Reducing risk and damage
Shredder plants face a variety of risks on a daily basis, including the all-to-common explosions, noise and other environmental concerns.
Not only are these risks laboring on the shredder operator, they result in costly damages, downtime and inefficiencies in the shredder operation.
Increase shredder throughput
Installed upstream of the primary shredder, preshredders can help reduce and defuse material before it is fed into the shredder. In addition to reducing the risks of unshreddables and explosions, preshredders can homogenize incoming material, allowing the shredder operator to better control the feed rate for the main primary shredder.
Based on before-and-after studies of a Metso EtaRip preshredder and a 98-inch Metso Texas Shredder, the average tons per hour processed increased by more than 17 percent.
A preshredder can improve wear life on the main primary shredder’s castings, protect against unshreddable or explosive materials and reduce peak power loads to the shredder.
Depending on a yard’s downstream processing capacity and market conditions, some yards can benefit by yielding the same tonnage of output but with fewer operating hours. This reduces operator burnout, labor costs and energy costs without sacrificing throughput. It also can allow for routine scheduled maintenance to keep the shredder operating in peak condition.
By stabilizing the operating load of the shredder with preprocessed material, the main primary shredder can operate in a more efficient energy range, reducing or eliminating “peak loads” as charged by utility companies. This is an especially important feature for shredder yards that are charged on an electrical power demand basis.
Lower cost per ton processed
In testing, we found a 20 percent reduction in hammer consumption when material was preprocessed with an EtaRip preshredder. Similarly, less high-impact shock results in longer life for the complete power driveline.
In a power consumption analysis, there was nearly a 14 percent kilowatt-per-ton energy savings by preprocessing material with an EtaRip preshredder.
Together, the savings from wear parts, reduced energy costs, increased operational efficiencies and greater material throughput can significantly lower the cost per ton processed.