TL Multi-spec Single Shaft  Comprehensive Renewable Resource Factory Upgraded with TL40120 Medium Single Shaft Shredder, 50% Higher Multi-material Mixed Processing Capacity

Multi-category mixed solid waste recycling factories generally face six major industry pain points: single-function equipment, cumbersome screen replacement, frequent thick material jamming, high blade consumable costs, unqualified dust emission and poor downstream separation quality. Dual-machine separate operation leads to high labor and floor occupation costs. A comprehensive renewable resource factory in Hunan eliminated two old split single-shaft shredders and adopted a dual-mode configuration of “heavy-duty main machine + small auxiliary machine”. Upgrading to TL40120 Single Shaft Shredder as the main host and TL32100 as the auxiliary machine builds an integrated shredding production line for plastics, electronic waste and wood materials, achieving all-round upgrades in production capacity, profit, environmental compliance and operation & maintenance, replicable for all national mixed waste recycling plants.

1. Project Background

This licensed comprehensive recycling factory in Hunan legally recycles large waste plastic parts, circuit board electronic waste and warehouse wood pallets from surrounding industrial zones, with a stable daily incoming waste volume of 12 tons. It supports three downstream deep processing lines: granulation, metal magnetic separation and biomass baling. Before renovation, the factory was equipped with two 37kW old ordinary single-shaft shredders, one dedicated to large plastic parts and the other for electronic and wood thin materials. Long-term operational pain points severely restricted production expansion:

1. Low material switching efficiency: Old models only support manual bolt screen disassembly, requiring more than 1 hour for single screen replacement when switching plastics, electronics and wood materials, resulting in frequent production shutdowns and limited overall capacity;
2. Frequent jamming and shutdowns: Without PLC intelligent overload reverse protection system, thick chemical plastic barrels and circuit boards with welding feet easily jam the rotor, requiring manual material cleaning over 3 times per shift with an effective machine operation rate below 65%;
3. High labor and consumable costs: Ordinary single-sided carbon steel blades have poor wear resistance and require weekly shutdown for grinding and replacement. Two machines require two full-time workers for feeding, de-jamming and maintenance, causing double labor and consumable loss;
4. High environmental compliance risks: Open shredding cavities without supporting dust removal devices lead to serious workshop dust pollution, receiving multiple environmental rectification notices and facing shutdown risks;
5. Unstable downstream processing quality: Uneven shredded particle sizes cause fluctuating load on downstream fine crushers, resulting in many impurities and color differences in recycled plastic particles and low metal separation purity for electronic waste, forcing low-price bulk sales.

In July 2026, the factory comprehensively upgraded and streamlined production lines, eliminated two old shredders, and adopted oneTL40120 (55kW hydraulic medium flagship single-shaft shredder) as the main heavy-duty shredding host, matched with one TL32100 auxiliary machine for thin material diversion, building an automatic divided-operation shredding production line.

2. Customized Production Line Implementation Solution
3. Core Main Host: Adopted TL40120 Single Shaft Shredderwith 55kW low-speed high-torque configuration and 55rpm heavy-duty speed. Equipped with original hydraulic automatic screen opening & replacement system, independent air-cooled hydraulic station and standard DC53 four-edge reversible cutter set. Reserved cooling water interface for later cooling system upgrade to adapt to high-sediment mixed waste shredding;
4. Auxiliary Diversion Equipment: Matched with TL32100 small shredder to specially divert thin films, small circuit boards and wood scraps, balancing feeding flow and avoiding main machine overload;
5. Automatic Conveying Transformation: Both machines are connected with closed belt conveyors for fully automatic feeding, canceling manual feeding duty. The discharging end adopts a bidirectional diversion belt to deliver plastic scraps to the granulation workshop and electronic & wood scraps to the separation and baling section with zero material mixing;
6. Environmental & Particle Size Matching: The full line is equipped with pulse dust collection cabinets for closed dust gathering. Equipped with 40mm universal screens, 20mm small-aperture screens for electronic separation and 60mm large-aperture screens for wood volume reduction, enabling rapid particle size switching to meet downstream processing standards of three types of materials.
7. Verified Full-dimensional Efficiency Improvement & Cost Reduction Benefits
8. 50% Higher Comprehensive Shredding Capacity, Zero Inventory Backlog

The peak hourly output of the TL40120 Single Shaft Shredder reaches 4 tons, with far stronger heavy-duty shredding capacity than old 37kW models. The coordinated operation of main and auxiliary machines increases the daily processing capacity from 8 tons to 12 tons, realizing daily incoming material zero backlog. Hydraulic automatic screen replacement only takes 10 minutes for material switching, enabling flexible daily processing of plastics, electronics and wood materials with excellent production line flexibility.

