100,000-ton Recycling Industrial Park Upgrades TL65300 Heavy-duty Single-shaft Shredder with Double Cost Reduction and Double Capacity Increase

Medium and large 100,000-ton comprehensive recycling industrial parks generally face five major pain points: cumbersome material switching for mixed multi-material processing, high blade consumable costs, high manual feeding costs, frequent jamming and motor burnout failures, and non-compliant environmental and safety supervision. Ordinary old single-shaft shredders with simple configurations cannot synchronously process RDF fuel, medical hazardous waste and mixed cable materials. Limited capacity forces external crushing outsourcing with additional costs. A licensed comprehensive recycling industrial park in East China eliminated two old 75kW shredders, adopted the production line layout of “flagship host heavy-duty primary crushing + medium auxiliary machine thin material diversion”, and upgraded TL65300 heavy-duty single-shaft shredder as the main host to complete full-line upgrading, achieving all-round improvement in capacity, cost, safety and environmental compliance. The renovation solution can be directly replicated for medium and large solid waste parks nationwide.

1. Complete Project Background

The licensed comprehensive recycling industrial park in East China holds qualifications for general industrial solid waste, qualified medical waste, recycled plastic, agricultural and forestry wood, and waste cable recycling and processing. It is equipped with granulation workshops, RDF fuel pressing workshops and metal magnetic separation workshops, with an annual approved processing capacity of 100,000 tons. It long-term processes four types of mixed materials: thick-walled plastics, solid wood pallets, copper-aluminum cables and medical RDF materials. Before renovation, two old 75kW hollow-roller single-shaft shredders were used as primary crushing hosts with outdated configurations and low automation, causing prominent full-link pain points in production, operation, safety and profitability, restricting annual qualification review and capacity compliance:

1. Extremely low material switching efficiency: Old models adopt pure manual bolt screen disassembly, taking 1 hour for single material switching between plastics, wood and hazardous waste. Frequent daily shutdowns for screen replacement greatly reduce effective production time;
2. High blade operation and maintenance costs: Equipped with ordinary single-sided carbon steel blades with poor impact resistance, blades are easily passivated and chipped when shredding metal-containing cables, requiring weekly shutdown, disassembly, polishing and replacement, occupying a large amount of production time;
3. Frequent material bridging and jamming: Without high-thrust dual-cylinder forced feeding structure, fluffy winding films and compressed wood piles easily bridge and hang in the hopper, requiring dedicated staff to clear jams 2-3 times per shift with potential mechanical injury risks;
4. High front-end feeding costs: Narrow and closed original feed inlet cannot directly load full pallets and cable bundles, requiring manual material splitting and disassembly with 4 full-time feeding workers per shift, resulting in high monthly labor costs;
5. Lack of electric control protection: No original PLC intelligent reverse unclogging system; the motor keeps hard running when materials jam the shaft, leading to high overload burnout risk. Two motor burnout shutdown accidents occurred in one year before renovation, causing order delays and economic losses;
6. Inadequate environmental compliance: No closed spray explosion-proof structure, prone to high-temperature ignition during metal friction shredding; no centralized workshop dust collection, failing multiple environmental dust inspections and affecting annual hazardous waste qualification review.

In August 2026, the park launched a special upgrading of the core primary crushing production line, eliminating two old shredding equipment. One TL65300 flagship heavy-duty single-shaft shredder was purchased as the main host for thick material processing, matched with one TL48250 medium shredder to divert thin films and small scraps, building a divided automatic closed-loop shredding production line.

1. Customized One-stop Implementation Solution
2. Core Main Shredding Host: Adopt TL65300 heavy-duty single-shaft shredder, equipped with 132+132kW bilateral dual motors, 650mm quenched & tempered solid roller, 3000mm ultra-long cutting rotor, original DC53 reversible four-edge blade set, 15kW independent air-cooled dual-cylinder hydraulic station, and factory-standard one-click automatic hydraulic screen changing;
3. Front-end Automatic Feeding Renovation: The host is matched with an ultra-wide enlarged hopper and dedicated forklift direct feeding platform. Full-pallet materials require no manual splitting, enabling direct forklift feeding with zero manual contact with the hopper;
4. Hazardous Waste Environmental & Safety Supporting Facilities: The whole machine is equipped with an integrated spray explosion-proof sealing cover and high-flow pulse dust removal unit to suppress high-temperature ignition during shredding and collect full-range dust, realizing compliant disposal of medical waste and RDF combustible fuel and meeting explosion-proof and dust-proof standards for hazardous waste workshops;
5. Back-end Diversion & Separation Layout: A two-way diversion belt conveyor is installed at the discharge port, delivering plastic scraps to the granulation workshop, wood/RDF scraps to the fuel packaging section, and metal-mixed scraps to magnetic separation equipment for zero-mixed classified transportation;
6. Particle Size Standby Configuration: Equipped with 40mm general screen, 30mm fine screen for metal separation and 60mm large-hole screen for wood volume reduction. Hydraulic fast screen replacement completes within 10 minutes to adapt to different back-end processing particle size standards.

