M a c h i n e s P l a n t s P r o c e s s s o l u t i o n s

Creating The Future

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Machine technology

UNI-CUT®CC CableCutter the specialist for all cable waste

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UNI-CUT®UC rotary shears endlessly versatile in pre-granulation

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High-performance UNI-CUT®UG granulators For individual grain sizes from 8 to 100 mm

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UNI-CUT®USM cutting mills the perfect cut for small grain sizes

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Hammer mills UNI-CUT®UHMeffective purification

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The patented UNI-CUT®QZ Querstromzerspaner Perfect in separation. Perfect in the result.

>>> Page 12UNI-CUT®AC AlphaCutter single-shaft pre-shredder for difficult materials

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UNI-CUT®SB2 Smash Boom Bang Gentle and effective

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UNI-CUT®SP tyre wire cleaner clean steel wire from tyre recycling

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the diversity of the MeWa range of machines is aligned to the require-ments for the size reduction of dif-ferent types of waste. as a single machine or integrated in complete plant solutions, recycling machines from MeWa have already proven their worth more than 1000 times.

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over 300 large-scale plants world-wide speak for themselves: with size reduction machinery from in-house development as well as the speci-fic separation, sorting and conveying technology, MeWa delivers turnkey recycling solutions at one stop. Mo-dular construction means that the systems can be put together quickly and efficiently to meet individual re-quirements.

Increased gas output by up to 30 %life‘s a gas with the QZ

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Metal-cleaning plantseffective separation

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Processing plants for electrical and electronic scrapsingle-stage and fully automatic

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Plant engineering

Refrigeration recycling plantshighest recycled resource rates – complete cFc separation

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Recycling plants for used tyresFrom old tyres to actiMeWa

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Cable recycling plantshigh-quality fractions in primary raw material quality

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Processing of domestic and industrial wastesolid recovered fuels with high energy content

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From old tyres to fine rubber powderThree-stage process delivers high-quality secondary raw material

Tyre recycling

With the active fine milling process for used tyres, MeWa produces a substitute raw material of a single material type. The fine granulate (ActiMeWa) can be mixed with other materials without difficulty to manufacture rubber products. In road construction, there is a great demand for ActiMeWa as an additive to bitumen.

ecycle before incineration – this guiding principle also applies to used tyres from passenger cars

and trucks. in hungary and Kazakhstan, MeWa recently built two highly modern processing plants for old tyres, producing actiMeWa for direct deployment in road construction.

in the three-stage processing principle (pre-granulation, granulation, fine mil-ling), rotary shears first of all fragment the complete used tyres into shreds the size of the palm of your hand.

the precisely machined cutters of the uc are seated on a polygon-shaped rotor. this enables the machine to achieve optimised power transmission. even with metallic parts, the uc shows its irresistible bite.

subsequently, a granulation line processes the pieces of tyre step by step into a rub-ber granulate of a single material type. in a complex process, various separati-on processes separate the steel and tex-tile fibres from the pieces of rubber. the size of the granules is between 0 and 4

ActiMeWa

Granulation line.

Rotor shears and granulator

Universal rotary shear UC 150.

millimetres with a final purity of 99.95 percentage by weight.

Active fine millingMeWa integrated the newly developed fine milling process as a third process stage for the first time in both plants in hunga-ry and Kazakhstan. Powdery actiMeWa of the highest purity is the result at the end of the process. it can be added di-rectly to the new rubber to manufacture rubber products.

Deployment in road constructionactiMeWa is also used in road construc-

tion as an additive to bitumen. the rubber granulate not only balances out tempera-ture differences to a considerably better degree, thus preventing the formation of cracks, but the mixture also dampens the noise level of the road surface and provi-des significantly greater adhesion for ve-hicles in the rain.■

With their reliability, the versatile granulators and rotary shears have ad-vanced to become the truly successful team of machines in the MeWa machine pool. together, the two machines frag-ment above all tyres, cables, oil filters and mixed wastes into homogeneous fractions in all desired grain sizes.

