Case Study: Twin-Shaft Tire Shredder for Secondary & Tertiary Cutting
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The Challenge: Managing Blade Wear in Steel-Reinforced Tire Shredding
A tire recycling facility required a high-performance solution for secondary and tertiary cutting of passenger tires into uniform pieces. The primary technical hurdle was the extreme abrasive wear caused by internal steel wires. Standard shredder blades deteriorate rapidly in these conditions, leading to frequent downtime and inconsistent particle sizing. The client needed to achieve a final output of Φ28 mm or smaller while balancing the high cost of specialized tool-steel blades against the unit’s overall Operational Expenditure (OPEX).
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Our Solution: Heavy-Duty Twin-Shaft Shredder with Integrated Sizing Grate
Our team engineered a bespoke twin-shaft shredder configured for precision size reduction:
- High-Torque Twin-Shaft System: Utilises a dual-axis shearing mechanism to provide the high-torque force required to cut through both rubber and steel reinforcement.
- Integrated Φ28 mm Sizing Grate: A custom-manufactured grate was positioned at the discharge to ensure only material of the correct size passed through, while oversized pieces were automatically recirculated.
- Advanced Metallurgy for Blades: We selected specialized, high-hardness alloy steels for the shredder blades. While these materials increase initial costs, they provide a significantly longer service life against wire abrasion.
- Optimized Cutting Geometry: The blade profiles were designed to minimize heat buildup, protecting the rubber quality for Tire-Derived Fuel (TDF) or crumb rubber applications.
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The Result: Consistent Granulometry and Controlled Maintenance Costs
Our twin-shaft system delivered a reliable, high-output processing line:
- Precision Particle Sizing: The Φ28 mm grate successfully delivered a homogenous end-product ready for tertiary processing.
- Extended Maintenance Intervals: By utilizing superior blade metallurgy, the plant achieved longer production runs between blade changes, reducing the frequency of maintenance shutdowns.
- Balanced OPEX: The facility now operates with a clear understanding of the cost-per-tonne ratio, using high-durability blades to stabilize production costs despite the aggressive nature of the feedstock.