About Industrial Shredders: Applications and Selection Criteria
Shredders play an indispensable role in many applications including manufacturing, recycling, substantial waste reduction, security, wastewater treatment, oil and gas production, the transportation and production of biosolids, and more. Shredding offers a multitude of benefits in addition to the most obvious – size reduction. Shredders are used for processing materials used for producing a product or fuel, protecting business intelligence by destroying secret product or documents, recycling of product or waste and shredding solids to ensure that other equipment or processes run smoothly. Corporations, government agencies and municipalities all use shredders.
Some industrial applications for reducing solids include the destruction of foods, pharmaceuticals, rubber, pallets, steel and plastic drums, furniture, construction debris, tires, containers, corrugated boxes, packaging, labels, and other bulky materials. Industrial shredders are also used for the destruction of documents, x-rays, media such as hard drives and other electronics to protect the privacy of individuals and corporate information.
Municipal applications include recycling centers and smaller shredders with multiple cutting teeth for finer reduction for use in wastewater treatment plants. The recycling industry has found many uses for shredders such as shredding tires for the recovery of rubber. This recycled rubber is found in many applications and products including hot melt asphalt, basketball courts, playgrounds, and shoe products. The rubber is also used in civil engineering practices for the sub-grade insulation of roads, backfilling, and for fuel as “Tire Derived Fuel”. fragment wood is shredded for recycling and used for the manufacture of many types of wood products such as particle board and paper. Plastic bottles are recycled into PET (polyethylene terephthalate) plastic chips for the production of new bottles. Recycling or reusing all of these products by shredding reduces waste in the ecosystem, increases corporate profitability, and reduces carbon emissions.
SELECTING THE RIGHT SHREDDER
kind of Material to be Processed
Different types of shredders excel at processing specific materials. Tree branches are typically shredded using a high-speed chipper. Plastics are most often processed in a granulator (rotary knife cutter) however; bulky plastic shapes are often put into a shredder as a first stage before granulating. When planning to shred cars, this kind of application is typically achieved using a hammermill. Although, processing a variety of waste materials may require versatility with a minimal amount of noise and dust, then a twin shaft shredder can be the optimal solution.
Understanding the output size requirement will help in calculating the kind of equipment to install. Some facilities require the material to be separated, while others may need re-shredding and grinding. A single-pass shredder will cost less but if the material needs to be reduced to a very small size and compressed then compaction equipment may be required.
Choosing a shredder to manager the correct capacity is important to the success of any installation. Capacity is typically expressed in pounds per hour and is determined by the physical size, weight (bulk density), and the amount of material to be shredded. The capacity may be limited by the cutting chamber size. Check the capacity rating carefully before purchasing the machine and allow for some excess capacity. Using a shredder with a maximum capacity too close to the desired capacity can rule to a shortened service life. However, over-sizing a shredder by a wide margin can rule to excessive strength use and take up too much floor space.
Two basic satisfy types are shared: manual and automatic. Manually fed shredders usually have a hopper and work by either hand feeding the material or using a fork lift to drop the material in. Automatic feeders or conveyors help optimize shredder performance by giving a continued and regular supply of materials to the shredder.
Portability, safety, and noise are concerns when selecting a shredder. Select the proper location for the shredder because it is not easy to move a machine weighing a half ton or more. Depending on the material, dust and other airborne particles can be an environmental danger. Noise is another factor to consider as some shredders (such as hammermills) create more noise than others.
Shredders persevere a great deal of stress and maintenance is necessary to keep them running efficiently. Cutters, blades, or hammers will use under normal use and require sharpening, adjusting, or ultimately replacing. Consider maintenance, repairs, and ease of obtaining substitute parts when choosing a manufacturer. Always estimate the access location for maintenance when calculating where to locate any equipment including your shredder.
TWIN SHAFT SHREDDER
One of the most versatile types of shredders is the twin shaft shredder, such as the Franklin Miller TASKMASTER Shredder. These devices use two similar counter rotating stacks of cutters that intermesh at low speed under extremely high torque. As the cam shaped cutters intermesh at close clearance, they cut, shear, tear, slice, and rip apart a variety of materials into smaller pieces typically in a strip or chip-like output shape. The geometry of this dual shaft cutter also makes it very good at feeding in irregular shaped solids. This kind of shredder generally employs no sizing screen so the output particle is determined by the cutter shape. Twin shaft shredders may be designed for specific solids such as tires, medical waste, documents, bottles with liquids and more. The specifics of the application determine the configuration of the unit although some shredders have a specific design for only one application and are not versatile by any method. The shredder’s form numbers usually describes the unit’s cutting chamber length and width. The complete unit is typically comprised of the main cutting mechanism with shafts, cutters, bearings, excursion and housings, stand, hopper (a funnel like feeding chute), and a controller either mounted on the unit or in other places.
In operation, the material is fed into the top hopper of the unit and is discharged out the bottom. Some shredder designs can be set up vertically in addition as horizontal. Specific designs are fitted with progressive shaft seals and sealed housings appropriate for handling liquids.
As there are varying degrees of quality, accuracyn, engineering and care from different supplies of shredders, the choice of a manufacturer in addition as kind of shredder can greatly influence the success of the installation.
CRITERIA FOR SELECTING THE RIGHT SHREDDER:
• Is the shredder rated for the capacity to meet your requirement?
• Is the shredder made by a manufacturer with long-term experience and a reputation for customer service?
• Can the shredder manager your material in addition as unprotected to the desired output particle size and consistency you desire?
• Is the shredder rated for liquids in addition as solids, if necessary?
• Does the shredder have a design and cutter chamber size appropriate for your materials?
• Do you have the electrical service to meet its strength requirement?
• Is the shredder obtainable with the options or materials you require?
• What are the maintenance requirements?
• Is the shredder of a strong design for long-term dependable operation?
• Does the manufacturer offer the sustain and guidance to help you in the selection, installation and sustain of the equipment?
As you can see there are many considerations before selecting a appropriate shredder. Gathering all the necessary information to match against the shredders specifications will help shorten the time of action of matching the equipment to your requirement. If you are considering recycling, check that you have the necessary permits. Seeking skill and advice from a reputable company is a good start and requesting a demonstration using a sample will confirm the shredder’s effectiveness. Visit the manufacturer’s website to review the company’s history and read some case studies to learn how other businesses have used shredders to solve operational difficulties. The last part of the equation is calculating your budget. Keep in mind some units, although initially are less expensive may be inferior quality and in actuality cost more long-term to function and continue.