Perfectly geared to one anotherthe duo is deployed at several

hundred locations in pre-granulation and finish-crushing. here, operation times of more than 70,000 hours of operati-on are no rarity. as far as throughput is concerned, the team of machines is perfectly co-ordinated.

the rugged machines have been conceived for metal processing, which means they display exceptional stami-na even in highly demanding applica-tions.

A double plus

UG cutting mechanism.

Active fine milling.

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E lectrical scrap, telecommunications, old cars, mining, high-voltage cables - today, approximately 150,000 me-

tric tonnes of cable waste is produced per year in Germany alone. underground, mil-lions more kilometres have been laid, and these have to be replaced at some time or other. With the copper, aluminium, lead and steel metals they contain, the lines are extremely rich in recyclable resources.

in hungary‘s capital Budapest, a com-pany has specialised in recycling cables. not far from the banks of the Danube, the facility has installed a processing line with pre-granulation, granulation and fine granulation.

Turnkey cable processing plants from MeWa have been delivering the highest output qualities for years. A processing plant in Buda-pest has now integrated the newly developed UNI-CUT® CC CableCutter into its plant.

Initial conclusion: grade 1 in economic efficiency.

CableCutter CC 1200.

CableCutter

The modern copper mine

Cable processing CableCutter and USM

Specialist for cable fragmentisationthe company has now invested in an

additional special machine that can fur-ther increase the efficiency of processing. the cutting geometry of the new cc 1200 cablecutter from MeWa has been special-ly geared to taking cables apart.

With a throughput of up to three me-tric tonnes per hour, this technical innova-tion is highly effective. the easy-to-change granulating screen achieves grain sizes of 10 to 50 millimetres in diameter. special sizes are available as required. the input shaft is 2.30 metres wide, i.e. configured for loading by means of power shovels.

Copper sorted by material typethe initial processing with the new unit

is so precise that even one subsequent gra-nulation stage is sufficient to be able to feed the material directly to the final cut-ting mills. the result: copper in primary raw material quality. ■

if aluminium, copper cables, plastics or tyres are to be granulated, the uni-cut® usM cutting mill handles the pre-cision work. the rugged MeWa cutting mill is in demand everywhere small grain sizes are required.

in cable processing, the cutting mills cut the enclosed metal from its clad-ding. co-ordinated cutting and separa-tion units then extract metal fractions of a single material type, for example copper. Plastics and rubber from the in-sulation material are left behind.

in the modern tyre processing plants, the machine is often set up in a row of four located upstream of the cutting and separating units. in a number of runs, the rubber granulate is cleaned and finally fragmentised by the 5.5 me-tric tonne machine to a size of less than 4 millimetres in diameter.

Partner for precision work

Cutting mill USM 1000.

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he first encounter leaves a lasting im-pression: the alphacutter is hungry. the new bulky waste shredder

devours enormous quantities of household, commercial and industrial waste.

the homogeneous fragmentation me-ans that the throughput can also be in-creased in the downstream granulation line by more than 30%. Particularly in the

MeWa has developed the high-performance AlphaCutter for large throughput volumes and materials that are difficult to process such as mattresses, truck tarpaulins, large compressed bales or rolls of foil. The unit is handling the pre-granulation in plants for the manufacture of solid recovered fuels.

TFor more than 20 years now,

MeWa granulators have been driven by flywheels weighing 3 to 5 metric tonnes. the flywheel serves simul-taneously as a belt pulley for a sim-ple V-belt drive that works with the lowest possible losses due to friction. the energy of the disk flywheel co-vers the peak torques required in the short term. this means that the elec-trical drive motor runs smoothly, si-gnificantly below the rated voltage range. expensive peak loads do not occur in the first place.

