Metal Shredder Suppliers

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Scrap metals are usually heavy objects which would be ridiculous to move in their original state. A perfect illustration is a used automobile, which occupies a lot of space yet is considerably lighter and easier to handle once it has been crushed and shredded. Shredding greatly reduces scrap metal's volume and separates it into smaller, easier-to-handle pieces.

The shredding procedure facilitates the separation of ferrous from non-ferrous metals and other materials such as rubber, plastics, and fabrics.

Metal Shredder Parts

Blades

Blades are a vital part of a shredder, but because not all blades are compatible with all materials, they must be carefully selected to suit the material to be shredded. For shredding various kinds of metals, several blades are used. They are made of hardened alloyed steel and can be coated to increase their useful life.

Rotor

To shred scrap and waste, a shredder's rotor comprises saw teeth cutters that mesh with knives.

Motor

The motor of a shredder operates at a low speed to minimize strain. The shredder can shred various materials because of its tremendous torque and slow rotating speed.

Housing

The housing, made of sturdy metal, contains every shredder component.

Types of Metal Shredders

Single Shaft Shredder

A rotor and hydraulic ram are employed in single-shaft metal shredders to press waste and debris against the rotor, which initiates the cutting action. Pressure sensors avoid jamming and material overheating by allowing the ram to move backward and forwards. These shredders, which come with different screen widths, can reduce large bulk materials into pieces as small as 0.4 in (10 mm). Every single single-shaft metal shredder has a classifier screen that offers the operator a range of measurement options to size output units.

Double Shaft Shredder

Due to its low working speed, high throughput, and high torque, which can efficiently treat a range of materials, the double-shaft metal shredder is a common industrial shredder. Industrial shredders with dual shafts can process various materials and may have electric motors or hydraulic drives.

Double-shaft metal shredders are particularly helpful for the volumetric reduction of materials, reducing the amount of space waste items would otherwise take up. Industrial dual-shaft metal shredders sometimes lack a classification grid. Still, their distinct blade shape and ability to manage production factors allow them to control the output material's size.

Three Shaft Shredder

Metal shredders with three shafts can be used alone or as the hub of customized shredding lines. The three variants (800-1000-1300mm) have capacities from 1.5 to 3.5 tons per hour depending on the type of material handled and include a screen for sorting the output material. The treated material's output sizes range between 1.2 by 1.2 inches (30x30 mm) and 2 by 2 inches (50x50 mm).

The metal shredder has a slicing system that combines a sweeper shaft and strong rotor blades. A three-shaft metal shredder also features a pivotable screen bin in the middle, individual cutter disc replacement, and bulkhead seals that protect the shaft bearing. In addition, there are mechanical and hydraulic three-shaft metal shredders with automated power-down and reverse functions.

Four Shaft Shredder

Two drive rotors on four-shaft metal shredders feed scrap metal to the lower cutting rotors. Separate gear motors propel these cutting rotors. These extra cutting rotors are employed to prepare materials for size reduction or further processing with a granulator. Four-shaft metal shredders are commonly used for trash not processed by a dual shaft, such as cars, and are comparable in size to a dual shredder. Industrial four-shaft metal shredders have been constructed for crushing a variety of materials as well as for dimensional management of the output material due to the availability of replacement classifying grids.

Metal Shredding Process

• The material to be processed is put into the shredder's hopper; some systems use a conveyor belt.
• Depending on the type and design of the shredded metal, the material is sliced into different sizes as it passes through the shredding machine. A secondary shredder can be used with some materials to reduce a particle's size further.
• To cut material to a set size with bulk shredders, sizing or discharging screens filter materials and send oversized bits back through cutting blades. Screens are manufactured to fit the type of metal and come in various sizes. Only properly aligned screens will cause the cutter to operate.

