cutting system
designed to maximize production in a single pass and is utilized
in all film and fiber applications.
“The large Zoidal product is the gold standard for carpet shredding
and the system’s patented design provides throughput from 2,500
to 8,000 pounds per hour ‘sustainable.’ The product offers lowered
operating costs to less than a penny per pound when processing
more than a million pounds of carpet in a live production setting.
Our patented Monorail Self-Guiding Ram assembly eliminates the
need to replace any guide rails and is part of our Eagle Series
Single Shaft Shredder family.
“Perhaps most important of Republic’s latest innovations in single-shaft
shredders is our Insta-torque Detection System. This system provides
the most reliable drive train in the industry today, and the
ultimate protection to the gearbox in the event of metal contamination,”
Bradley said. Belt drive and right angle drive lash-ups are also
available. The Insta-torque system is included in all Falcon,
Eagle and Modular Split-a-Part single-shaft shredders made by
Republic and he believes the system represents the added value
customers demand and deserve.
In describing the company’s newest product, Bradley announced,
“Republic’s newly designed and re-engineered pipe shredder solves
the problem of pre-cutting pipe. It is the only North American-made
pipe shredder on the market that can grind 20-foot and longer
pipes. It is also the first North American-made pipe shredder
sold at an attainable price point. The machine’s modular design
includes a flexible size bed that begins at 20 feet and can be
extended to 60 feet long. The shredder is intended to serve well
in any difficult-to-process, single-shaft shredder applications.”
Bradley said innovations at Republic are driven by customer needs
that arise within the variety of markets they serve, and he expects
Republic Machine will continue as a leader in single-shaft size
reduction in North America.