Double Shaft Shredding Machine
Double Shaft Shredder: Rugged Industrial Shredding for Complex and Bulky Waste
Double Shaft Shredder
What is Double Shaft Shredder?
Double Shaft Shredder is industrial size-reduction equipment featuring two counter-rotating shafts with intermeshing cutting discs, engineered for processing tough, bulky, or heterogeneous materials requiring aggressive tearing action. These high-torque systems excel in handling challenging waste streams that demand both shearing and ripping forces, including electronic waste, automotive shredder residue, mixed construction debris, and industrial byproducts. The dual-rotor design (typically 400-1800mm diameter per shaft) creates a scissor-like cutting action between staggered cutting tools, enabling efficient processing of materials that would stall single-shaft units. With throughput capacities ranging from 1-50 tons/hour, these shredders produce uniform output sizes between 10-300mm, making them ideal for preliminary size reduction before finer grinding or sorting operations in modern recycling facilities.
Advanced double shaft shredders incorporate synchronized hydraulic or electric drive systems that maintain precise shaft timing while automatically reversing to clear jams. Modern designs feature adaptive control systems monitoring 50+ operational parameters, including instantaneous torque demands, bearing temperatures, and cutting tool wear. Specialized configurations exist for specific applications: slow-speed high-torque models for tires and metals, mid-range units for municipal solid waste, and high-speed variants for plastics and paper. Recent innovations include AI-powered load balancing between shafts, integrated metal detection systems, and self-sharpening cutting disc designs that extend service intervals by 300% compared to conventional models.
Double shaft shredders operate through precisely synchronized mechanical action: Material enters a reinforced hopper where hydraulic press rams (50-400 ton force) pre-compress bulky items before introduction to the cutting chamber. Two parallel shafts with helically arranged cutting discs rotate inward at 15-60 RPM, creating three distinct size-reduction zones. In the intake zone, large hooks grab and feed material; the primary shear zone features intermeshing discs generating 50,000-200,000 N·m torque; finally, the sizing zone uses screen-controlled recirculation to ensure uniform output. Particle size is determined by interchangeable bottom screens (10-300mm) and adjustable cutting disc clearance (1-20mm).
Integrated smart systems optimize performance: Strain gauges measure real-time cutting forces, automatically adjusting hydraulic pressure to maintain optimal shaft synchronization within 0.5° precision. Advanced models feature water-cooled rotor bearings and infrared temperature monitoring of cutting tools. Material purification occurs through optional in-process components: Overband magnets extract ferrous metals, eddy current separators remove non-ferrous metals, and air knives eject lightweight contaminants. Post-shredding, the fragmented output is conveyed to downstream systems, with regenerative drives capturing up to 30% of deceleration energy. The entire process operates within sound-insulated enclosures maintaining noise levels below 82 dB(A), with dust extraction systems ensuring OSHA-compliant particulate control.
Selecting the optimal double shaft shredder requires comprehensive evaluation of material characteristics and operational requirements:
- Material Type: For e-waste and WEEE, choose models with hardened steel discs and integrated PCB separation; for tires, select slow-speed (15-25 RPM) high-torque units
- Throughput Needs: 1-10 tons/hour (compact units), 10-30 tons/hour (standard industrial), 30-50+ tons/hour (heavy-duty systems)
- Output Specifications: Coarse fragmentation (100-300mm) for waste-to-energy, medium (30-100mm) for recycling, fine (10-30mm) for SRF production
- Drive System: Hydraulic drives (variable torque), electric drives (constant torque), or hybrid systems balancing energy efficiency and power
Critical evaluation factors include wear protection (tungsten carbide disc coatings), safety systems (ATEX compliance for explosive dust), and automation features like predictive maintenance alerts. For facilities processing hazardous materials, prioritize models with sealed chambers and negative pressure systems. Always conduct material testing with actual waste samples, evaluating throughput, particle size distribution, and wear rates during trial runs.
MSWsorting's double shaft shredders incorporate cutting-edge engineering solutions:
- Rotor Assembly: 42CrMo4 alloy steel shafts with dynamic balancing to ISO 1940 G2.5 standard, supporting disc tip speeds of 20-35 m/sec
- Cutting Tools: Interchangeable discs with Sandvik HV500 tungsten carbide inserts, available in hook, star, or square profiles
- Power Transmission: Synchronized planetary gearboxes with torque ratings to 400,000 N·m per shaft and fluid couplings absorbing shock loads
- Control Systems: IoT-enabled PLCs with 15" HMI touchscreens monitoring 50+ parameters including:
- Shaft synchronization accuracy (0.1° resolution)
- Bearing vibration spectra via integrated accelerometers
- Energy consumption per ton processed
- Disc wear through laser measurement
Specialized configurations include Arctic-grade units (-40°C operation), explosion-proof models for chemical waste, and mobile versions with self-contained power packs. Safety systems encompass methane detection, pressure relief vents (EN 14491), and automatic fire suppression. Environmental packages feature closed-loop water cooling, HEPA filtration (99.97% efficiency), and regenerative drives recovering deceleration energy. Industry 4.0 capabilities include digital twin simulations, cloud-based performance optimization, and AR-assisted remote maintenance.