Choosing the Proper Metal Shredder Manufacturer

To make sure you have the most positive outcome when purchasing metal shredders from a metal shredder manufacturer, it is important to compare at least 5 manufacturers using our directory of metal shredders. Each metal shredder manufacturer has a business profile page that highlights their areas of experience and capabilities and a contact form to directly communicate with the manufacturer for more information or request a quote. Review each metal shredder company website using our patented website previewer to get an idea of what each business specializes in, and then use our simple RFQ form to contact multiple metal shredder companies with the same form.

Mobility combined with productivity for recycling

The stand-out feature of the mobile crusher or tracked impactor for recycling applications, is its mobility, combined with high productivity per hour. Units are fully self-contained on their tracked undercarriage and can easily be driven off a trailer by one operator and quickly put to work, with excellent capability for moving directly to materials. Some models are even capable of tracking (moving about on their tracks) while crushing.

"The ability to move within the job site and job to job is important to the contractor, or other end user, thus driving the demand for portable crushers," says Jody Beasley, national sales director at Screen Machine. "One of the biggest expenses in material processing is physically handling the material. Every time material is moved, labour and expenses are involved. Tracked impact crushers bring the machine to the job site, right to the pile, and allow for very efficient material processing.

"It's all about tons per hour. Our machines have been designed to produce maximum tonnage and one significant way they do that more efficiently is through our patented Crusher Relief System. The Screen Machine Crusher Relief System allows the operator to raise the crusher lid up to six inches while the machine is in operation. This is a huge help in preventing jams inside the crusher and ultimately delivers thousands of additional tons of product over the life of the machine."

Higher capacity crushing

According to Stephen Whyte, KPI-JCI and Astec Mobile Screens, "Mobile impact crushers are higher capacity than they were when they first came on. When the first tracked machines came in, they were seen as crushers that were highly portable but would do less weight than the typical portable [trailer-mounted] machine. Whereas now, some of the tracked machines we manufacture can reach those same capacities, and compete with the portable setups.

"Another great feature with our impact crushers is that they allow operators to crush and track at the same time," he continues. "This is why you'll see a lot of these units being used along the highway. One operator can basically load the machine and operate the tracked crusher at the same time."

"This is very important," adds Kolberg-Pioneer's Tim Harms. "You can be crushing and don't have to disengage the crusher to track the machine. You can continue to crush while the machine is being moved around on its tracks, which is a big advantage with respect to time savings. Time is of a huge value. If you lose 10 percent of your time, just because you've got to wait for the crusher to stop so you can move it, those are dollars."

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Impactor fuel efficiency and electric power  

Traditionally, mobile impact crushers have used a diesel-hydraulic engine for the track-drive and power to the crusher. The advent of electric-drive and hybrid systems is one of the main advancements that has occurred over the last decade, and its development is seen by many as one of the most significant trends going forward, especially considering the importance of fuel efficiency, rising transport and operational costs and the global focus on reducing emissions. 

"Lowest cost per ton produced is crucial in the customer's business," says Metso Minerals' product manager, Jouni Hulttinen, who adds that main focus areas in their Lokotrack line development have been ease of transport, maintenance and service, as well as safety and energy efficiency.

"Energy efficiency has been a very focused development area," says Hulttinen. "We have reduced fuel consumption up to 20 percent with our tracked impactors."  He says one good example is the Lokotrack LT1213(S) (‘S' designates a built-in screen component) which uses a ‘stand-by function' where the machine switches to idling mode if there is no load on the engine. "Just five minutes on stand-by, per hour, can save 10 litres of fuel per day."

Diesel-electric and fully electric power for crushing

According to Norbert Dieplinger, the drive systems in crushers manufactured by SBM are available as diesel-electric or can be run 100-percent electric. "Not only does electric power reduce the carbon footprint, it can save contractors up to 30 percent on fuel costs when you compare them to the diesel-hydraulic drive systems that were common in the past and are still used by lots of manufacturers," he says. 

For Kleemann, a division of the Wirtgen Group, the new EVO 2 Mobirex mobile impact crusher utilizes direct drive crushers and electric drives for the vibrating conveyors, belts and the pre-screen. 