Maintenance-free coupling systema sophisticated coupling and

control system monitors the speed, torque and current consumption of the machine. this prevents high start-up peaks of the electrical drive motor and in the event of sudden blocking the flywheel is uncoupled so that the machine is not damaged.

the new alphacutter series from MeWa is equipped with four disk flywheels. two of these on each side gear down the speed of the drive motors from 1500 revolutions to approx. 70 revolutions. MeWa CEO Ulrich Hink in front of two of the four

disk flywheels of the AlphaCutter XXL 3700.

Der Schwungmassenantrieb im AlphaCutter XXL 3700.

Flywheel mass drivecase of materials that are difficult to pro-cess such as mattresses, truck tarpaulins or large compressed bales, the progress made compared to other machine solu-tions is enormous.

AlphaCutter XXL for high throughput

the alphacutter XXl 3700 is parti-cularly suitable for facilities that have to

handle very large volumes of waste. up to 60 metric tonnes of mixed wastes per hour can be processed with the high-per-formance unit.

Depending on requirements, version l with a rotor length of 2200 millimetres and version Xl with a rotor length of 3200 mil-limetres supplement the range of availa-ble products.

Turnkey plantsMeWa builds and delivers turnkey

plants for the processing of household and industrial waste, providing services from the first draft design to commissio-ning at one stop. Depending on the requi-rements of the customer, MeWa creates pure sorting plants with manual sorting or mechanical separation all the way to com-plex plant concepts with sophisticated cut-ting/separating techniques for the manu-facture of solid recovered fuels.

near Ghent, for example, the British shanks Group operates a complete MeWa plant for the processing of mixed construction waste.

Three granulatorsFollowing pre-granulation, vibra-

ting screens, wind screening, metal se-parators, near-infrared technique as well as three large granulators ensu-re output sorted by material type and a throughput of 35 metric tonnes per hour the main purchaser of the high-calori- fic substitute fuels is the cement industry in Belgium. ■

Turnkey MeWa plant in Ghent with vibrating screen, wind screening, metal separator and granulation line. Pre-granulation takes place outside of the shop.

Solid recovered fuels AlphaCutter

Manufacture of Solid Recovered Fuels

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The patented UNI-CUT® QZ Querstromzerspaner has replaced the traditional fragmentation technology with chain tools – and thus thoroughly revolutionised the process with a level of success that literally makes a bang. The new Smash Boom Bang is the junior partner in electrical scrap recycling.

Smash Boom Bang

Where the hurricane rages insideThe Querstromzerspaner and Smash Boom Bang revolutionise recycling technology

lectrical and electronic scrap, refrigeration devices, aluminium composites, plastic-me-tal composites of all types, but also biolo-

gical waste - the Querstromzerspaner is deployed everywhere different material mixtures have to be broken down. the patented QZ was developed to separate a wide variety of composite materials.

in the meantime, the technology that works according to a completely new concept has de-veloped into the most successful machine in the MeWa range of products. in contrast to cutting tools, the Querstromzerspaner separates the ma-terial with its acceleration instruments. here, the chains generate a kind of cyclone in the proces-sing chamber.

the QZ exploits the physical forces of the im-pact energy, thus guaranteeing particularly fast and gentle material separation. even after a few seconds, secondary metals of high purity that are fit for the market exit from the drum of the ma-chine.

Low wear costscompared to cutting processes or sw-

ing-hammer pulverisers, the resulting wear costs are significantly lower. in the meantime, the patented Querstrom-zerspaner is deployed worldwide in a wide variety of plant variants.

refrigeration devices and electrical scrap in par-ticular can be gently and economically fragmen-ted with MeWa techno-logy. With different drum sizes from 900 to 2500

millimetres, the suitable machine for every requi-rement is on hand.

