Customized benefits

To optimize safety, productivity and return on investment, size-reduction systems in recycling applications can benefit from being designed and maintained as an integrated system by a sole supplier that also offers postinstallation support, says John Neuens, an industrial consultant for BCA Industries.

The Milwaukee-based recycling system original equipment manufacturer (OEM) provides complete custom recycling systems for a variety of complex industrial and commercial applications.

Neuens weighs in on when and how customization can provide significant benefits to the waste management process.

Construction & Demolition Recycling (C&DR): The environmental services sector is a huge, multifaceted marketplace. How does customization apply specifically to recycling applications?

John Neuens (JN): In the vast field of recycling, the variations of materials, size, processes and desired outputs can be virtually endless. In addition to paper, plastic bottles and aluminum cans, industrial recycling can include electronics, LEDs, batteries, catalytic converters, precious metals, medical supplies, construction materials and more.

Today, EV [electric vehicle] batteries can be nearly as large as the vehicle and laden with valuable materials to reclaim. Even outdated military ammunition and equipment need to be safely recycled.

There is so much variability in recycling material, size and processes that each shredding system really needs to be customized to meet the requirements of a specific application, with consideration of the desired throughput and profitability objectives.

C&DR: What kinds of issues can complicate recycling systems?

JN: Recycling equipment providers often manufacture only segments of a complete system, necessitating the involvement of engineering firms for the [proper] specification and assembly of component parts into a cohesive shredding system.

However, this can lead to a “Frankenstein” system that doesn’t work as intended and requires extensive troubleshooting.

For optimal efficiency, the shredding system should be designed by a single supplier to ensure seamless coordination and communication among the system’s component parts for achieving the desired output.

Ongoing technical support and maintenance are also required postinstallation.

It is common for recyclers to reach out months or years later with the desire to process new materials, many of which have different dimensions and feedstock.

A single point of contact and accountability is necessary to design and maintain a custom recycling system that delivers optimal productivity throughout its lifespan.

C&DR: What drives the need for recycling system customization and how extensive can it be?

JN: The need for a recycling system often begins with just an idea of the material that requires shredding. However, the ultimate requirements may involve a complex process of reduction, separation and destruction—with many repeated steps.

Given the array of potential outcomes, BCA, for instance, can design and manufacture thousands of shredder systems when considering all the possible markets.

Although BCA frequently collaborates with engineering firms on projects, the OEM’s in-house engineering staff can design a complete recycling system that meets the specific requirements of the materials, throughput and profitability.

C&DR: Can you explain some of the ways more complex systems require customization?

JN: Designing and manufacturing a recycling system is particularly challenging when large packages or assembled structures must be efficiently shredded. In the case of EV batteries, the recycler may start with a structure as large as 8 feet long, 4 feet wide and 1 foot thick filled with cells.

The first goal is to separate and reduce the material to a more manageable size. To facilitate this task, the OEM may use vibratory conveyors, which help to separate the packing material from the product and promote feed regularity.

The vibratory conveyors often move partially separated materials to shredders designed to provide primary destruction. A second or even third shredder may be required to reduce the material to achieve the required minimal size.

The material is then separated using various techniques. For example, ferrous materials may be separated using stationary overhead, head-pulley or cross-belt magnets.

While a magnetic separator may not capture all stainless steel, BCA employs rare earth magnets to attract and capture a significant percentage. Nonferrous metals such as copper and aluminum can be effectively separated using a combination of density separation and eddy currents.

Density separation differentiates materials according to varying weights, while eddy current separators utilize a robust magnetic field for the separation of nonferrous metals from a waste stream.

When very fine material sizes are required, such as 10-20 mesh, granulator or turbo mill systems can be utilized. For rubber, a cracker mill with chilled roller is used for breaking apart, plasticizing and mixing rubber materials.

Even if reduced to small sizes, efficient recycling necessitates the production of uniformly sized materials to facilitate the separation process.

C&DR: Tell us more about how that process works.

JN: For this task, BCA often implements its patented Triplus knife system technology, which uses the precision grabbing action of the high torque, dual-shaft shredder to cut the width of the material, while the bed knife design of the shredder sizes the length. This is accomplished in one operation, which produces accurately sized material in one pass without a screen. The end product size is based on the size and geometry of the knives.

It is also important to consider how the material will be packaged for shipping. This could involve totes, steel drums, bulk bags or even open-top truck trailers.

The outfeed system needs to be designed to accommodate how the client wants to ship the material.

C&DR: How do the parts of the system communicate with each other?

JN: Ensuring seamless integration and communication among all parts through the PLC- (programmable logic controller-) based control system is a critical challenge in shredding system design.

Engaging a third-party to develop a control system becomes significantly more challenging and costly when the component parts are sourced from multiple manufacturers. For this reason, BCA programs the PLCs and provides a copy of the software to the system owner so it can be reprogrammed in the future, if needed.

A quality system includes programmable software to adapt the system for various input types and materials.

C&DR: Is customization also required in other areas?

JN: Ideally, successful system implementation would extend to simplifying maintenance and operator training postinstallation as well.

The OEM does its best to “futureproof” the [processing] system to ensure there is continuity if a trained employee suddenly leaves. This entails being prepared to make adjustments when customers reach out in the future to modify the system for new material types or sizes, which is a common request.

Often the customer doesn’t know what the future holds in terms of recycling. It is common for recyclers to start with one feedstock and then request processing of additional materials of different types or sizes. Even the seemingly straightforward decision to switch to a hopper of a different size can pose challenges.

The geometry of the hopper significantly impacts performance. The hopper plays a crucial role in material orientation during the feeding process and must be properly implemented.

C&DR: Anything you’d like to add?

JN: Consolidating design, installation and ongoing support with one provider can streamline operations, reduce troubleshooting and facilitate adapting to new materials and processing requirements.

BCA Industries is an equipment manufacturer based in Milwaukee. Visit www.bca-industries.com for more information.