2. Dual Cost Reduction in Labor & Blade Consumables, Greatly Lower Maintenance Expenses

Equipped with automatic reverse anti-jam and no-load sleep shutdown functions, the machines require no full-time manual de-jamming and feeding. Only one worker is needed for daily inspection of two machines, cutting labor costs by 50%. DC53 four-edge reversible alloy steel blades work stably for 22 days per edge and can be recycled by surface rotation, with a total service life of nearly 3 months per set. Compared with weekly grinding and replacement of old carbon steel blades, the comprehensive cost of blade procurement, grinding and manual maintenance is reduced by 72%.

3. Full Environmental Compliance & Improved Workshop Working Environment

The fully closed shredding cavity and supporting pulse dust collection system control dust emission from the source, fully meeting environmental dust detection standards and eliminating rectification and shutdown risks. The independent air-cooled hydraulic station maintains constant oil temperature without thrust attenuation in high-temperature summer weather, realizing stable annual production capacity unaffected by seasonal temperature changes.

4. Controllable Discharge Particle Size & Synchronous Premium Income for Three Materials

Uniform V-shaped shearing produces regular and consistent particles, stabilizing the load of downstream fine crushers and greatly reducing color differences and impurities in recycled plastic particles. Controllable electronic scrap particle size increases metal magnetic separation purity by 4%, enabling classified sales of high-purity metals and clean plastics. Uniform wood scrap particles meet biomass fuel acquisition standards. All three recycled materials achieve a stable premium of 220 yuan per ton, significantly increasing monthly factory profits.

5. Stable Operation & Ultra-low Long-term Maintenance Threshold

The machine body is welded with thickened manganese steel, matched with a reinforced 410mm heavy-duty rotor, ensuring no shaking or deformation under long-term full-load operation. The original PLC electric control system is highly adaptable to dusty environments and voltage fluctuations. After one and a half months of operation, only regular bearing lubrication and screen cleaning are required without major faults including motor burnout, transmission jamming and hydraulic leakage. Daily maintenance can be completed by zero-experience operators.

6. Reduced Floor Occupation & Saved Fixed Asset Investment

The new main & auxiliary dual-machine configuration occupies less space than the original two old machines, saving 20㎡ of workshop area for finished product storage. No additional dust removal and cooling auxiliary equipment is required, reducing environmental supporting equipment procurement costs and shortening the factory renovation payback period.

4. On-site Feedback from Production Supervisor

The factory production supervisor commented: “Mixed multi-category solid waste recycling is troubled by slow material switching, labor-intensive jamming cleaning and high blade costs. The upgraded full TL single shaft shredder production line completely solves these industry pain points. The TL40120 main machine has excellent thick material processing capacity, automatic screen replacement saves massive time and labor, and automatic reverse anti-jam eliminates manual material digging. The matched TL32100 auxiliary machine doubles thin material processing efficiency. With complete power gradient models covering small workshops to large industrial parks, TL shredders can be freely matched with conveying, dust removal and fine crushing equipment for automatic lines. Their durability and cost performance far exceed generic brands, making them the perfect choice for mixed waste recycling plants.”

5. Replicable Standard Selection Guide

This divided-operation main & auxiliary shredding solution is applicable to plastic & electronic comprehensive recycling stations, wood pallet processing factories, multi-category solid waste recycling plants and industrial zone centralized waste disposal centers. Standard selection: TL2260 small manual model for daily thin material processing within 3 tons; TL3280/TL32100 small main models for 3–8 tons daily conventional mixed waste; TL4080/40100 medium hydraulic models for 8–15 tons daily thick & hard mixed materials; TL40120/TL40150 extended heavy-duty flagship models for daily processing over 15 tons of large thick materials.

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