Southeast Asian scrap metal recycling plant efficiency increases by 60%, transportation costs drop by 40% directly

1、 Customer background

Customer Name: Indo Metal Recycling

Industry field: Recycling and reprocessing of industrial scrap metals (scrap steel, scrap aluminum, automotive shells, metal drums)

Collaboration Time: May 2023 Core Requirements: Addressing the pain points of large volume, high transportation costs, and low manual crushing efficiency of scrap metal raw materials, while improving material purity to meet the high standard requirements of downstream smelters.

2、 Customer core pain points

The raw material form is complex: the recycled lightweight scrap steel, scrap metal drums and other materials have irregular volumes, with a single weight of 50-200kg, making manual disassembly difficult and low safety.

High transportation costs: Unscented scrap metal has a porosity of 70%, and each vehicle can only load 3-4 tons. The unit cost of long-distance transportation to the smelter is as high as $80/ton.

Low processing efficiency: The original small crusher could only process 1 ton of material per hour and was prone to material jamming, requiring 2-3 workers to be on duty. The daily production capacity was less than 8 tons, which could not meet downstream order demands.

Insufficient material purity: Impurities (such as plastic and rubber) are mixed in during the manual shredding process, resulting in a 15% -20% decrease in the purchase price of the smelter.

3、 Solution: Customized solution for Gangzheng dual axis metal shredder

In response to customer needs, we recommend the GZ-1400 dual axis metal shredder and provide customized supporting services:

Equipment customization: equipped with a 75KW power motor and wear-resistant alloy steel disc, optimized disc spacing (80mm) for hard materials such as color steel tiles and metal drums to ensure crushing efficiency and discharge uniformity; Equipped with automatic feeding device and overload protection system to avoid material jamming and shutdown.

Capacity adaptation: Designed with a processing capacity of 5-6 tons per hour, in line with the customer's raw material recycling scale, it can operate continuously for 24 hours.

Supporting services: Provide on-site installation and debugging, operation training, as well as 1-year warranty and lifelong technical support to ensure the rapid production of equipment.

Material optimization: After shredding, the particle size of the discharged material is precisely controlled, the porosity is reduced to below 30%, and some impurities are separated by squeezing with a disc cutter to improve metal purity.

4、 Implementation effect (data-driven presentation)

Significant efficiency improvement: The daily processing capacity of the equipment has reached 70 tons, an increase of 60% compared to before. Only one worker is needed to operate a single shift, saving 67% of labor costs.

The transportation cost has sharply decreased: after crushing, the material density has increased, and the loading capacity of each vehicle has increased from 3-4 tons to 8-10 tons, reducing the unit transportation cost to $48/ton and saving about $12000 in transportation expenses per month.

Significant revenue growth: Material purity increased to over 95%, smelter purchase price increased by 12%, combined with efficiency improvement and cost savings, customer monthly net profit increased by approximately $35000.

Outstanding stability: The equipment has been running continuously for 12 months without major malfunctions, the wear rate of the cutterhead is lower than expected, and maintenance costs are controlled within 2% of monthly revenue.

5、 Customer feedback

Mr. Adi, Head of Indo Metal Recycling, said, "Gangzheng's metal shredder has completely solved our core problem - the transportation cost and labor efficiency used to be the most headache, but now the equipment runs stably for 18 hours a day. The crushed materials are not only more cost-effective to transport, but also sell at a good price. The team's installation and after-sales response are very timely, and even if there are operational problems, they can be quickly resolved. This gives us more confidence in expanding production capacity in the future, and we have recommended it to three neighboring peers.