III. Full-dimensional Efficiency Improvement & Cost Reduction Data (Payback, Maintenance & Qualification Supplement)

1. Doubled shredding capacity and eliminated outsourcing crushing profit increase

The single-unit peak hourly output of TL65300 heavy-duty single-shaft shredder reaches 12 tons. Cooperating with TL48250 auxiliary machine for thin material diversion, the park’s daily shredding capacity increased from 55 tons to 110 tons with doubled daily output, steadily achieving the annual approved 100,000-ton capacity index. The annual outsourcing crushing cost of over 620,000 CNY is completely eliminated after equipment upgrading, bringing direct annual cost savings.

2. Zero feeding labor and greatly improved switching & maintenance efficiency

The forklift direct feeding mode completely cancels 4 full-time material splitting and feeding workers, cutting 100% of feeding labor costs. Hydraulic automatic screen changing completes material switching in 10 minutes, 6 times more efficient than the old 1-hour manual disassembly, reducing shutdown switching time by 83%. The original DC53 reversible four-edge blade set operates continuously for 22 days per single edge with a total service life of nearly 3 months via four-edge cycle reuse. Compared with weekly replacement and polishing of old carbon steel blades, the comprehensive cost of blade procurement, surfacing and manual maintenance is reduced by 78%.

3. Nearly zero jamming and motor burnout failures, sharply increased equipment operating rate

The long-stroke dual-cylinder forced feeding realizes uniform material feeding, completely solving film and wood pile bridging problems without manual close-range jamming clearance. Siemens PLC intelligent overload reverse unclogging and multi-stage current protection fundamentally eliminate motor burnout caused by hard material jamming. No major failures such as motor burnout, shaft distortion and gear cracking occurred within two months of operation. The effective equipment operating rate increased from 62% to over 96%, maximizing continuous production stability.

4. Dual environmental and safety compliance, smooth qualification annual review

The integrated closed spray explosion-proof cover eliminates high-temperature ignition risks from friction, and pulse dust removal realizes full dust collection with stable compliance with environmental inspection standards. Triple interlock protection including door-opening power-off, overload locking and body emergency stop ensures smooth passing of the emergency management bureau’s standardized annual review for hazardous waste disposal. The park faces no safety and environmental rectification fines or production shutdown risks.

5. Uniform discharge particle size and increased premium profit from sorted materials

V-type uniform shear produces regular and uniform discharge particles without long irregular scraps. The metal separation purity of back-end magnetic separation equipment is increased by 5%. High-purity copper-aluminum metals, clean recycled plastics and qualified biomass wood are sold separately, with an average premium of 230 CNY per ton compared with mixed bulk materials, bringing considerable annual incremental profits together with outsourcing cost savings.

6. Low maintenance threshold and short renovation cost payback period

The electric control system comes with built-in fault self-check codes, and the air-cooled hydraulic system requires no summer disassembly maintenance. Zero-basis operators can complete daily maintenance including lubrication and screen cleaning. The one-main-one-auxiliary new unit occupies less space than two old equipments, saving workshop storage area. Relying on savings in labor, consumables and outsourcing costs, the equipment renovation investment can be recovered in 9 months with outstanding long-term cost performance.

1. Real Feedback from Park Equipment Supervisor

The park equipment supervisor commented: “Mixed recycling of multi-type hazardous waste, plastics and wood is plagued by slow material switching, high blade costs, jamming-induced motor burnout and environmental non-compliance. After upgrading the complete TL heavy-duty single-shaft shredder production line, the TL65300 solves industry pain points with three core advantages: durable wear-resistant DC53 four-edge V-type blades, time-saving and labor-saving fully automatic hydraulic feeding and screen changing, and stable Siemens electric control anti-clogging protection. The brand has a complete model gradient: the 48 series suits medium and small plants, while the 65 series adapts to 100,000-ton super industrial parks. Its strong 24-hour full-load fatigue resistance fully meets the park’s year-round non-stop high-intensity mass production.”

1. Standard Industry Selection Guide

Heavy-duty single-shaft shredders are applicable to: comprehensive solid waste recycling industrial parks, provincial hazardous waste disposal centers, RDF fuel processing plants, large automobile and home appliance dismantling bases, and large-scale cable recycling plants. Accurate selection: TL48160/TL48200 for 30,000–60,000-ton annual capacity medium-sized recycling/medical disposal plants; TL48250 for 60,000–100,000-ton medium and large capacity plants; TL65220/TL65250 and top flagship TL65300 for over 100,000-ton super industrial parks, large RDF plants and full vehicle dismantling bases.

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