120,000-Ton Recycling Industrial Park Doubles Production Capacity by Adopting TL65300 Large Heavy-Duty Single-Shaft Shredder

100,000-ton-level comprehensive solid waste recycling industrial parks generally face five core pain points: cumbersome feeding, blade chipping from thick materials, material bridging and blocking, insufficient production capacity and unsafe hazardous waste production. Old and small and medium-sized shredders cannot meet annual capacity indicators, resulting in high costs of external crushing processing. A 120,000-ton comprehensive recycling industrial park in Anhui eliminated two old ordinary single-shaft shredders and adopted the production layout of “flagship main machine for heavy-duty coarse shredding + medium auxiliary machine for thin material diversion”. The upgraded TL65300 large heavy-duty single-shaft shredder serves as the main production host, completely solving five major problems in capacity, labor, operation and maintenance, safety and profitability. The renovation solution can be directly replicated in large-scale hazardous waste and recycling parks nationwide.

1. Project Background

As a provincial-level certified large-scale comprehensive recycling industrial park, it holds qualified licenses for hazardous waste disposal, recycled plastic processing and agricultural & forestry material processing. The park annually processes 120,000 tons of materials including large plastic parts, waste cables, general medical solid waste and solid wood pallets, supporting three deep-processing workshops for RDF fuel compression, plastic granulation and metal separation. Before renovation, the park was equipped with two 75kW ordinary single-shaft shredders as coarse shredding hosts, with outdated configurations and poor adaptability, leading to prominent full-link production bottlenecks that restricted annual capacity compliance:

1. Extremely low feeding efficiency: Old equipment has narrow closed feeding ports, disallowing direct forklift pallet feeding. All palletized turnover boxes, wood pallets and cable bundles require manual splitting, with 4 dedicated feeding workers per shift, resulting in extremely high monthly labor costs;
2. High blade wear and failure rate: Ordinary thin hollow rotors have insufficient hardness, prone to blade chipping and breaking when shredding thick-walled chemical barrels and metal soldered cables. Weekly shutdowns for blade surfacing and repair are required, with the effective equipment operating rate below 65% and poor continuous mass production capability;
3. Frequent material blocking and bridging: Without long-stroke forced hydraulic feeding devices, fluffy films and compacted wood stacks easily bridge in the hopper, requiring manual poking and unblocking 2-3 times per shift with potential mechanical injury risks;
4. Severe capacity shortage: The peak hourly output of the two old equipment totals only 6 tons, with a daily processing volume of 60 tons, falling short of half the annual 120,000-ton capacity target. A large number of materials have to be sent for external crushing, costing over 700,000 CNY in annual outsourcing fees;
5. Non-compliant safety and environmental protection: Lack of closed dust-proof and spray explosion-proof structures leads to high-temperature ignition during metal friction and RDF material shredding, as well as uncollected workshop dust, resulting in multiple unqualified environmental dust inspections and blocked safety rating upgrades for hazardous waste production.

In July 2026, the park completed full upgrading of the coarse shredding production line, eliminating two old shredders and purchasing one TL65300 flagship large heavy-duty single-shaft shredder as the main coarse shredding host, matched with one TL48250 medium heavy-duty model to divert thin films and small scraps, building an automatic divided-duty closed-loop shredding production line.

Contact: WeChat/Phone: +86 15092868822 ｜ Email: [email protected]

2. Customized Production Line Implementation Solution
3. Flagship Main Shredding Host: Adopt TL65300 large heavy-duty single-shaft shredderwith 132+132kW high-power dual motors, 650mm integral forged solid rotor, 3000mm ultra-long cutting rotor and 15kW upgraded air-cooled hydraulic feeding unit, delivering full heavy-duty torque for direct shredding of vehicle-sized and palletized oversized materials;
4. Front-End Automatic Feeding Renovation: The main machine feeding end is matched with a heavy-duty closed belt conveyor and dedicated forklift direct feeding platform, enabling direct forklift unloading without manual material splitting or processing, achieving zero manual contact with the hopper;
5. Hazardous Waste Safety & Environmental Protection Configuration: The whole machine is equipped with fully enclosed dust covers, spray cooling explosion-proof systems and high-flow pulse dust removal units to suppress high-temperature ignition from friction and collect all shredding dust, complying with the standardized disposal of medical solid waste and RDF combustible materials;
6. Back-End Diversion & Separation Layout: A two-way diversion belt conveyor is installed at the discharge port, transporting thick hard plastic scraps to the granulation workshop, wood and RDF scraps to the fuel baling workshop, and metal-mixed scraps to the magnetic separation section for classified and non-mixed material conveying;
7. Particle Size Backup Configuration: Equipped with 40mm universal screen, 30mm fine separation screen and 60mm volume reduction screen for large materials. The hydraulic quick-opening door enables screen replacement within 10 minutes, quickly adapting to different discharge particle size standards for various materials.
8. Measured Full-Dimensional Efficiency Improvement and Cost Reduction Benefits
9. Doubled overall production capacity to meet annual targets

The single-machine peak hourly output of TL65300 reaches 12 tons. Matched with the TL48250 auxiliary machine for thin material diversion, the park’s daily shredding capacity increases from 60 tons to 120 tons with doubled daily output, stably achieving the annual 120,000-ton solid waste processing capacity and completely eliminating external outsourcing crushing business, saving over 700,000 CNY in annual outsourcing costs.

