Shredder industrial shredder. What is an industrial shredder? Types of industrial shredders

Most shredders are designed to work with high-quality wood, so it is difficult to process thick, twisted trunks and branches.

Any nail that gets caught with wood causes such serious damage that further work possible only after repair.

Unlike these devices, the shredder is initially designed to work in harsh conditions– it will easily crush wood with twisted fibers, and in most cases a nail, small metal fragment or bullet that gets inside will not harm it.

During rotation, the shaft with its hooks (knives) hooks and drags it towards the breaker knife.

As it approaches the chipping knife, sometimes called the counter-knife, the piece of wood being chopped takes up a position in which further movement or even rotation is impossible.

When this happens, the hooks begin to crush the wood, breaking off big pieces. Having reached the counter knife, hooks act as scissors and cut debris wood into pieces of a certain size.

Then all the shredded wood either goes into the hammer mill, where further crushing occurs, or flies out.

Thanks to the low (200–300 rpm) shaft rotation speed and enormous torque, the shredder easily crushes wood of any species, and also cuts metal parts that are not too thick.

Due to the fact that the hooks move quite slowly, when meeting parts made of non-hard grades of steel, they do not receive serious damage. But this is precisely what is most common cause breakdowns of shredders of other models.

The shafts are made of high-alloy steel, which has high strength, and are also hardened different ways, due to which the part receives high strength.

Varieties

These shredders differ in:

• number and design of shafts;
• wood supply method.

Number and design of shafts

The most popular are single- and double-shaft shredder models. In a single-shaft model, the shaft works together with the breaker knife, and in double-shaft devices, both shafts simultaneously act as shafts and breaker knives for each other.

Twin-shaft devices are noticeably more expensive and more complex, but have higher productivity. However, it is more difficult to regulate the size and shape of the chips.

On single-shaft devices Most often, the shaft is made in the form of a blank (cylinder), to which knives are attached using bolts.

This design is more difficult to manufacture, but more maintainable - if the knives are damaged, then simply unscrew the countersunk bolts and replace them.

On twin-shaft Shredders are used composite shafts made from a hexagonal shaft and replaceable bits. Half of the attachments are equipped with knives, the second half is smaller in diameter and serves as a counter knife. If one or more knives are damaged Both shafts will have to be removed for repairs., then disassemble them and replace damaged parts.

For the production of small chips, stacking shafts are used, in which the thickness of each nozzle is 5–10 mm. The gap between the nozzles of both shafts is tenths or hundredths of mm, and the greater the thickness of the nozzles, the smaller the gap.

This is due to the fact that splitting up wood leads to shaft heating, and thin parts heat up faster, which means they have higher thermal expansion.

Sometimes composite shafts are assembled with a slight offset at each attachment, resulting in a total offset along the entire length of the shaft of 5–25 degrees. This design is better suited for chopping curved wood.

Wood feeding method

In shredders 3 methods of supplying material are used:

• top loading, in which the wood is pressed against the shafts by its own weight and the weight of the pieces lying above it;
• gear (gear), in which rotating gears engage the wood and push it towards the knives;
• pressing (pusher), in which the wood is pushed towards the knives by a special plate connected to a hydraulic, electric or crank drive.

Top loading used only on the cheapest shredders, because it cannot create enough pressure for rapid processing wood, which reduces productivity.

The lack of sufficient pressure leads to the fact that a piece of wood constantly rotates until it reaches a position in which both the shaft and the counter-knife will interfere with further rotation.

Despite some shortcomings, this method of feeding wood is becoming increasingly popular. The reason for the increase in popularity is that such shredders are easier to load using technology, because you just need to pour the trimmings into the receiving hopper, and gravity will do the rest.

Often top loading is combined with a pusher, thanks to which it is possible to eliminate the main drawback of the press feed - the limitation on the height of the press. Excess wood will rise up the hopper while the press is moving, and after it returns, it will take up the free space.

Gear feed

Gear feed system wood provides constant pressure, sufficient for effective grinding of any wood. Toothed gears are made in the form of shafts, the length of which is equal to the width of the space intended for the movement of wood.

Thanks to this, the chopped wood receives a forward momentum, regardless of the location in which it is located.

In some shredders, the height of the space for the movement of wood exceeds the size of the shaft protruding above the counter knife, so they provide for the redistribution of the crushed material.

