The Details Make the Difference
Vecoplan is always looking for ways to improve shredding processes. One of the key areas they’re focusing on is digital technology. By using data, the company is helping to monitor processes reliably and automate tasks. This reduces errors that often happen when operators set shredders manually, boosting machine performance and increasing their lifespan.
“Many machine settings that workers used to adjust by hand can now be automated,” says Paul Mockenhaupt, who handles digitalisation at Vecoplan. “It’s becoming more important for us to give our machines ‘intelligence’ so customers get better support.” To make this happen, Mockenhaupt and his team are creating new features to improve the shredding process. One of these is the introduction of an electrically powered ram.
Energy-Efficiency with Electric Power
“We’ve equipped our new electrically powered ram with high-performance ball screw drives,” explains Mockenhaupt. “These components are very energy-efficient, so users save power.” Unlike hydraulic systems, electric ones don’t need oil, which can sometimes contaminate the material being shredded. This is becoming more important for customers. Another benefit is the stronger design. Electric drives have fewer moving parts, which means less wear and tear.
“Compared to a hydraulic ram, our electric solution can be more precisely controlled,” says Mockenhaupt. Operators can set the exact torque, or pressure, applied to the material. The electric ram steadily pushes the material towards the rotor, and the new design is quicker, improving throughput.
High-Powered Direct Drive
Vecoplan also offers an optional, more powerful HiTorc direct drive for its shredders. This drive operates efficiently, even when processing large amounts of material. “A controller in the frequency converter ensures the rotor always has the optimal torque, no matter the operating conditions,” says Mockenhaupt. This makes the drive highly energy-efficient. Because it’s an all-electric system, there are no clutches, belts, or flywheels, which means lower maintenance costs. “By removing mechanical parts, the system’s mass inertia is reduced,” adds Mockenhaupt. “This ensures smooth start-ups, even when the shredder is full.”
The system uses continuous speed monitoring and electrical current analysis to spot overloads during shredding. If foreign material is detected, the rotor stops within milliseconds to prevent damage. After a short reverse motion, it quickly starts again in the right direction. Compared to traditional shredders with electromechanical drives, those with this system can save up to 40% on energy, and up to 60% when compared to hydraulic drives.
Smart Detection of Extraneous Material
Another new feature is the smart, vibration-based detection of foreign material, such as stones or metal objects. This helps prevent damage to the shredder. The system is easy to use and adjusts automatically. “Our solution is self-learning,” says Mockenhaupt. “When the shredder starts, sensors gather data on the material being shredded, such as its type, size, and shape. The system then adjusts to the conditions automatically.” Operators no longer have to manually adjust sensitivity, which can be time-consuming. The system can also be controlled remotely. “With our smart material detection, the shredder can even stop automatically if it detects small stones, without the operator needing to step in,” adds Mockenhaupt. “We gather data from the sensors, learn how the machine is performing, and can fine-tune the process if needed.” Vecoplan can even retrofit existing machines with this smart detection system if requested.
Quick Adjustment of Cutting Gaps
Vecoplan now offers automatic adjustment of counter knives. “Normally, workers need to manually adjust the counter knives each shift to keep the cutting gap correct,” says Mockenhaupt. If the gap is too wide, the shredder uses more energy and doesn’t cut the material properly. This often results in lower-quality output. Manually adjusting the gap can take anywhere from 15 to 30 minutes. “Our automatic system cuts that time down by a factor of ten—without needing any manual intervention,” says Mockenhaupt.
When the shredder runs empty, the counter knives are automatically reset. This is a major benefit for customers who need their machines running efficiently throughout the day. The result is more consistent output quality and less wear and tear on the shredder, extending its lifespan. “Manual adjustment of the counter knives requires skill and experience,” says Mockenhaupt. “Our automatic system removes that guesswork, setting the gap precisely every time, no matter who’s operating the machine”.
Cooling with Minimal Water
Some materials, like certain plastics, can soften due to the heat produced during shredding. This affects the quality of the shredded material. To prevent this, cooling water can be used, but the right amount is crucial. Too much water can interfere with later processes. Vecoplan has developed a minimum-quantity cooling system to address this. “We measure the material temperature to control the right amount of cooling water,” says Mockenhaupt. “Adjustable temperature limits let us control the water supply exactly.” The water is vaporised and dissipated. When new material is fed into the shredder, there’s no need to adjust the machine; just change the material settings. “All you need is a water connection. There’s no need for expensive additional equipment,” adds Mockenhaupt. The Vecoplan Smart Centre (VSC) also allows operators to track costs and other key metrics.
Supporting Customers with Smart Technology
“These new technical features help us provide even better support for our customers,” says Mockenhaupt. “With the smart components in these machines, their performance no longer depends on the skill level of the operator. Consistent, high-quality results are achieved through precise, repeatable settings.” This helps avoid mistakes, saves time, and reduces costs. “Our goal is to offer the best possible support to our customers.”
To get started today with Vecoplan, contact us at Gibson’s on 02 6559 4001 or email us on info@aegibsonman.com.au
Learn more about Vecoplan Industrial Shredder: https://aegibsonman.com.au/products/vecoplan-industrial-shredder/
View original article: https://vecoplan.com/en/news/2024-07-optimising-shredding-processes-utilising-new-technical-features