Smash Boom Bang – the solution for small electrical appliances

in the field of pre-granulation of electrical and electronic scrap, MeWa has conceived a supple-mentary solution: the smash Boom Bang. this technical innovation is particularly suitable for small electrical appliances. after processing, the housing, processor boards, motors, cables, trans-formers lie exposed; parts containing pollutants, for example capacitors and batteries, remain intact. the individual components can be easily taken from the conveyor belt by hand in the next operation.

the dismantling machine saves the time-con-suming and costly manual pre-dismantling of the electrical appliances while still enabling the plants to carry out combined processing of the wastes in one mechanical and manual system. ■

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Querstromzerspaner

Smash Boom Bang.

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lectrical appliances and refrigera-tion devices constitute the flow of waste with the highest growth

in europe. alongside numerous recycla-ble resources, however, the devices and appliances also contain harmful sub-stances.

across europe, more than 200 mil-lion cFc refrigeration devices are still operated. these generations of devices are now coming in for recycling. the en-vironmentally harmful chlorofluorocar-bons are in the refrigerant and in the appliance insulation.

in austria, a country that requires particularly high environmental stan-

E dards in this area, MeWa commissioned a highly modern refrigeration device re-cycling plant recently. the new opera-tors and attending guests from the field of politics agreed at the opening: „With MeWa technology, we are setting new standards in the disposal of refrigerati-on devices in europe.“

The plant achives 900,000 metric tonnes of CO2 reduction

up to 300,000 refrigeration devices per year will be processed here in futu-re, recovering around 90 metric tonnes of cFcs. the functioning principle of the plant corresponds to an annual re-duction in the environmental burden of 900,000 metric tonnes of co2. For this

Single-stage, fully automatic and environmentally friendly WEEE processing plants for electrical scrap and refrigerators convince with their economic efficiency and the highest environmental standards

In line with the WEEE Directive of the European Union, many nations have established an effective recycling system for electrical and refrigeration devices. Very often, the Querstrom-zerspaner (QZ) from MeWa plays the main role in this process. The machine takes the appliances apart in a single-stage pro-cess in a particularly efficient and gentle manner.

Environmental Award for the MeWa fridge recycling plant: Daphne in gold.

Fridge recycling

Refrigeration device pro- cessing plants from MeWa convince with high rates of recycled resource recovery and complete CFC separation. achievement, the plant in Kematen recei-

ved the austrian environmental award „Daphne“ in gold in March 2009.

With the Querstromzerspaner tech-nology, cFc and pentane appliances can be processed simultaneously wi-thout their having to be sorted before-hand. not only the recovery rate of the cFc is exceptionally high, but also the economical operation of the plant and the high recycled resource rate with fer-ric, aluminium / copper and plastic frac-tions sorted by material type at the end of the process have led to the plant type being deployed in almost all european countries.

MeWa plants for processing household appliances, home electro-

nics or computers are even more wi-despread. With the first plants in ca-nada and california, the step across the atlantic has been made.

the patented Querstromzerspaner also handles the dismantling work for electrical scrap processing. the parts containing pollutants, for example ca-pacitors or batteries, remain intact in the chain fragmentation process and can then be sorted without difficulty using separating techniques or by hand. at the end of the process, more than 90% of the input volume is available, cleanly separated and sorted according to dif-ferent material fractions.

Fully automatic operationin Daventry, england, a highly mo-

dern MeWa plant configured for fully automatic sorting was recently commis-sioned. after processing in the Quer-stromzerspaner, metal detectors, ferric and non-ferric separators, plastic sorting devices, circuit board separators, proxi-mity infrared devices as well as air se-parators separate the material into dif-ferent material flows. only four to six employees per shift are responsible for ongoing operation.

the combination of refrigeration de-vice and electrical scrap processing can also be implemented using QZ techno-logy. in st. helens, england, MeWa put europe‘s biggest processing plant into operation for mixed treatement with de-vices classified according to the europe-an Weee Directive. ■

Fridge recycling

Ferric fraction, separated into a single material type.

Fully automatic WEEE-plant in Daventry.

