Scrap metal recycler cuts costs and hazards with pre-shredder upgrade
Managing scrap metal today focuses less on operational efficiency and more on mitigating risks. The introduction of electric vehicles into the recycling stream has made material composition less predictable. At the same time, modern shredding equipment has become more interconnected and detailed, increasing the potential for costly failures.
Attar Metals, a recycler based in Mississauga, Ontario, addressed these challenges by modifying its approach before material reached the shredder’s rotor. Tony D’Alonzo, the company’s maintenance manager with 40 years of experience, determined that reducing stress on incoming material would protect both machinery and personnel.
Before 2023, Attar sent raw scrap directly into its shredder system. The primary machine bore the full load, leading to frequent malfunctions and excessive wear across the entire setup. Beyond the financial burden of repairs, this method posed a serious safety hazard. High-speed rotors generate intense friction and sparks, and when material contains residual fuels or pressurized components, the risk of explosions rises sharply.
In April 2023, the company installed a low-speed pre-shredder, the Blue Devil model from Zato, placed before the main shredder. Unlike conventional shredders that rely on high-speed impact, this system uses counterrotating shafts and replaceable blades to cut material gradually. The process produces lower bulk density and exposes enclosed components safely before they enter the primary shredder.
The upgrade delivered measurable improvements. Attar reported a 30% reduction in maintenance costs for the main shredder, a substantial saving given the company’s operational scale. The pre-shredder also reduced strain on downstream equipment, enhancing overall system stability. Safety benefits included a lower likelihood of high-energy incidents inside the shredder, particularly when handling oversized or hazardous loads.
Attar’s evaluation of the pre-shredder extended beyond raw performance metrics. The team assessed how the new machine would integrate with existing operations, its long-term impact on maintenance demands, and the level of technical support available. Zato’s continued assistance proved essential, given the growing complexity of modern shredding technology.
D’Alonzo emphasizes that operators exploring similar upgrades should prioritize safety first. He recommends selecting equipment that aligns with specific operational requirements and confirming robust supplier support. The company’s shift to pre-processing has not only cut costs but also created a more dependable recycling workflow.