To do this, the mobility of the last feed gear installed in front of the chopping shaft is limited by the height of this shaft, due to which the lower layer of wood first passes under it, then, after its end, the upper one passes.

This system allows you to load quite large volumes of crushed material, but only works well with logs and branches.

Typically such a feed system connected to a separate electric motor through a powerful gearbox with a large gear ratio.

However, there are models where the grinding shaft and feed system are connected to the same motor.

All gears are connected to each other by a chain transmission, due to which, at low rotation speeds, they create huge torque.

Most often, this drive is used where it is necessary to shred not waste, but non-commercial round wood, so such shredders are not widely used. After all, such a drive greatly increases the price of an already very expensive unit for chopping wood.

Pusher

Pusher used on small-capacity shredders designed for grinding wooden material small sizes, for example, chopped firewood, trimmings of trunks and branches or parts of chipboard, MDF and other wood.

Regardless of the drive type, it creates such pressure, which ensures fast grinding wood, because no time is wasted waiting for the correct position to be achieved.

However, this also limits the speed at which the pusher returns to its original state. After all, you have to choose a balance between speed and pressure, so the return time is 1–2 seconds.

Such feeding systems always powered by a separate electric motor, because there is always a possibility that you will get caught too hardwood, which the shredder cannot shred in normal time.

If the feed system and shredder shaft are connected to a common motor, this may lead to its complete stop. If the engines are different, then in such a situation the load on the motor of this system increases sharply, which can be compensated in various ways.

For example, we use the principle of a car clutch, in which a large load causes the discs to slip relative to each other. In a feeding system with hydraulic drive a bypass valve can perform the same function.

On systems with electric drive automation reduces the current strength, which is why excess pressure on the wood disappears.

A significant disadvantage of this system is limited amount of material, which can be loaded into them.

Exceeding this amount will cause the feed mechanism to jam, because for maximum efficiency it is necessary that upper layer wood did not exceed the level of the upper edge of the shaft or shafts.

Therefore, exceeding the amount of wood will lead to the fact that some of it will rest against the body and cause jamming. Because of this, such systems are used only in small-capacity shredders.

Advantages and disadvantages of these wood chipping units

Main advantage shredders of this type is that they suitable for processing any material, including those containing metals, wood. At correct setting all shredder mechanisms, it is made of any wood produces technological chips which we talked about.

Therefore, wood crushed with its help can be used for any purpose, with the exception of manufacturing, because it does not meet the requirements for wood chips. You can read more about wood chips for wood concrete and the equipment for its production here (Chips for wood concrete).

Changing the shape and size of chips

They are better suited for producing wood chips from trunks and branches. gear driven devices. When feeding whole trunks, the wood comes into contact with the knives at the end, which is why the knives not only crush it, but also immediately separate it along the border of the growth rings. The resulting chips are short, thin and narrow.

If the trunks and branches are first cut into pieces, the length of which is equal to or slightly less than the length of the shaft, then the knives begin not to crush the wood, but to separate them into fibers, which is why the chips are wide and quite thick.

Top loaders are better suited for shredding small-sized waste. When processing long trunks or cuttings of suitable length that move down parallel to the shafts, the chips obtained are the same as described above.

However, small-sized cuttings fall differently all the time, so the shape and size of the chips also turn out different.

The same thing happens in press-feed shredders, where the feed press constantly moves in and out of the shaft.

That's why change the size and shape of wood chips in shredders with top and press feed almost impossible.

However, in gear-fed shredders, you can change both the feed speed and the shaft speed. An increase in feed speed, as well as an increase in shaft rotation speed, leads to a decrease in chip size, and a decrease leads to an increase in size.

Popular models and their prices

We did not include prices for shredders in the table, because their cost directly depends on the configuration, which is why the same shredder model, but in different configurations, can differ significantly in price.

In addition, many manufacturers and intermediaries offer the manufacture of shredders to specific requirements, so that maximum efficiency can be achieved at a minimum cost.

Modern furniture and woodworking enterprises are faced with the problem of grinding waste from the production of chipboard, fiberboard and MDF boards, veneer, plywood, pallets/containers and lump waste. For such problems, the ideal solution is wood shredders UNTHA(Austria). The equipment is capable of processing all types of wood waste into chips: shavings, branches and other recyclable materials for boiler houses, providing further production biofuel and creation of wood concrete blocks.

Technical features

In UNTHA model LR shredder crushers, processing is carried out by a shaft with replaceable knives and a movable plate that pushes the material onto the shaft. To obtain chips of a certain size, a replaceable sieve is used.