Automotive Shredder Residue: Recycling plants process 20 tons/hour of post-shredder fluff into 50mm fragments, recovering residual metals and producing RDF for cement kilns through integrated air classification.
Electronic Waste Recycling: Specialized facilities shred mixed e-waste into 25mm particles, with downstream separation recovering 98% copper content from PCBs while isolating hazardous materials for proper disposal.
Municipal Solid Waste: Waste-to-energy plants preprocess 30 tons/hour of MSW into 80mm fragments for efficient combustion, with integrated removal of inert materials and metals.
Industrial Plastic Scrap: Manufacturing facilities convert production purge and rejects into 15mm regrind for direct reuse, achieving 99.5% purity through in-line metal separation and optical sorting.
Construction & Demolition: Recycling centers process mixed C&D debris into 100mm fragments, separating wood, metals, and inert materials for respective recycling streams.
Tire Recycling: Plants shred 10 tons/hour of OTR tires into 50mm chips, with subsequent removal of steel cord for production of rubber-modified asphalt.
Implement a comprehensive predictive maintenance program:
- Daily:
- Laser measurement of cutting disc wear (0.05mm accuracy)
- Infrared scans of electrical panels and bearings
- Hydraulic fluid level and contamination checks
- Weekly:
- Ultrasonic thickness testing of shafts
- Gearbox oil condition monitoring
- Screen integrity inspections
- Monthly:
- Bearing lubrication with high-temperature grease
- Torque verification of all fasteners
- Dust collection system maintenance
Quarterly overhauls should include rotor removal for magnaflux inspection, gearbox oil analysis (ISO 4406), and recalibration of all sensors. Maintain critical spare parts inventory: Cutting disc sets, hydraulic valves, and shaft coupling assemblies.
Advanced monitoring techniques include:
- Vibration spectral analysis for early bearing failure detection
- Oil spectroscopy identifying component wear metals
- Acoustic emission monitoring for crack detection
- Thermal imaging of electrical systems
Annual recertification encompasses safety system validation (SIL-2), explosion protection testing, and control software updates. Store spare cutting tools in humidity-controlled environments with VCI corrosion inhibitors. Implement operator training on synchronized shaft operation and emergency jam-clearing procedures using hydraulic reversal systems.
Single Shaft Shredder
The single-shaft high-speed shredder is specifically designed for processing Refuse-Derived Fuel (RDF) and Solid Recovered Fuel (SRF). With a robust cutting system and high rotational speed, it efficiently shreds municipal solid waste (MSW), industrial waste, and biomass into uniform particle sizes. Its durable construction ensures reliable performance in demanding applications, while the high-speed operation enhances throughput and material homogeneity. This shredder is ideal for waste-to-energy plants, recycling facilities, and SRF production lines, helping to optimize fuel quality and processing efficiency.
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Double Shaft Shredder
The dual-shaft shredder operates at low speeds with high torque, making it ideal for tough and bulky waste materials. Its interlocking blades and counter-rotating shafts ensure efficient shearing and crushing, reducing waste volume while minimizing wear. This robust design excels in processing heavy-duty applications such as tires, metals, construction debris, and industrial waste. The slow-speed operation enhances durability and reduces energy consumption, while the high-torque output guarantees consistent shredding even under heavy loads. Widely used in recycling, waste-to-energy, and scrap processing industries, the dual-shaft shredder delivers reliable performance for demanding shredding tasks.
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Four Shaft Shredder
The four-shaft shredder delivers superior shredding performance through its multi-stage cutting system, featuring two primary shafts for coarse reduction and two secondary shafts for fine grinding. This advanced configuration enables efficient processing of mixed, bulky, or challenging waste materials—including municipal solid waste (MSW), industrial scrap, and electronic waste (e-waste). With synchronized, high-torque rotation, it ensures thorough size reduction while minimizing jamming risks. The four-shaft design enhances throughput, reduces downtime, and produces consistently uniform output for RDF/SRF production, recycling, and waste pre-treatment. Ideal for large-scale operations requiring high-capacity, precision shredding.
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