In the metal recycling sector, and especially in scrap processing, operational efficiency is a decisive factor for profitability. Hammer mills are the heart of the process, but they are often forced to work under severe stress: bulky, heterogeneous, contaminated, or compressed materials can cause accelerated wear, high energy consumption, and operational risks.
Integrating a pre-shredder upstream of the mill is not just an additional accessory—it is a strategic choice. The BRAVO pre shredder, in particular, optimizes the entire workflow, reducing costs and critical issues while increasing process safety.
1. Material preparation: the foundation of efficiency
BRAVO acts as a true “material preparer.” It coarsely and uniformly reduces materials such as: ELVs (End of Life Vehicles), scrap bundles, heavy scrap, etc...
This pre shredding ensures a constant and controlled flow into the hammer mill, preventing sudden overloads or the entry of unsuitable material.
2. Reduced hammer mill maintenance costs
Since only material already shredded by the pre shredder reaches the mill hammers experience fewer violent impacts, wear plates last longer and grates do not have to handle oversized pieces.
The result is a significant extension of the mill’s service life and reduced maintenance operations lowering operating costs and minimizing downtime.
3. Lower energy consumption and less noise
A hammer mill fed with pre treated material operates under more stable conditions Power peaks decrease and overall energy consumption is reduced.
The electrical load spikes typically generated by a hammer mill—often several times higher than normal load—are drastically reduced thanks to pre shredding.
Reducing violent impacts inside the mill leads to lower noise emissions
4. Reduced operational risks
The BRAVO pre shredder helps prevent some of the most feared issues in the sector.
Thanks to pre-shredder BRAVO most of the components highly flammable are released before reching the grinding chamber of the hammers millreducing the risk of explosions in the rotor housing, decreasing contamination of the incoming material and structural damage due to explosions improvvise.
5. Protection against sabotage
One of the most important—and often overlooked—advantages of the pre-shredder BRAVO is its ability to protect Hammers mill from heavy, tough, or dangerous materials that may be hidden inside incoming scrap.
If such elements are not intercepted beforehand they can reach the hammer mill’s grinding chamberchamber and cause extremely serious damage. The rotor cannot stop immediately due to its high angular momentum: impact with a massive object can break the rotor or force it out of its bearings. In such cases, structural damage can easily lead to costly downtime and repairs amounting to hundreds of thousands of dollars.
The pre-shredder BRAVO eliminates this risk at the source by processing the material in advance and safely handling even the most problematic objects. This is possible thanks to three key features:
6. Labor optimization
The BRAVO pre shredder also reduces the labor required for scrap inspection:
Inspection is still necessary to detect unsuitable waste (tires, miscellaneous refuse), but the overall workload is significantly reduced.
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