Case Study: Twin-Shaft Shredder & Depackaging System for Biogas
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The Challenge: Automated Depackaging of Liquid-Filled Waste
A biogas production and recycling facility faced the complex task of processing large volumes of expired Tetra Pak containers (milk, juices, yogurts). The requirement was two-fold: the packaging needed to be destroyed for secure disposal, and more importantly, the organic liquids had to be efficiently separated from the solid plastic/foil waste. Manual separation was impossible at scale, and the facility needed a turnkey depackaging solution to recover high-value organic feedstock for their digesters while sending clean solids to the recycling chain.
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Our Solution: Integrated Shredding and Drainage Screw Technology
Our team engineered a high-torque, dual-stage processing line:
- Twin-Shaft Shredder (44.0 kW): We installed a heavy-duty twin-shaft shredder powered by two 22.0 kW motors. This unit provides the shearing force necessary to instantaneously rupture and shred multi-layered Tetra Pak packaging.
- Integrated Drainage Screw (Screw Press): Following the shredding stage, the material enters a specialized drainage screw conveyor.
- Perforated Sizing Screen: The screw features a precision-perforated sheet metal base. As the material is moved, centrifugal and mechanical pressure forces liquids (e.g., chocolate milk, orange juice) through the perforations.
- Dual-Stream Discharge: The system was configured with two distinct recipients: one for the liquid organic feedstock (destined for biogas production) and another for the shredded solid packaging waste.
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The Result: High-Efficiency Feedstock Recovery and Waste Diversion
Our depackaging system delivered a highly profitable circular economy solution:
- Effective Liquid-Solid Separation: The plant achieved near-total recovery of organic liquids, significantly increasing the calorific value of their biogas feedstock.
- Clean Recycling Streams: The shredded solids are discharged “dry” and ready for secondary recycling processes, reducing landfill costs.
- Reliable Industrial Throughput: The 44.0 kW power configuration ensures the system handles dense, wet loads without stalling, providing a consistent flow for the recycling unit’s 24/7 operations.