Operators need to do their homework when assessing the right shredder for their needs.
With shredders playing an increasingly crucial part in waste management and recycling facility operations, operators need to ensure these assets deliver on performance. But for equipment that was once required simply to act as a heavy-duty workhorse, today’s shredders must now demonstrate far more sophisticated performance criteria if they are to provide a true return on investment.
Here are 10 things to consider when thinking about purchasing a new shredder.
The first component of finding the right shredder for your needs is considering the specifics of the materials you wish to shred. Assess the type and bulk density of the waste you’re handling, as well as any likely variation in this specification and the preferred in-feed method for loading the shredder. These factors will influence everything from the drive power and the the chamber dimensions to the cutter capabilities and the height of the machine. It’s also important to define the likely volume of input materials that need to be processed and at what pace, as this will shape the shredder’s throughput criteria.
As difficult as it can be to predict the future—and you don’t want to invest in too large a machine unnecessarily—it is crucial to forecast for what your needs will entail down the road. Very few organizations remain stagnant, so purchasing a shredder with additional capacity for increased volumes is often helpful, as is a shredder’s flexibility in handling different input materials with quick and simple reconfigurations. A mobile shredder will offer even further flexibility if it can be relocated around a site with ease.
Operators must be clear on exactly what the shredder’s job will be before purchase.
Some facilities invest in shredding machinery purely to reduce the size of the bulky materials they no longer have use for and/or find difficult to store, in which case output fraction is not such a priority. Others are driven by increasing compliance requirements, which means output performance matters far more. Then there are organizations with extremely defined specifications to satisfy. If a plant is manufacturing a waste to energy fuel such as solid recovered fuel (SRF) for example, a clear calorific value and homogeneous particle size of less than 2 inches is typically desired. It is therefore important to look for a shredder with an ability to achieve the desired output specification. In an ideal world, the machine should be flexible to evolve alongside the operator’s changing needs, too. Often, this is possible thanks to just a simple screen swap.
Next, operators should ask detailed, application-specific questions to shredder manufacturers to understand the machine’s true performance capabilities. Things to consider include:
Waste companies know industrial shredding has the potential to be a hazardous exercise, which is why manufacturers have worked to ensure equipment safety through more conscientious design.
Maintenance tasks that minimize operators’ exposure to the inner workings of the shredder, proactive diagnostic control panels that prevent the need for machine entry, and foreign object protection mechanisms that ensure equipment auto-stops when processing an unshreddable item have heightened equipment safety in recent years. Still, engineering innovation is driving even more safety benefits.
For example, low-noise shredders help protect against prolonged exposure to noise. Additionally, machines can now feature UV, infrared, heat and spark detectors to help prevent fires. Ergonomic design is even being prioritized so that personnel can service and maintain equipment quickly, safely and in an upright position without the need to hunch or over-stretch, which can lead to injury.
Attitudes towards recycling and waste management differ significantly across the U.S. That’s why operators must prioritize their own performance criteria when investing in fit-for-purpose shredders.
This is why a number of modern machines are driven by energy-efficient electric motors composed of synchronous drives instead of diesel hydraulic drives. Not only does such technology represent far less of a fire risk, it translates to reduced energy consumption. There seems little point of transforming trash into a renewable fossil fuel substitute if the cost of the manufacturing process is harmful to the environment.
Pursuing more “green” machines also makes commercial sense, as energy-hungry shredders don’t just have a detrimental carbon impact—they can prove costly in terms of fuel consumption, too. This can limit a machine’s possible ROI.
Identify reputable shredder manufacturers who can supply individual pieces of machinery, as well as those that can help design, source and install an entire recycling or waste management system. Whether an operator needs a complex plant or a simple waste processing line, true shredding experts will be able to help map out a turnkey solution for maximum efficiency.
Also, operators shouldn’t just trust suppliers at face value. Seeing is believing, so those involved with purchasing should speak to existing customers, and better still, request a site visit to witness a working demonstration of the equipment. The best trial of a chosen shredder requires using one’s own materials. This can offer evidence on whether the shredder can truly deliver on any promises made.
Many industrial shredders are built to last, which means that while a machine may have reached the end of its useful life in one facility, it could still have years of operational potential with another organization. This presents an attractive investment option for many businesses, especially those who can procure a high-performance used shredder for a fraction of the cost of new technology.
Some manufacturers offer shredder rebuild services, too, which can give the operator greater peace of mind regarding the ongoing condition of the equipment.
Of course, the shredder needs to fulfill the performance criteria set out for it, but wider due diligence is also important.
Users should ask the manufacturer about typical service intervals and to what extent they are likely to affect uptime, for example. Labor-intensive maintenance tasks can soon cause operational disruption, which isn’t just inconvenient, it costs money, restricts the payback period of the shredder and could even put operators’ health and safety at risk.