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ompanies that specialise in proces-sing special scrap have moved into industrial centres with very good

transport links.

at first glance, the volume of waste coll-ected there in the yard and in the shop

C looks like normal domestic and industri-al waste.Processing for use in steel works

however, the composition differs fundamentally. the waste consists of more than 60 % metal. the plants have specialised in processing the so-called

metal separation fraction from sorting or metal pro-cessing plants so that it can be used in steel works. the delivered metal fractions, for example tinplate cans, still adhere to a great ex-tent to external materials.

the MeWa Quer- stromzerspaner has pro-ven to be the ideal tech-nology to separate these stubborn composites. the positive results have led a number of com-panies to invest in this direction in the past few months. existing plants

Input motor blocks: the QZ separates brass-aluminium composites.

When breaking down metal-plastic mixtures, the Querstromzer-spaner delivers particularly good results. One of the tasks is to clean metals that have already run through magnetic separators in sorting systems for domestic and industrial waste.

Resistance is pointlessQZ separates metal composites ready for the steel mill

have also extended their processing to in-clude other lines with the patented Quer-stromzerspaner.

Low wear coststogether with the separating tech-

niques that are geared to it, the chain principle of the MeWa QZ ensures high throughputs, output fractions sorted by material type and low wear costs. Parti-cularly in the last point, the advantages compared to cutting shredder systems are huge.

Metal composites of all typesas a general principle, the QZ process

is suitable for the separation of a wide va-riety of metal composites. applications in-volving components made of aluminium are just as frequent as the processing of swarf and metal chips. after all, the result is plastic, non-ferric and ferric fractions – ready for collection by the steel works and resmelting shops that are connected by the relevant transport systems. ■

Metal composites

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n order to protect the machines in the downstream tyre recycling process steps against ex-

cessive the wire is re-moved from the pro-cess directly after the first granulation step by magnetic separa-tors.

this fraction, however, is in a very un-clean state at this point. along with the wires, around 10 to 35 percentage by weight of rubber and textiles is also with-drawn. this proportion is too high for use in a steel smelter. MeWa has now speci-fically devoted its attention to this frac-tion. equipped without sensitive blades, the tools mounted on the rotor shaft rub

he double swing-hammer mill uses a kinetic impact effect to pulverise the material to be

ground. two rotors, to which steel hammers are attached, rotate in a me-tal housing. the impact of the ham-mers pulverises the conveyed mate-rials. the hammers sling the units against the grinding wall, where the impact breaks them up further. the ground material remains in the pulve-risation zone until it is small enough to pass through a defined screen. this screen determines the output size of the material. a characteristic of the hammer mill is also the spherical out-put. ■

the rubber and steel mixture on the stator shaft of the machine against one another,

thus exposing the individual fractions.

specially con-figured vibration channels and ma-gnets separate the exposed wire, tex-

tile and rubber fractions. the entire sepa-ration plant is encapsulated. this enables exposed textiles to be blown out via air separation devices and captured in a fil-ter. the turnkey MeWa line is also equip-ped with its own control system. at the end, the wire emerges with a purity of gre-ater than 98% – ready to use in a steel smelter. ■

Tyre wire cleaner separates steel and rubber

Tough refinement

Tyres contain a substantial amount of steel wire. For this content, MeWa has developed the UNI-CUT® SP tyre wire cleaner. This special machine removes textile and rubber residues from the steel wires, fully recovering the metal in the highest quality.

The UNI-CUT® UHM Hammer mill has proven effective in the preparation of material mixtures of plastic, alu-minium and copper. The advantage: fractions sorted by material type can be extracted in defined grain sizes. This is frequently a requirement for the manufacture of new products from recycling material.

Tyre wire cleaner and Hammer mill

Output: Copper and aluminium.

High quality fractions in primary raw material qualities.