2. Zero feeding labor and 78% reduction in blade operation and maintenance costs

Direct forklift pallet feeding eliminates 4 dedicated splitting and feeding workers, cutting feeding labor costs by 100%. The factory thickened alloy steel four-edge rotating cutter group features strong metal impact resistance, requiring maintenance and surfacing only after more than 30 days of continuous full-load operation. Compared with weekly blade grinding and replacement for old models, the comprehensive costs of blade procurement, disassembly, surfacing and maintenance labor are reduced by 78%. The solid quenched rotor resists distortion and deformation, with no major faults such as spindle bending, gear cracking or motor burnout after more than two months of operation.

3. Complete elimination of material bridging and blocking, equipment operating rate increased to 95%

The long-stroke high-pressure hydraulic forced feeding plate realizes uniform feeding, enabling automatic feeding of fluffy films, stacked wood pallets and thick hollow barrels without bridging or emptying. Manual close-range poking and unblocking is eliminated, avoiding mechanical injury accidents in the workshop. The effective equipment operating rate rises from 65% to over 95%, with greatly extended 24-hour continuous full-load production time and uninterrupted production rhythm.

4. Dual compliance of environmental protection and safety with upgraded safety production rating

The integrated fully enclosed and spray explosion-proof structure eliminates high-temperature ignition risks during metal and combustible material shredding. The pulse dust removal system collects all workshop dust with stable compliance with environmental inspection standards. Full PLC multi-stage safety interlock protection, door opening power cutoff and overload protection enable successful passing of the provincial-level first-class hazardous waste safety production standardization review, with no environmental or safety rectification fines and zero production shutdown risks.

5. Uniform discharge for efficient separation and premium revenue from recycled materials

Heavy-duty shearing produces uniform and controllable discharge particles without long irregular scraps. The metal separation purity of back-end magnetic separation equipment is increased by 5%. High-purity ferrous metals, non-ferrous metals, clean plastics and qualified biomass wood materials are sold separately, achieving an average premium of 240 CNY per ton for the four types of recycled materials compared with mixed ordinary materials, bringing considerable annual value-added benefits.

6. Short renovation cost payback period and minimal daily maintenance

The new one-main-one-auxiliary unit occupies less space than the two old equipment, saving factory storage area. The air-cooled hydraulic system requires no summer maintenance, and the electric control system supports self-inspection of faults for easy maintenance by zero-basic operators. Annual electromechanical maintenance costs are greatly reduced. The renovation cost can be recovered within 10 months relying on savings in labor, outsourcing and consumable costs.

4. Real Feedback from Park Equipment Director

The park equipment director commented: “In 10,000-ton-level hazardous waste and mixed solid waste treatment, we are most troubled by bulky material feeding difficulties, thick material blade chipping, blocking shutdowns and capacity shortages leading to high outsourcing costs. After upgrading to the complete TL heavy-duty single-shaft shredder production line, the TL65300 reinforced solid rotor provides sufficient bearing capacity. Direct forklift pallet feeding saves time and labor, and forced hydraulic feeding completely solves material bridging problems. The explosion-proof and dust-proof configuration meets high-standard hazardous waste production requirements. The brand has a complete model tier system: the 48 series suits medium and small factories, while the 65 series adapts to super industrial parks. Its 24-hour full-load stability far exceeds ordinary single-shaft equipment on the market, ideal for long-term high-intensity mass production.”

5. Replicable Standard Selection Guide

The divided-duty shredding production line of large heavy-duty single-shaft shredders is applicable to provincial-level hazardous waste disposal centers, industrial parks with annual output above 100,000 tons, large-scale automobile dismantling bases, RDF biomass fuel processing plants and exclusive waste treatment workshops of large packaging groups. Standard selection: TL48160/48200 for factories with annual capacity of 30,000–60,000 tons; TL48250 for 60,000–100,000 tons; TL65220/65250 and flagship TL65300 super heavy-duty models for super industrial parks above 100,000 tons and high-risk hazardous waste working conditions.

Contact: WeChat/Phone: +86 15092868822 ｜ Email: [email protected]