Think also about factors such as the cost of spare and wear parts, typical wear rates, and the availability of these crucial components. Again, this will all impact future uptime statistics and influence the shredder’s lifetime running costs.
Some suppliers take aftersales support very seriously, which means long-term ROI is far more likely. Others don’t think much beyond the initial sale of the machine, which can leave operators feeling isolated when it comes to refresher training or future process optimization.
In short, users should look for a shredder specialist that prioritizes a long-term partnership approach.
While some facilities can be flexible in their lead times for a new shredder, others have to work to strict project plans. So, whether a machine is replacing incumbent technology and downtime cannot be afforded, or the commissioning timeframes risk jeopardizing the likelihood of a new plant coming online, operators should talk to the supplier about next steps and key production deadlines.
Shredders are commonly engineered to order, so a rapid turnaround is probably not possible. But a serious and engaged supplier will respect the project criteria and do what they can to keep the installation moving while communicating with the operator every step of the way.
The business case for an investment in new equipment will almost always come down to the numbers. The price tag matters, of course, although different financing routes can make things more affordable for organizations that need to spread the cost. However, other metrics are also important. Calculate ongoing wear costs, as this will rapidly inflate the financial impact of the investment. Users should also think about power consumption—some electric-driven machines are now so energy-efficient that fuel savings alone accelerates the payback period. Then there’s the possible revenue that can be generated from the sale of cleanly segregated recycled products, so include these projections, too.
If there is doubt regarding the business case of investing in a machine, operators can ask the shredder supplier to help plot this out, as this exercise should be straightforward for them.
This article originally appeared in the March issue of Waste Today. Bernhard Martinz is the president of UNTHA America. He can be contacted at bernhard.martinz@untha-america.com.
Federation of New York waste and recycling associations will meet Oct. 4-7.
The Federation of New York Solid Waste Associations has announced that its 2020 conference and trade show previously scheduled for May 17-20 has been rescheduled to Oct. 4-7. The event, postponed because of the COVID-19 virus, remains at The Sagamore in Bolton Landing, New York.
The federation indicates its intention is “for everything to stay the same, except instead of the trees budding, the leaves will be falling.” Individuals and companies who had registered to take part in May have been contacted says the federation, and room nights at The Sagamore have been transferred to the October dates.
Adds the federation, “Our goal is to move all the May sessions and speakers to the new dates. All moderators and speakers are being contacted separately regarding availability.” An online updated Conference Program will be available July 3, says the group.
The May program had been planned to include more than 75 technical sessions and 110 trade show exhibits, along with recreational activities at the Adirondack Mountains lodge, adds the federation.
The Federation of New York Solid Waste Associations describes itself as the umbrella organization for the New York State Association for Reduction, Reuse & Recycling; the New York State Association for Solid Waste Management; and the Solid Waste Association of North America - New York State Chapter.
Quality recyclables these programs generate are part of the packaging supply chain, the associations say.
Leaders from within the aluminum, glass and plastic industries have joined together over the past month to emphasize the critical role that bottles and cans redeemed and returned through the country’s 10 state-level beverage container deposit programs play in the supply chains for producing essential packaging.
Federal guidance issued by the Department of Homeland Security’s Cybersecurity and Infrastructure Security Agency (CISA) Division, along with dozens of state executive orders, have recognized the food and beverage industries, along with their packaging and supply chain partners, as “essential” during the COVID-19 outbreak in the United States. Recycled bottles and cans, similar to raw materials and other inputs, are part of this supply chain for food and beverage packaging.
Material from beverage container deposit systems generally accounts for 20 percent to 60 percent of the inputs used by the metal, glass and plastics industries to make packaging, the associations say. The high quality of recyclables collected and purchased from these programs require very little sortation and can go quickly back into the manufacturing processes.
As the food and beverage industries have ramped up production to meet unprecedented demand, a strong, dependable supply chain of recycled material is essential to meet their packaging needs, according to the Glass Packaging Institute, the Aluminum Association, the Can Manufacturers Institute and National Association for PET Container Resources (NAPCOR).
The coalition says it has reached out to leaders in several states with beverage container deposit programs, urging that safe redemption and return options be made available for consumers and that these options be made clear to residents through updated online resources. With nationwide redemption rates for these programs north of 70 percent, consumers have shown a strong desire to return, redeem and support manufacturing industries and their supply chains, the associations say.
With these programs putting COVID-19 safety measures in place for their workers and customers, the associations say they are encouraging respective state agencies to post accessible information (in addition to the accompanying, consumer-facing infographic) on redemption location options, hours and any other measures being taken during this temporary time frame.