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Extract the maximumBiogas plants: Querstromzerspaner from MeWa prepare substrates ideally for the bacteria

hether fuel crops from the fields, expired foodstuffs, bi-ological waste from bins,

slaughterhouse waste or surplus seaso-nal crops – there is a great deal of ener-gy in the biomass. converting this energy quickly and efficiently into usable biogas is the task of modern fermentation plants. this is how around 5,000 biogas plants in Germany produce environmentally friend-

W ly power and heat, and the trend is on the up and up.

however, an important process step has often been neglected during planning. exploitation of the substrates in fermenta-tion can only be optimised with the right separation. this means that the strains of bacteria in the fermenter can only begin their decomposition process quickly and

effectively when the cell structure of the input materials has been broken up.

With the patented Querstromzerspa-ner (QZ), MeWa offers the suitable soluti-on for this application. instead of cutting

Increasing the gas yield, stabilising the operating state, reducing the holding time in the fermenter – in short: many plant operators will soon be optimising existing biogas plants. With the Querstromzerspaner (QZ), MeWa offers a solution that starts right at the front of the process chain. „Properly preparing substrates“ is the simple but effective formula for the patented machine.

Querstromzerspaner QZ 900.

Bio QZ Bio QZ

up the input materials, the Bio-QZ works with the principle of a pestle and mortar. this creates a significantly larger contact surface for the bacteria, enabling a signi-ficant rise in the energetic yield of the substrates. rotating chains on the floor of the machine chop up the fuel crops in seconds. „this gives the substrate a homogeneous composition, making it much more ‚palatable‘ for the bacteria, so to speak,“ says a biogas plant opera-tor in describing the result.

the principle provides sustained effects above all in the case of agricultural plants that feed fuel crops from the field into the fermenter. Where the Bio-QZ has been retrofitted, a significantly more stable operating state of the entire biogas plant has been achieved. the homogeneous-ly prepared substrate can not only be pumped more easily, the energy-intensive stirring periods in the fermenter can also be more than halved. Floating layers disap-pear very quickly. a farmer in nördlingen, Bavaria, describes the situation in his plant: „the material in the fermenter now moves of its own accord. it‘s visibly alive.“

30 % more gas yieldDepending on the input material used

originally, up to 30 % more gas yield is measured in plants with Bio-QZ operati-on. evaluations have also indicated a hig-her methane content in the biogas. and an even more far-reaching difference can be determined compared to before: in the plant in nördlingen, the yard now stock- piles not only corn silage but now also seasonal crops such as red beets, pota-toes, oil radish, sugar beets or grass cut-tings. „it is now much more flexible to feed the plant, enabling me to exploit seasonal business,“ says the farmer.

Insensitive and versatilein the meantime, the machine has

proven its suitability for the preparation of substrates on a wide variety of plant categories. alongside the renewable re-sources plants that operate with a high dry-substance content, the principle also delivers the same positive results in mu-nicipal fermentation plants with biologi-cal waste bins as well as for slaughter-house waste and packaged foodstuffs, for example. the machine is also insensitive to metal parts or stones and completely unwraps packaging. in a downstream separator circuit, the packaging can be easily removed from the biomass. ■

The QZ 1600 at work.

Corn silage.

Fruit and vegetables. Slaughterhouse waste.

Sugar beets.Packaged food.

Red beets.

MeWa recycling Maschinen und anlagen-bau Gmbh has been playing a leading role in the recycling industry for more than 25 years. the core business is on deve- loping and building recycling machines and engineering turn-key plant solutions.

MeWa machinery is processing electric- and electronic scrap, fridges, tyres, domestic and industrial waste, oil filters and organic waste for biogas plants. Being an international market leader, MeWa’s innovative technology is patent-protected.

at the headquarters in Gechingen/ Germany and in other international sites more than 150 employees are working for MeWa.

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Mewa recyclingMaschinen und anlagenbau GmbhGültlinger straße 375391 Gechingen/Germany

tel. +49 (0)7056 925-0Fax +49 (0)7056 925-169info@mewa-recycling.com

www.mewa-recycling.com