Raw materials are fed into the loading hopper manually or mechanically. Next, using a hydraulic press plate, it is pressed against a rotary mechanism with knives for chopping.

The pressure force of the plate is adjusted automatically. The operation of the equipment continues until all the raw materials are completely crushed to the desired fraction.

For waste that is difficult to crush - durum varieties wood (beech, oak, birch) - a particularly durable and reliable grinding mechanism with increased wear resistance of all components is required. For the LR line, a safety margin has been specially developed and included for processing the hardest materials, designed for a long period of operation.

Advantages

• Rich experience – the Austrian brand has been in the shredding equipment market for 40 years.
• Demand - more than 8,000 machines have been put into operation around the world.
• Highest quality manufactured with a large margin of safety.
• Usage modern technologies in the manufacture of equipment.
• Own engineering and design department.
• Individual approach in solving every problem.

Advantages of KAMI

Shredders for waste or recycled materials are also called shredders or knife mills. The main purpose of this equipment is crushing, reducing the size of the fraction for subsequent use of solid waste. Shredders are typically used to crush waste or recyclable materials into a smaller fraction. The waste is reduced to reduce volume, followed by compaction. Recycled raw materials: metal, plastic, PET bottles, rubber, wood, etc. reduced to chip sizes - from 30x30 cm to 10x10 cm, for subsequent grinding using a knife mill or sale in the form of chips.

Shredders vary in the number of shafts in the design according to need - from one shaft to four shafts. Shredders have in their design a different number of crushing elements installed on both the rotor and stator. Knife mills are equipped with knives for finer grinding of the fraction. The types of crushing and grinding elements also differ: removable and located directly on the disks.

Typically, to achieve the goal of grinding a fraction to a certain size, several devices are used, e.g. car tires it is necessary to use two or three shredders for coarse grinding and one or two knife mills to achieve a fraction size of 3 mm. The size of the fraction at the outlet of the knife mill is regulated by an installed sieve. The resulting fraction at the exit of this equipment allows us to produce useful products through processing, for example, wood briquettes for heating, rubber tiles, additives in production road surface, rubber pads, from flex film for the production of granules, etc.

Shredders for solid waste and secondary raw materials are used in work

• waste sorting complexes;
• recycling centers;
• manufacturing enterprises;
• companies involved in processing raw materials;
• film and plastic granulation lines;
• tire processing plants.

Shredders designed for crushing:

• solid household waste;
• metal;
• plastic;
• PET bottles;
• bulky waste;
• wood, etc.

Order

Today Russian market recycling of solid household waste is developing rapidly. This is due to the fact that laws have been introduced and put into effect regulating the procedure for the delivery, disposal and processing of all types of waste. Among other things, waste recycling is a necessary and important area in our country, which allows us to obtain secondary raw materials used in the production of new goods during the processing process, and also solves many environmental issues.

Any enterprise engaged in processing and disposal of waste requires specialized equipment for processing, crushing and loading waste, producing finished products of recycled material, as well as reducing volumes during further transportation or disposal at solid waste landfills.

Industrial shredder

The ALFA-SPK company offers modern and compact industrial shredders for the processing and disposal of solid waste waste of its own production. Industrial shredder from our company - minimum investment, fast payback period, minimum number of working personnel, mobility, quality and reliability. We offer optimal solutions in the field of waste processing and shredding for waste processing enterprises, both large and small towns And populated areas. From us you can order and buy the industrial shredder (waste shredder) you need for your company at affordable price. As well as related equipment for loading and cutting waste into dimensions.

Universal industrial shredder (waste shredder) with a capacity of up to 500 kg per hour or more, depending on the raw material. Ideal for businesses with low waste generation. Crushes wood, plastic, construction and other solid waste.

Industrial shredder for crushing solid waste, as well as raw materials suitable for recycling. Ideal for companies involved in waste recycling and construction. Productivity up to 1 ton per hour or more.

Industrial shredders, models ATR/S-2000, are manufactured in a stationary version; they can be equipped with a conveyor and separators. Productivity up to 2 tons per hour or more depending on the raw material. Ideal for processing construction waste and solid waste.

Shredders of the ATR/M-3000 model are manufactured in both stationary and mobile versions. Equipped with conveyors, magnetic and other cleaning separators. Easy to transport. Productivity up to 3,000 kg per hour depending on raw materials. The optimal solution for large companies and landfills for solid waste processing.

