Lane Blount and Chad Phares
In today’s economy it is critical that companies engage in creative cost saving and money-making activities to maintain their profitability. Innovation and “going beyond normal business activity” keeps a few companies ahead of the curve. Some landfills have figured out the old saying “one man’s trash is another man’s treasure” and are implementing progressive opportunities to uncover and collect marketable materials from the waste flows entering their facilities. When considering a shredder purchase, be sure to address the following points in order to better clarify your final decision.
Application and Capability of Machine
The first things to consider are the applications where the shredder will be used. Is it a pre-shred application or can it make the final product size required? One pass, or two, and how much and what kind of material will it process? Will it be used on the same product all the time or for several different products. It is much easier to pay for the machine if it constantly produces sellable product.
Finish Material Sizing Capability
Is the unit capable of producing finished sellable material? Does the product require further processing or can it be sold as is? What sizing capability does the machine offer? What percentage of the throughput is finished and which portion has to be further reduced?
Control of Functions/Programs:
Is the unit easy to operate? Does it have a remote control system that can be used from the loader? Is the machine “smart” with preset programs for handling different materials? Can you design unique programs to handle specific requirements? Some materials don’t require full throttle operation, so can the engine capacity be adjusted to reduce fuel consumption? Does the shredder automatically reduce its engine capacity to idle when there is a delay in loading? Will it shut off after a lengthy idle time? All these things help reduce the cost of operation.
Power Make and Serviceability, Power Options
Who makes the engine? Is it a common reputable brand with parts available from many sources or do you become a slave to the manufacturer? How easy is it to get consumables and repair parts? Does the unit offer an extended engine warranty? Will the engine be a diesel, natural gas, or electric drive? Where does the closest service support come from?
Method of Power Transfer
How does the engine attach to the shaft? Does it use a direct coupling, belt, shaft or hydrostatic drive system? Is there a clutch, a fluid coupler, or does it use hydraulic motors? What are the maintenance and repair implications of either?
Cost of Wear Parts
There are many wear parts on shredders starting with the knives (teeth), the counter knives (counter teeth), anvils, wear plates, guards, drive systems, engine, conveyors and more. What is the expected longevity of these items and what is the cost including down time and labor to repair or replace?
Cost of Operation
What is the cost of operating the unit per ton of finished material, not processed material? There is often an available spreadsheet to help in these calculations. Will you have enough material to keep this unit working every day?
Fuel Usage and Maintenance Requirements
These items are usually included in the manufacturer’s spreadsheet, and verify accuracy for each make of shredder. A rule of thumb for full load capacity is fuel consumption will be 4 gallons per hour for each 100 HP of engine capacity. If the unit allows you to adjust the engine output for certain operations, the fuel consumption can change. Also, some engine manufacturers recommend servicing the engine at 250-hour intervals, and some at 500-hour intervals. This can be a major effect on the cost of operating the shredder. Certain operating conditions can also require more attention to service. Dusty or dirty environments can impact the bottom line. Keeping the machine greased and lubricated is critical.
Service, Parts, and Training Support
What support is available from the dealer, distributor or manufacturer of the machine? Can you get access to help anytime? Can you get parts locally or is it an overnight response from somewhere? Are there trained support personnel local or do they have to drive in from other areas?
Knife and Counter-Knife Placement, Size and Expected Wear
Various shredders offer different configurations for shafts and teeth. Some machines are single rotor with larger knives and counter knives while others offer dual shaft designs with smaller teeth. There is great controversy over which design is best as both offer unique benefits for various materials processed. Wear is a critical consideration as it takes time to change teeth. Often, larger and heavier teeth, though initially more expensive, last longer and have to be changed less so the shredder can stay productive.
Access for Changing Knives
The most frequent maintenance function on a shredder is changing the teeth. Whether they get broken or they wear, it is critical to have good access for changing knives (teeth) and counter knives (counter teeth). How the machine opens up and allows access for quick and easy changes makes a big difference in how enthusiastically operators approach this task. The easier it is, the less resistance there is to taking care of the machine.
Clean-Out Capability and Access
Similarly, the shredding operation involves materials being hung up and wound around the shaft as they are torn, cut and shredded. Often, it is necessary to stop and dislodge materials that are either not shreddable or are positioned so the shredder cannot process them. How the unit allows for this is crucial. Some units enable auto-reversing of the shaft and can dislodge the hung up materials themselves, others don’t reverse and have to be stopped, freed up and restarted. Some units have mechanisms that adjust the cutting chamber in some way to free up clogged materials while others have access doors enabling easy removal and re-start of the shredding operation. Several units are difficult to access with tight spaces and no room to work. Understanding the operation and access to the machine is important in choosing a shredder for the best performance.
Service Access
Servicing the unit comes around frequently as hours of operation build. Easy access to the serviceable parts is essential to encourage operators and maintenance personnel to perform necessary services to the machine. How the unit opens up makes a huge difference in the time required to perform these tasks.
Portability Options
Most units are available on wheels or tracks. Environment and how often the unit is moved to different jobsites is the primary consideration. If the shredder is involved in lots of “off road” applications, tracks are a good investment. With tracks the loader/operator can move the unit remotely as required to reach more materials, or to change the direction of discharge. If it is on multiple locations weekly, moving the unit over the road can be the biggest consideration and a wheel-mounted shredder makes more sense. If the material will be brought to the machine, an electric or natural gas driven unit may be ideal to reduce overall operating expenses.
Monitoring Capability
Keeping track of the operating conditions of the machine helps to reduce breakdowns and maintenance surprises. Most units offer gauges or panels that monitor engine conditions. Some manufacturers offer remote access to the unit’s status via the Internet and, from anywhere on a cell phone, management can see exactly how the machine is operating in real time.
Discharge Measuring Device
Scales can be added to the discharge belts to measure the production of the unit. Some manufacturers allow Internet access to this function as well so management can see current operating parameters in real time from anywhere.
Height of Discharge
Another factor is the height of the discharge belt. This determines if you can load trucks directly from the machine. Manufacturers offer standard lengths and optional lengths depending on requirements.
References From Current Users
Once you have narrowed the list of preferred shredders, it’s best to contact several current users of the machine. Manufacturers can supply a list of references. Make sure to get real feedback from these people, as they have experienced what you will be experiencing in the future. Make sure to research the facts of all the manufacturers, how long they have been in business, how many machines they have out and in what applications.
Cost of Machine
Cost is the last factor to consider. Pricing weighs in on every decision of course, but often it’s smarter to spend some extra money up front for a feature that can save thousands of dollars in the long run. Shredding any material is a violent action and shredders are tough, but they aren’t designed to last forever. Expect an eight- to12-year life of constant production then look to replace the unit. Not all revenue is profit, there is a significant amount that must be used to purchase and keep the shredder in good working condition. Factor in the business model expenses for a good operator and maintenance and repair cost. This should keep your shredder active and a continued source of making money.
Shredders are great machines that can handle most products. Some are specifically designed for certain materials and applications while others offer flexibility that enables them to be used in a variety of applications. For example, a high torque shredder can process almost any type of waste stream, separate the ferrous metals and make much of the waste into a usable fuel product that can help in the generation of electricity taking the place of coal and minimizing the consumption of fossil fuels. Addressing these 19 considerations can help make a buying decision easier.
Lane M. Blount is Regional Sales Manager for Tana North America, Ltd. and is based out of Cleveland, TX. He can be reached at (832) 594-2818 or e-mail [email protected].
Chad Phares is Vice President of Humdinger Equipment (Lubbock, TX). He can be reached at (806) 771-9944 or via e-mail at [email protected].