The production line of shredder+vertical crusher+dry mill achieves a purity of 99.5% for waste aluminum in the engine

1、 Customer background

Customer Name: Recycle

Industry field: Recycling of waste aluminum from used engines and automotive parts, with the core product being high-purity recycled aluminum ingots (supplied to European automotive parts manufacturers)

Collaboration time: March 2024

Core requirement: The engine scrap aluminum has a high impurity rate (iron, plastic, oil, rubber, etc.), and the original single crushing equipment cannot completely remove impurities. The purity of recycled aluminum is only 85%, making it difficult to connect with downstream high-end customers; At the same time, the dispersion of processes leads to low production capacity and environmental non-compliance, requiring an integrated production line of "crushing fine crushing grinding impurity removal" to achieve fine recycling of engine waste aluminum.

2、 Customer core pain points

Purity not up to standard: The engine structure is complex, and aluminum parts are closely combined with iron parts, plastic parts, and oil stains. The original equipment can only crush and cannot deeply remove impurities. The purity of recycled aluminum is less than 85%, and downstream manufacturers have lowered prices by 20%. The ability to undertake high-end orders is weak.

The process is inefficient and cumbersome: it requires manual disassembly of the engine casing, crushing, manual sorting, and cleaning. The four processes take a long time, with a single ton processing time of 2 hours. The daily production capacity is only 15 tons, which cannot digest the daily recycling volume of 30 tons.

Environmental Protection and Cost Pressure: Manual sorting and water washing to remove oil generate a large amount of oily wastewater and dust, which does not comply with the local Circular Economy Act and faces the risk of environmental fines; The single ton processing cost (labor+water and electricity+environmental protection) is as high as 300 euros, and the profit margin is severely squeezed.

Poor equipment adaptability: The original crusher was designed for ordinary scrap aluminum, and when processing hard aluminum parts such as engine cylinder blocks and pistons, the hammer head wears out quickly, with a monthly maintenance cost of over 12000 euros and a shutdown rate of 20%.

3、 Solution: Gangzheng Engine Waste Aluminum Fine Recycling Production Line

In response to the complex structure, high impurities, and high purity requirements of engine scrap aluminum, we have customized a three in one production line consisting of a shredder, vertical crusher, and dry mill, equipped with intelligent impurity removal and environmental protection systems

1. Core equipment linkage configuration

Heavy duty dual axis shredder (GZ-1800): equipped with 110kW dual motors, using wear-resistant alloy steel cutterhead, the feeding port can directly swallow complete engine aluminum blocks, and preliminarily separate large iron and aluminum parts.

Vertical crusher (GZ-1260): equipped with a 90kW motor and alloy hammer head, optimizing the crushing chamber for coarse crushed aluminum parts, cylinder bodies, etc., achieving "fine crushing+metal separation" through high-speed impact, with a discharge particle size of 5-10cm, and separating more than 90% of iron impurities through a magnetic separation device.

Efficient Dry Grinding Machine (GM-1000): Using low-temperature dry grinding to remove oil stains, dust, and small plastic particles on the surface of aluminum parts, the purity is greatly improved.

2. Upgrade the supporting system

Environmental protection treatment system: Closed dust collection+oil adsorption device, dust emission concentration ≤ 10mg/m ³, no wastewater generation, in compliance with German environmental standards;

Automation control system: PLC centralized control, achieving seamless connection of "feeding crushing grinding impurity removal", supporting remote monitoring of equipment operation status.

3. Service guarantee

Multinational technical team: A team of 4 engineers will travel to Germany to complete the installation, debugging, and environmental acceptance of the production line within 10 days;

Customized training: providing German operation manuals and on-site practical training, covering equipment operation, maintenance, and troubleshooting;

After sales support: 1-year complete machine warranty+6-month warranty for core vulnerable parts (hammer head, grinding medium), European local spare parts warehouse, response time ≤ 24 hours.

4、 Implementation effect (data-driven presentation)

Leap forward purity improvement: The purity of recycled aluminum has increased from 85% to over 99.5%, meeting the raw material standards of European automotive parts manufacturers. The purchase price has increased by 25%, successfully entering the high-end supply chain.

Doubling production capacity and efficiency: The single ton processing time of the production line has been shortened to 40 minutes, and the daily production capacity has reached 45 tons, an increase of 200% compared to before. It can easily digest the daily recycling volume and also undertake outsourcing business for surrounding enterprises.

Significant reduction in overall costs:

Labor cost: Only one operator and one inspector are needed per shift, saving 80% of labor costs and reducing expenses by approximately 18000 euros per month;

Maintenance cost: The equipment is optimized for hard aluminum parts, reducing the wear rate of hammer heads and cutterheads by 60%, and controlling monthly maintenance costs within 4000 euros;

Environmental cost: Eliminating the risk of environmental fines, eliminating the need for water washing and oil removal, saving about 6000 euros in monthly water-saving costs and sewage treatment costs.

Win win for both revenue and compliance: monthly net profit increased by approximately 65000 euros, with an investment return period of only 11 months; The production line has passed the T Ü V environmental certification in Germany and has become a demonstration project for fine recycling of waste aluminum in the local area.

5、 Customer feedback

Mr. Thoes, Technical Director of Recycle: "Gangzheng's three in one production line is the key to our business upgrade! Previously, the recycling of waste aluminum from engines was dirty, inefficient, and the purity was not up to standard. Now, from feeding to producing high-purity aluminum particles, it is fully automated, with a purity of 99.5%, which has enabled us to obtain supplier qualifications from many automobile manufacturers. The equipment has been running without any malfunctions for 8 months, and the dust and oil pollution issues have been completely resolved. The response speed of the after-sales team has also exceeded expectations. Next, we plan to double the scale of our production line to cover more aluminum recycling business for waste construction machinery! ”