Twin-shaft industrial shredder for recycling construction and household waste and other solid waste. Productivity up to 4 tons per hour. Manufactured in stationary and mobile version. Ideal for companies involved in waste processing.

Hydraulic shears for cutting waste. Used for cutting worn tires, ferrous and non-ferrous scrap, cables, fittings, aluminum, wood, plastic and other waste in the required size. Knife length 900 mm. One person is required to operate the scissors.

Many clients call us and ask us to select "crusher-shredder" for grinding any type of waste, and the most advanced certainly want this "shredder type crusher" crushed ALLtypes of plastics and almost into a finished granule.

Shredder type crushers simply does not exist in nature, since industrial shredders And crushers- this is equipment different classes and they perform different tasks.
In this article we will look at industrial shredders , their types and advantages.

Industrial shredders used for primary (coarse) materials that are difficult to grind to a fraction of 150-20 mm, which cannot be crushed in crushers.

Advantages of using an industrial shredder compared to impact crushers:

• the ability to grind waste of any thickness;
• less wear on knives due to slower rotation of the rotor;
• low cost of maintenance;
• lower noise level.

Industrial shredders effectively crush massive wood waste, tree trunks, railway sleepers, various construction waste, tires, solid waste, old furniture, refrigerator cases, wooden pallets with nails, woodworking waste, waste wood sheet materials, waste paper, glass waste, thick-walled plastic waste, bulk plastic containers, sprues, plastic pipes, PET bottles, film, that is, almost any type of existing waste.

According to their design, shredders are divided into:

• Single-rotor shredders with hydraulic press plate;
• Two-rotor and four-rotor shredders.

Single-rotor shredders.

Single-rotor (single-shaft) shredder is a low-speed shredder with a hydraulic press plate (pre-presser) for crushing waste of large thickness and high resistance to crushing: corrugated cardboard, wood waste, wooden boxes and pallets, various types of plastics, bulk polymer containers, plastic pipes, sprues, solid waste, car tires.

The operating principle of a single-rotor (single-shaft) shredder:

The material to be crushed is fed into the feed hopper of the shredder. Loading of material can be done manually or mechanically, using an inclined conveyor or loader. A hydraulic press plate (presser) with a reciprocating motion presses the incoming material against a rotating rotor with knives installed on it, which carry out the grinding. The pressure force of the hydraulic press plate is adjusted automatically. When the maximum pressure is applied to the shredder cutting shaft, the press plate automatically stops feeding material and returns to its original position.
The grinding process continues until the particles of the crushed material can pass through the cells of the fractional sieve installed under the shredder rotor.

Video of a single-shaft shredder in operation

The size of the final material fraction depends on the cell diameter of the fraction sieve (15-150 mm.). The rotors of single-shaft shredders are made smooth and profiled, coated with wear-resistant alloys.

When grinding hard, abrasive or easily heated materials, the profiled rotor more evenly distributes the resulting heat from friction over the entire area of ​​the rotor, which prevents overheating or sticking of the raw materials and winding on the rotor.

The cutting knives of the shredder are attached to the rotor using screw connections.
When the knife becomes dull, you need to: unscrew it, turn it 90°, screw it back on and continue using it. Square knives of a single-shaft shredder last 4 times longer.

Twin-shaft shredders.

Twin shaft shredder Thanks to the high torque, it allows you to grind almost any waste.

Description of the operation of a twin-shaft shredder. When loading waste into the loading hopper (1), they are captured by knives (2) in the form of hooks and cutting discs (3), mounted on two shafts moving towards each other and crushed to the required fraction. And the side pads (4) clean the knives, discs and ensure that the material falls down.

Four-shaft shredder.

Quad shaft shredders capable of grinding any types of waste: municipal solid waste (MSW), bulky waste (BWW), polymer waste of varying hardness and thickness, paper, cardboard, wood, leather and textile waste, car tires, rubber waste, asphalt. Description of the operation of a four-shaft shredder. A four-shaft shredder has two main shafts (4) and two auxiliary shafts (3). Auxiliary shafts are equipped with special sharp-angled cutting discs (3) and hook-shaped knives (2). The knives of the auxiliary shafts begin to crush the waste and, thanks to their hook-shaped shape, catch the crushed material and drag it to the knives of the main shafts, which complete the grinding. The grinding of the material continues until the crushed waste particles reach such a fraction that they can easily pass into the cells of the installed sieve (5). Industrial shredders most often used in the polymer industry for grinding defective products - injection moldings, drains, pipes, various profiles, large injection molded products and in the processing industry for grinding - municipal solid waste (MSW), bulky waste (cabinets, sofas, refrigerators, windows, doors ), electrical cables, various wood waste (wood waste, stumps, wooden pallets, boxes), cardboard, waste paper, packaging waste, car tires, rubber waste, asphalt, etc.