“Container deposit programs are a key element of a strong aluminum scrap supply chain,” says Tom Dobbins, president and CEO of the Aluminum Association, Washington. “A recent analysis by environmental research firm Circular Matters showed that while the deposit states consume about a quarter of all beverage cans, they generate more than a third of all cans recycled. It is important that we find a way to keep this vital material flowing while maintaining strong public health guidelines.”
“The average U.S. aluminum beverage can contains 73 percent recycled content and a significant portion of that recycled material comes from the 10 deposit states,” says Robert Budway, president of the Can Manufacturers Institute, Washington. “The can manufacturing industry wants to keep making cans with high recycled content because of the significant environmental and economic impact that results. We look forward to working with states now to get the needed recyclable material back and in the future to strengthen deposit systems and recycling policies.”
“Glass food jars and bottles that consumers see today are, on average, made of one-third recycled glass,” says Scott DeFife, president of the Glass Packaging Institute, Arlington, Virginia. “The majority of that recovered material comes from the 10 bottle deposit states due to the high volume of quality glass created by their programs. This recycled material is a key element of the essential food and beverage packaging manufacturing supply chain. It is imperative that we work to make redemption programs fully operational and resume the flow of quality material before disruptions occur that impact consumers' access to the products on local grocery shelves.”
“Beverage container deposit programs are essential to preserve the supply of postconsumer recycled PET,” says Darrel Collier, executive director of NAPCOR, Charlotte, North Carolina. “By incorporating postconsumer recycled PET in the production of new bottles, significant environmental savings are achieved while continuing to work toward achieving content commitments by leading brand owners.”
Beth Israel Deaconess Medical Center and Home Market Foods were recognized for their 2018 accomplishments to prevent and divert waste that would otherwise be disposed of in landfills or incinerated.
Two Massachusetts organizations are among the 2019 winners of the National WasteWise Awards announced April 20 by the U.S. Environmental Protection Agency (EPA).
EPA’s WasteWise program is designed to encourage organizations and businesses to achieve sustainability in their practices and reduce select industrial wastes. Participants in the program work to prevent and divert waste that would otherwise be disposed of in landfills or incinerated.
Of the 2019 awardees, Beth Israel Deaconess Medical Center of Boston (BIDMC) was recognized as a Partner of the Year in the Non-profit Organization category, and Home Market Foods of Norwood was recognized as the Honorable Mention in the Small Business category.
Recognized for their efforts documented in 2018, EPA WasteWise partners, including today's award winners, collectively reported preventing and diverting more than 1.9 million tons of municipal solid waste that would otherwise be disposed in landfills or incinerated, saving close to 100 million dollars in avoided landfill tipping fees.
"As we begin to celebrate the 50th anniversary of Earth Day, it is fitting to highlight these WasteWise partners for their dedication to waste reduction, environmental stewardship and sustainable materials management," says EPA Administrator Andrew Wheeler. "These efforts not only provide environmental and cost savings benefits, but they also increase the efficiency of these businesses and organizations positioning them for greater success."
In 2018, BIDMC tracked and reduced 18 waste streams that resulted in diverting 3,610 tons from waste-to-energy incineration, while a newly-hired sustainability program manager helped facilitate more accurate measurements and further waste reductions. In addition, the medical center’s waste reduction programs targeted excess packaging, disposable batteries, laboratory waste, office supplies, single-use medical devices and operating room surgical trays.
For Home Market Foods, the grocery store’s accomplishments included increasing its waste diversion rate from 61 percent in 2012 to 93 percent in 2018, as well as participating in community outreach by donating 150 tons of food to a local food bank.
"EPA is proud of these Massachusetts organizations who have stepped up and are setting a great example for other businesses and institutions to help the environment by employing sound practices," says EPA New England Regional Administrator Dennis Deziel.
"Recycling Today" surveys reveal a high level of uncertainty within the recycling industry as recyclers face fluctuating levels of generation and demand.
Shortly after the COVID-19 pandemic hit North America, Recycling Today surveyed our readership to gauge the impact of the outbreak on their operations. An initial survey was sent out via SurveyMonkey to our readers March 24. A second survey was dispatched April 10. The results indicate significant changes to inbound material volumes. Some respondents also report that their companies have had to lay off staff as they adjust to the changes that have affected their operations and cash flow.
We received 255 responses to our initial survey and 83 responses to our second survey. Charts with the results are presented below, and the full results of the first survey can be accessed here, while those from the second survey can be accessed here.
In the second survey, we also asked our readers to identify the primary material type they handled. The majority of respondents at 31.33 percent handle metals, while 16.87 percent handle plastic, 13.25 percent handle paper and 6.02 percent handle electronics. Nearly 33 percent of respondents say they handle materials other than these, indicating residential recyclables in most cases.
