1800 heavy-duty shredder+355 crusher car shell processing production line, helping Middle Eastern recycling enterprises double their production capacity

1、 Customer background

Customer Name: Auto Recycling Co

Industry field: dismantling of waste cars, recycling and reuse of waste metals (core materials: waste car shells, engine casings, door frames, etc.)

Collaboration time: January 2024

Core requirement: The original single equipment for processing car shells has low efficiency and uneven particle size, which cannot meet the procurement requirements of downstream metal smelters for "fine crushing+high purity". A complete production line is needed to achieve one-stop processing of "car shell coarse crushing fine crushing resource utilization", while improving production capacity and reducing comprehensive costs.

2、 Customer core pain points

The processing flow is cumbersome: the original small shredder cannot directly process the entire car shell, and needs to be manually cut into small pieces twice before entering the shredder. The processing capacity of a single device is only 3-5 tons per hour, and the daily production capacity is less than 30 tons, which cannot digest the daily 100 tons of car shell recycling.

The discharge quality does not meet the standard: impurities such as plastic and glass are mixed in during the secondary processing, and the particle size fluctuates greatly (20-50cm). The purchase price of the smelting plant is 18% lower than the industry average price, and the bargaining power is weak.

Human resources and safety risks: The manual cutting process requires 4-5 workers to work in shifts, resulting in high labor intensity and potential safety hazards such as metal fragment scratches and mechanical injuries. Labor costs account for 25% of monthly revenue.

Poor equipment stability: The original equipment has insufficient adaptability to hard materials (such as engine casings), frequent jamming, fast wear of the cutterhead, monthly maintenance costs exceeding $8000, and downtime accounting for 15%.

3、 Solution: Gangzheng 1800+355 Automotive Shell Special Processing Production Line

In response to customer pain points, we have customized a "1800 heavy-duty double axis shredder+355 high-efficiency crusher" linkage production line, equipped with a complete auxiliary system:

1. Core equipment configuration

1800 heavy-duty dual axis shredder: equipped with high-power dual motors and a 150mm thick alloy steel disc (customized "wolf tooth" teeth), specially adapted for tough materials such as car shells and metal frames. The feeding port can directly swallow the complete car shell, with a coarse crushing capacity of 15-18 tons per hour and a discharge particle size controlled at 15-25cm, achieving "one-time coarse crushing instead of manual disassembly".

355 type high-efficiency crusher: equipped with a 355kW motor and wear-resistant hammer head, optimized crushing chamber design for rough crushed car shell fragments. The discharge particle size can be adjusted (3-5cm), with a fine crushing capacity of 12-15 tons per hour to ensure uniform discharge. At the same time, plastic and rubber impurities attached to the surface are separated by high-speed impact.

2. Linkage supporting system

Intelligent conveyor belt: connects two devices to achieve seamless connection between coarse and fine crushing, without the need for manual transportation, reducing material loss;

Overload protection+automatic cleaning device: avoids hard material jamming and reduces the risk of shutdown;

Dust removal and noise reduction system: meets local environmental standards and improves the working environment in the workshop.

3. Service guarantee

On site installation and debugging: Establish a 3-person technical team and complete the production line setup and trial operation within 7 days;

Customized training: Conduct 2-day specialized training for operation and maintenance personnel, and provide multilingual operation manuals;

After sales support: 1-year warranty for the entire machine+6-month warranty for the cutterhead/hammer head, overseas after-sales response time ≤ 48 hours.

4、 Implementation effect (data-driven presentation)

Doubling production capacity: The daily processing capacity of the production line has reached 100 tons, an increase of 60% compared to before. It can easily digest the daily recycled raw materials and even undertake the outsourcing business of surrounding peers, adding new revenue channels.

Comprehensive cost reduction:

Labor cost: Only one operator and one inspector are needed per shift, saving 75% of labor costs and reducing monthly labor expenses by approximately $15000;

Maintenance cost: The equipment has been running stably for 10 months without major malfunctions, and the wear rate of the cutterhead/hammer head is lower than the industry average. The monthly maintenance cost is controlled within 3000 US dollars;

Transportation cost: After fine crushing, the material density increases, and the loading capacity per vehicle increases from 5 tons to 12 tons, reducing the unit transportation cost by 58% and saving approximately $8000 in transportation costs per month.

Significant increase in revenue: The discharge purity has been increased to over 98%, the purchase price of the smelter has been raised by 15%, combined with capacity improvement and cost savings, the monthly net profit of the customer has increased by about $42000, and the investment return period is only 4 months.

Compliance and safety upgrade: The production line complies with Saudi environmental and labor safety standards, eliminating safety hazards of manual cutting, and the customer successfully obtains long-term cooperation qualifications with local smelters.

5、 Customer feedback

Mr. Omar, General Manager of Auto Recycling Co.: "Gangzheng's 1800+355 production line has completely changed our operating model! Previously, processing car shells was slow and expensive, but now with fully automated feeding and discharging, our daily processing capacity of 100 tons makes us more competitive in the local recycling market. The most surprising thing is the quality of the discharge - the uniform and clean fragments have prompted the smelter to actively increase the purchase price, and the equipment has been running for almost 10 months without any problems. The after-sales team's response is also very timely. We have planned to purchase another production line to expand our recycling scale