According to their purpose, industrial shredders are divided into:

• universal shredders capable of shredding almost any type of material;
• shredders for solid waste and construction waste, with inclusions of a significant amount of metal;
• wood shredders (wood waste, wooden pallets, boxes with nails);
• shredders for plastics, allow you to grind any types of polymers;

Universal industrial shredders.

Universal industrial shredders can effectively grind various types of materials: wood processing waste, wooden logs, wooden boxes and pallets, cardboard, polymer film, plastic sprues, pipes, mixed types of waste, into a smaller fraction, which is regulated by the diameter of the sieve cells. Mainly used for grinding waste for subsequent disposal. For coarse grinding they have high throughput.

Main manufacturers of universal shredders:

• ZERMA - ZSS series shredders
• 3E - WT and GL series shredders

You can view the models in the section of our catalog

Industrial shredders (shredders) for solid waste and construction waste.

Industrial shredders for solid waste and construction waste designed for primary (coarse) grinding wooden logs of any diameter, stumps, uprooting waste, wooden sleepers, old furniture, bulk wooden structures, woodworking waste, wooden pallets, mixed polymer waste, soil, mixed construction waste.
Capable of grinding waste with metal inclusions up to 20% of the total volume.
Grinding fraction: 150-250 mm. They have very high productivity: 50-700 m3/hour.
Most often used for grinding recyclable waste at landfills for very large volumes.

The main manufacturers of industrial shredders for solid waste:

• HUSMANN Umwelt - HL series shredders
• HAMMEL – VB series shredders
• DOPPSTADT – DW series shredders

You can view the technical specifications in the section of our catalog

Industrial shredders for chopping wood.

Wood shredders designed for grinding various types wood waste: woodworking waste, boards, slabs, short tree trunks, chipboard waste, plywood waste, wooden boxes, wooden pallets with nails.

Shredders of this group are capable of crushing wood waste to a minimum fraction of 15 mm, which can be used for subsequent processing as fuel or process chips.

They have different productivity (from 100 kg/hour to 5000 kg/hour).

Depending on the required task and the type of material being crushed, they can be equipped with various additional options:

• Different types of rotors

• More fast system hydraulics to increase the performance of the hydraulic pusher
• Installing additional rows of knives on the rotor. Depending on the type of material being crushed, extra row knives on the rotor can increase grinding productivity by 15-25%.

• Hydraulic Press Tooth Plate - Ensures that the hydraulic pusher of the shredder firmly grips bulky and inconvenient waste. This option is effective when shredding wooden boxes, pallets, as well as large polymer containers.

• Segmented floor of the grinding chamber on 4 sides - eliminates the formation of gaps between the hydraulic pusher plate and the walls of the grinding chamber. This option prevents small waste particles from entering the shredder, which can often occur during shredding different types wood and plywood.
• Roller system for fastening the hydraulic pusher plate. Ensures easier movement of the pusher plate.

Main manufacturers of wood shredders:

• ZERMA - ZWS series shredders
• Votecs (similar to WEIMA) - EZ series shredders
• 3E - WT series shredders

WITH technical characteristics Shredders for wood can be found here:

Industrial shredders for shredding plastics.

Industrial shredders for plastics (plastics) used for grinding any polymer waste: polymer films, profiles, plastic pipes, sprues, castings, PET bottles, waste from injection molding and thermoforming production. They have different productivity and grinding fractions. For plastic crushing, a two-stage scheme is usually used with primary grinding in a shredder and subsequent additional grinding in plastic crushers. Single-shaft shredders are used to shred almost all types of plastics. Since polymers are characterized by increased strength and abrasiveness, shredders for plastics are manufactured with a significant margin of strength and wear resistance.

Major manufacturers of plastic shredders:

• ZERMA-shredders of the ZBS, ZSS, ZIS, ZXS, ZRS series
• Votecs (similar to WEIMA) - EZK series shredders
• ENMA - ESS series shredders
• 3E - WT series shredders