Regardless of sector served, many respondents mention the uncertainty that characterizes the current business environment. “Customer demand is chaotic and fluctuating wildly,” one respondent says. “Several major customers are doing temporary shutdowns with minimal notice. We expect more uncertainty over the next few weeks.”
“The biggest challenge we have is the unknown,” another respondent says. “Though we continue to operate on a reduced schedule, if any of the material supply chain breaks down, we will be severely impacted. As it is today, we are projecting our cash flow challenges will impact our business through 2021.”
A scrap metal broker whose business is based on exports indicates his company has not been actively trading since the pandemic was declared March 11. “[We are just trying to fulfill old orders, which also [is] a great risk in terms of market.” He mentioned the exposure that applies to goods en route to their destinations as his company is unsure of whether the buyers will honor their commitments and ‘dead slow’ payments.
A metals processor adds, “Not only has incoming scrap flow decreased, but inventory value has decreased considerably with metal prices tanking.”
Many scrap metal processors have closed their retail operations in response to the COVID-19 outbreak. One respondent says, “We have limited our retail operations no longer purchasing material from public but continue to support our industrial and commercial accounts that are still in operation. We have taken the CDC advice seriously limiting operations to be a safe distance, staggering employee lunches and breaks, providing latex gloves and N95 face masks, installing multiple hand sanitizer dispensers throughout the facility and providing drivers and scale operations with personal bottles of hand sanitizer. We believe in being honest in our communication with our employees and our customers will allow us to successfully navigate through these trying times.”
“The scrap business is significantly affected by COVID-19,” a respondent says. “Our export business is 60 percent down and expected to remain this way. Our suppliers and customers are all working on reduced hours, and it is very difficult for us to continue this way.”
“Steel mills aren't taking as many orders,” another respondent notes. “A normal month for us is to ship 20 to 30 100-ton railcar loads, and for April we have eight loads contracted. Nonferrous prices are down and shipments of those are reduced also.”
One respondent points to the need to close his company’s smelter, adding that half of the operation’s employees are working from home for minimal salary. He says that if things do not change before July, layoffs will be necessary.
An automotive recycler says, “Revenue is down 50 percent right now. Also, [it’s] very hard to buy cars with the price of steel so low.”
Some survey respondents have expressed concern for their employees’ potential to be exposed to the virus. “[The] virus is said to last three days on surfaces,” one respondent based in Hawaii says. “[We] will be sending instructional notice to customers to double-bag and tie any rubbish infected by the virus from people quarantining in their households or take it to the hospital for incineration.”
The respondent adds that his company is considered “critical” and has been asked to remain in operation while other businesses have been asked to shutter during Hawaii’s shelter-at-home period.
An operator of a dual-stream MRF comments, “Our containers line does not allow for 6 feet of separation between staff, so we have had to temporarily close that line. We will be able to run our fiber line once we have enough healthy staff to do so.”
“OCC (old corrugated containers) generation is down slightly and demand is increasing,” a respondent says. “SOP (sorted office paper) generation is down 70 percent, and demand is increasing. Residential generation is up modestly, demand for GW (groundwood) grades is off. Printing grades generation is steady, demand is up.”
A plastics reprocessor points to decreased recycled resin sales because of the impact on retail sales. “Most injection molders and blow extrusion companies cut down their production,” she says, adding that some operations have even been closed.
Another respondent says his company continues to buy and ship bales of plastics at its normal rate. “As far as resin sales, we have seen decline in automotive grade resins, but our demand for household cleaning and personal care packaging has drastically increased.”
“The impact of falling resin prices has a cascading effect,” another respondent notes. “We see recycled materials projects delayed and companies focusing on priorities and delaying recycled content initiatives.”
Consumers and generators were making changes daily as of late March, a respondent says.
“Everyone we’re talking to, both upstream and downstream vendors/customers, are in panic mode,” according to a respondent. “Material inflow is stagnant as companies shut down, and downstream outlets are drying up as vendors seek to conserve cash. Gridlock is going to get worse. Nothing [is] coming in and [there is] nowhere to get fair value for what you have.”
“We expect the financial impacts of the [coronavirus] pandemic to worsen across all aspects of our company the longer businesses are closed due to the virus,” a survey respondent says.
“We believe this will take many months to recover as we anticipate consumer confidence to start spending will take at minimum a strong economic quarter to recover,” one respondent says. “As a result, the lack of material in the supply chain will linger into the third and potentially the fourth quarter of 2020.”
A manufacturer who supplies equipment to the industry says, “[S]ome purchases from customers are on hold, but we are still working, and we are still [generating] new quotes and having sales take place. It seems to be causing a slowdown more than anything.”
One respondent chooses to look at the opportunities the outbreak provides, saying, “It’s a terrible event, however, it did give us the opportunity to step back and assess our business plan and goals. We also had some downtime to focus on cleanup and organization.”