With a growing, industry-wide demand for technology that achieves more, is too much pressure being placed on machinery such as waste and recycling shredders, to the point that safety could be compromised? Our MD Marcus Brew recently spoke to Recycling & Waste World magazine about this very topic. If you missed the write up you can read it in full, here…
Whilst the majority of recycling, waste management or alternative fuel production facilities have an evident environmental agenda, it would be naïve to suggest that such plants exist purely for altruistic reasons. Of course the ‘green’ benefits associated with these operations are vital to the UK’s resource security and progress towards a more sustainable economy. But unless the businesses are community-backed, they exist to make a profit too.
This is nothing to be ashamed of – profit is not a dirty word and if organisations can responsibly harness the wealth in waste, then this is something to be praised. In fact, their actions may even inspire other organisations to think smarter about their own approach to resource management.
In the face of often turbulent market conditions, with fluctuating recyclate commodity values and changeable demand for EfW fuels for example, one of the ‘easiest’ ways to safeguard profit levels is to try to minimise the shredding costs per tonne.
But the term ‘easy’ is used very loosely here, because this cost-control objective is often far from straightforward to achieve.
For some operators, this performance-driven mindset homes in on the ‘need for speed’. After all, it is logical that the more material a shredder can handle, the higher the throughputs and the greater the revenue generating potential of the technology.
But, however simple this ‘capacity = profit’ mantra sounds in principle, it is actually far from being this clear-cut. Because, concentrate too much on speed and the inherent risks of the facility could soon escalate as a consequence.
The target speed for a wood shredder, for example, should be no higher than 60 rpm. Above this and the machine will generate a significant level of dust which not only makes for a dirty shredding process – it also poses a significant fire hazard.
Balance a slower rotor speed with high torque, however, and the technology can maintain throughputs of 40 tonnes per hour, whilst generating less dust and thus reducing the risk of a spark. Not only this – the true capacity of the shredder will be optimised too.
Sticking with the wood shredding example, the biomass market demands a fuel manufactured to a defined specification, for utmost energy value. Operators should therefore strive to maximise the proportion of ‘on-specification’ feedstock that they can manufacture if they are to optimise their revenues, not to mention customer satisfaction. Dust-like, non-specification material (fines) will therefore not suffice. In fact, it represents nothing but a cost.
Studies have shown that high-speed wood shredders can produce up to 25% of fines whereas with slower speed equivalents this figure will drop to as little as 5%. As a result, choosing the right machine can yield up to 20% more saleable product, reduce the disposal costs associated with non-biomass material and protect the fire safety of the plant.
It is also important to note that this throughput vs safety debate is not exclusive to the world of wood shredding. The processing of confidential paper presents similar risks if a high speed machine is used, for example. And it cannot be forgotten that high speed applications also typically result in high wear. This is both costly and disruptive from a maintenance perspective, and the greater downtime a plant experiences, the more the throughputs will be affected anyway.
So, is the industry demanding too much from shredding technology? Often, from a price perspective yes. But in general, no. Technology is advancing apace so why not search for a machine that can tick all the boxes? Heightened safety can be engineered, by design, thanks to the ongoing level of innovation within the market. And, improved safety mechanisms needn’t be to the detriment of performance, or the bottom line.
7 things to look for when buying a shredder
Of course every shredder investment must satisfy the unique requirements of the waste or recycling scenario at hand. But there are a number of fundamental considerations that all organisations should consider, before selecting the machine that’s right for them:
1. Start at the end and work back
Once the specification for the output material has been defined, it is easier to identify exactly what the shredder must be capable of in terms of particle sizing, capacity, flexibility, low fines and/or DIN levels for example.
2. Consider whole life running costs
Of course the initial price tag is important but it’s also crucial that longer-term financial elements are considered, such as the power consumption/tonne, the cost of spares and repairs, typical uptime statistics and the ease of maintenance. This will all affect the overall ‘value’ of the machine. In evaluating the affordability of the asset, enquire about the finance options that are available too, as gone are the days of ‘one size fits all’ procurement methods.
3. See the machine in action
Seeing is believing, so don’t just take the supplier’s word for it. Ask to witness the machine in action tackling a like-for-like application or, better still, trial the machine using the exact materials it will be tasked to handle! This is the only real proof that the technology will fulfil the brief once the order has been placed!
4. Prioritise operator wellbeing
It is no longer acceptable to overlook ergonomic design features such as the ability to operate and maintain the shredder in an upright position. Organisations have a duty of care to protect the wellbeing of their staff and legislation is only going to become more stringent in this respect, which explains why so many companies are now demanding machines that run at less than 80 dB(A) – the first action point for noise.
5. Think about the future
Nobody wants to over-specify their purchase and waste money on functionality they don’t truly need. But it is important to think about future requirements otherwise the investment could soon become obsolete. That’s why many shredders now offer flexibility as standard – such as configurable screens and adjustable particle sizing – to safeguard against this.
6. Don’t forget ongoing support
There’s more to a shredder investment than just the tech itself! For long-term peace of mind and an optimum running condition far into the future, select a shredder backed up with a proven customer support package inclusive of operator training, service and maintenance expertise, and readily-available spare and wear parts.
7. Prioritise experience over gimmicks
A knowledgeable supplier that truly understands the waste or recycling challenge at hand will enable you to reap rewards a hundred times over. They will be able to assist with everything from plant design optimisation, to the procurement of auxiliary equipment, finance negotiations and even the identification of target customers for the end ‘product’. The world of shredding is complex, so look for a specialist in this field, as their insight will prove invaluable.
If you’d like to speak to a member of the UNTHA UK team about your next shredder investment, please contact 0845 450 5388 or email sales@untha.co.uk.
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