Injection & E-waste Mixed Recycling Plant Upgraded with TL40120 Single Shaft Shredder, Single-operator Dual-material Waste Processing Solution

Most comprehensive recycling factories handle both plastic and electronic waste. Traditional separate configuration of dedicated plastic shredders and e-waste shredders causes five major pain points: large floor occupation, excessive labor, high consumable cost, cumbersome material switching and summer capacity attenuation. A comprehensive recycling plant in Jiangsu eliminated two old split shredding machines and adopted one TL40120 Single Shaft Shredder. The single unit handles both large plastic materials and circuit board e-waste, achieving multi-dimensional upgrades including equipment simplification, labor reduction, lower consumable cost, higher material premium and environmental compliance. The solution is fully replicable for small & medium mixed waste recycling factories nationwide.

1. Project Background

This licensed comprehensive recycling plant in Jiangsu collects large injection molding head materials, hollow plastic barrels and film scraps from 20 local small & medium injection factories, and recycles waste circuit boards, ABS appliance shells and hardware aluminum parts from 3 electronic factories. With a daily mixed waste processing capacity of 5 tons, it is a typical dual-category mixed recycling plant. Previously equipped with two old ordinary single-shaft shredders (one for plastics, one for e-waste), the factory faced severe operational pain points restricting capacity expansion:

1. Frequent jamming & shutdowns: Old machines lack PLC overload reverse protection, easily jammed by thick plastic barrels and soldered circuit boards, requiring manual cleaning 4-5 times per shift with two full-time operators;
2. Extremely high blade loss: Ordinary carbon steel single-edge blades blunt rapidly within 3 days, requiring frequent shutdowns for polishing and replacement, causing massive waste accumulation and warehouse occupation in peak seasons;
3. Uncontrollable particle size & low profit: Fixed screens cause uneven discharge particle size, resulting in defective granulation products; mixed large e-waste particles reduce magnetic separation purity, forcing low-price bulk sales;
4. Unstable hydraulic performance: Old hydraulic systems have no independent air cooling, leading to soaring oil temperature and 30% capacity attenuation in high-temperature summer weather;
5. Non-compliant safety & environmental standards: Open shredding cavity causes severe dust and oil pollution, failing multiple regular environmental and safety inspections with high operational risks.

In 2026, the factory optimized production layout, eliminated redundant old equipment and purchased one TL40120 Standard Single Shaft Shredder to rebuild an integrated dual-material shredding production line for plastic and electronic waste.

2. Customized Implementation Solution
3. Main Shredding Host: Adopted TL40120 Single Shaft Shredderwith 30kW main motor + 3kW air-cooled hydraulic system and original DC53 standard 4-edge blade set, reserved with alloy overlay upgrade interface for future high-impurity material processing;
4. Flexible Material Switching Configuration: Equipped with hydraulic automatic quick-open screen door, enabling cavity opening/closing and screen aperture replacement within 10 minutes, meeting large-particle plastic shredding and fine-particle e-waste separation requirements;
5. Environmental Dust Control: Standard bottom closed fine material collection chute centralizes shredding dust without extra dust removal equipment, realizing zero dust leakage and low environmental investment;
6. Diversified Conveying System: Discharge port connected with customized bidirectional reversible belt conveyor to switch conveying directions, delivering plastic scraps to granulation workshop and e-waste scraps to magnetic separation workshop for complete material separation.
7. Verified Full-dimensional Cost Reduction & Efficiency Improvement Data
8. 50% Labor Reduction, Single-operator Full Coverage

One TL single shaft shredder replaces two old machines. Equipped with automatic reverse anti-jam and no-load sleep functions, it requires no full-time manual cleaning and feeding. The original two operators’ workload is fully covered by one ordinary worker, cutting monthly labor costs by 50% and simplifying workforce management.

2. 70% Reduction in Blade Consumable Costs & Downtime

Original DC53 rotatable heat-treated 4-edge blades work stably for 20 days per edge, with another 20 days’ service life after 90° rotation, achieving a total service life of 80 days per set. Compared with ordinary carbon steel blades requiring replacement every 3 days, comprehensive costs of blade procurement, overlay welding and manual maintenance are reduced by 70%, and monthly downtime for blade polishing is cut by 80%, eliminating seasonal waste accumulation.

3. Stable All-season Capacity with Flexible Material Switching

Quick screen aperture switching adapts large-aperture high-capacity plastic shredding and small-aperture precise e-waste shredding. The independent air-cooled hydraulic station maintains constant oil temperature without summer thrust attenuation, realizing stable annual capacity and completely solving seasonal output decline problems.

4. Higher Separation Purity, ¥180 Per Ton Material Premium

Uniform V-type shearing produces regular plastic particles, improving granulation stability and recycled material mixing ratio to reduce new material procurement costs. Controllable e-waste particle size increases magnetic separation metal purity by 3%. Classified high-purity metal and clean plastic materials gain a stable premium of ¥180 per ton compared with mixed bulk materials, bringing significant monthly profit growth.

5. Full Compliance of Safety & Environmental Standards, Minimal Long-term Maintenance

Fully sealed cavity and bottom centralized dust collection realize standardized workshop environment, passing regular environmental and safety inspections. Triple power-off protection eliminates accidental startup injuries. The machine has achieved zero electrical faults, hydraulic leakage and blade damage within 4 months of operation. Daily maintenance only requires regular lubrication and screen cleaning, operable by zero-experience workers.

6. Improved Space Utilization with Sufficient Expansion Capacity

Single-machine configuration saves 22㎡ of workshop space previously occupied by redundant equipment, providing additional storage area for raw materials and finished products, improving plant throughput without factory expansion and extra fixed asset investment.

4. On-site Feedback from Factory Director

The factory director commented: “Mixed waste recycling is troubled by single-function equipment, high labor and consumable costs. The upgraded TL single shaft shredder completely solves industry pain points. It handles both plastic and electronic waste perfectly. The V-type blade design avoids material bridging and jamming, automatic reverse function eliminates manual cleaning work, and DC53 four-edge blades are far more durable than ordinary carbon steel blades, saving massive annual consumable and labor costs. With complete gradient models for all-scale factories, TL shredders deliver outstanding versatility, stability and cost performance, being the most reliable choice for mixed recycling plants.”

5. Replicable Standard Model Selection Guide

This dual-material shredding upgrade solution applies to injection molding waste recycling stations, e-waste dismantling factories, township domestic waste volume reduction stations, wood & packaging recycling plants and mixed solid waste recycling factories. Standard selection: TL3080 short-cavity model for 1–3 tons daily small waste; TL40120 standard main model for 3–8 tons daily plastic & e-waste mixed waste; TL50150 extended heavy-duty model for over 8 tons daily thick & hard materials.

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