"This permits high fuel efficiency and allows optimal loading of the crusher," explains Joe Schappert, Kleemann's senior technical sales manager. "Outstanding performance is made possible in part by the extremely efficient direct drive, with which these machines are equipped. A latest-generation diesel engine transmits its power almost loss-free directly to the flywheel of the crusher, via a robust fluid coupling and V-belts. This drive concept enables enormous versatility, as the rotor speed can be adjusted in four stages to suit different processing applications."

Buyer considerations 

A first question to ask when considering a purchase, according to McCloskey's John O'Neill, is: what do you want the machine to do? He says it is necessary for a solid sense of reality to be a big part of the buying decision. "Too many times the customer is upset because they expect peak performance to be the norm, when they need to be looking at all aspects of their operation and how it can support the crusher and the desired end goals or products."

SBM's Dieplinger says there are many considerations for buyers and agrees that the available support equipment needs to be considered. 

"What kind of support equipment is available and can it support the tonnage capacity of the crusher?" he asks. He adds that other important questions include: Who are the customers? What is the application you intend to use it for? What spec are you working with? How large are the piles to be crushed?" 

"If the impact crusher needs a part or maintenance items, can you be confident that the manufacturer will get those parts to you as quickly as possible?" asks Screen Machine's Jody Beasley. "Our machines are manufactured in Ohio, and all parts orders are fulfilled here. We pride ourselves on the fact that more than 97 percent of in-stock parts orders ship the same day." 

He adds that buyers should also consider long-term durability. "Critical parts of our machines are built with U.S.-made, Grade-80 steel, which is the toughest, most durable steel in the world."

"All impactors are not created equal, and the differences are significant," says Daryl Todd, Frontline Machinery. "We strongly suggest taking a close look when comparing various models. Start off with the technical specifications, including engine horsepower, the weight of rotor and blow bars, as well as ease of transport, machine weight and dimensions." 

Todd says there are many questions to ask, including: Is the rotor direct-drive from the engine, electric drive or hydraulic drive? What is the hopper capacity and feeding height? And what are the after-screen options - single-, double- or triple-deck? Does the machine have the ability to track while in full production? What type / quality are the key components such as hydraulics and electronics? And what is the type and quality of steel used in the frame, crusher housing and rotor? He adds that any mobile impact crusher should also have a user-friendly design, with ease of changing blow bars, and ease of access for maintenance and servicing.

Keestrack's Michael Brookshaw says one of the main questions to ask when considering an impact crusher is: can you transport the unit with your own transport means? "The material that you need to crush in your area is important," he says. 

"Look at the costs per ton involved on the purchasing and running of the unit. What are the amounts of material that need to be crushed? Are they large deposits of 30,000 tons or smaller deposits of 500 to 1,000 tons? You should also consider the feed size and capacity that you will need. Would electric drive provide an advantage on the environmental side of the business?" 

He adds that the technical aspects of the unit are also very important. Electric drive, pre-screen before the crusher, crusher overload system, pan feeder under the crusher, weight, as well as service and operator friendliness of the unit are all areas that need to be considered. Joe Schappert from Kleemann says that buyers considering a purchase should make sure they choose the correct size for the application and consider how product will flow through the crusher. 

"The Kleemann Continuous Feed System (CFS) manages a more equal loading of the crushing area, in which the conveying frequencies of the feeder trough and the pre-screen are adapted independently of each other to the level of the crusher, thus significantly boosting performance. 

"Our new impact crushers are differentiated by their size and productivity," continues Schappert. "Our model MR 110 Zsi EVO 2 has a crusher inlet opening of 43.3 inches (1,100 mm), and the MR 130 Zi EVO 2 has a crusher inlet opening of 51 inches (1,300 mm). These provide feed capacities of up to 350 or 450 tph, respectively. 

"Consider diesel-electric drives," he adds. "Our latest EVO 2 Mobirex mobile impact crushers utilize direct-drive crushers and electric drives for the vibrating conveyors, belts and the pre-screen. This permits high fuel efficiency and allows optimal loading of the crusher."

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