Attar Metals cuts shredder wear with new pre-shredder
Managing risk is a key aspect of running a shredder, as material streams become increasingly inconsistent and equipment complexity grows. For Canada’s Attar Metals, a full-service recycler, protecting the shredder meant focusing upstream. Tony D’Alonzo, maintenance manager with four decades of experience, says reducing stress on material before it reaches the rotor is vital.
Before 2023, Attar Metals fed raw material directly into its shredder line, resulting in frequent breakdowns and heavy strain on the system. The primary concern was safety, as explosions can occur when high-speed rotors generate friction and sparks, especially if material contains residual fuels or pressurized components.
In April 2023, Attar installed the Blue Devil, a low-speed pre-shredder from Zato, to prepare material before it reaches the primary shredder. The machine uses a twin-shaft, high-torque configuration with counterrotating shafts and replaceable cutting blades that shear material rather than fracture it through impact.
The results have been significant, with reduced maintenance demands, fewer reactive repairs, and more predictable service intervals. D’Alonzo estimates the savings at roughly 30% on shredder-side maintenance, a substantial figure given the high costs of running a shredder operation.
The benefits extended beyond the shredder itself, with lower shock loads and more consistent feed easing wear on conveyors, bearings, and other downstream equipment. Safety also improved, as the Blue Devil reduced the likelihood of high-energy events inside the shredder by handling oversized and potentially hazardous material under controlled, low-speed conditions.
When choosing a pre-shredder, Attar’s team assessed integration with the existing line, maintenance demands, and technical support. D’Alonzo points to three practical priorities for operators considering upstream pre-processing: safety first, then the machine’s capability relative to the operation’s specific needs, and finally, the level of support offered by the supplier. Zato’s ongoing technical support has remained an important part of the investment, given the sophistication of these machines.
By adding pre-processing, Attar Metals has been able to reduce wear and improve safety upstream, ultimately leading to cost savings and a more stable system. This approach can be applied to similar situations, where managing risk and reducing stress on material can lead to significant benefits. In the context of the recycling industry, this shift in focus can help operators like Attar Metals to improve their overall efficiency and safety.
