Operating in a sector where precision and consistency dictate environmental and economic outcomes, specialist recycler JR Hammer has spent the past few years refining its production line to minimise downtime and maximise resource recovery.
Its latest investment, a Genox Granulator integrated into its existing system, marked a step in improving operational reliability, sustainability, and worker efficiency, according to Josh Robinson, Managing Director and Founder.
In the northern suburb of Thomastown, Victoria, JR Hammer offers end-of-life solutions for copper cables, mixed PVC and other plastic insulation formulas.
“We don’t just recycle the metals; we recycle the whole cable, so the polymers as well as the metals,” says Josh.
Granular success
The company initially invested in a complete system for cable recycling about five years ago, but there were recurring breakdowns and inefficiencies.
Josh says at the time he had little experience in new technologies and so began working closely with machinery specialist Peter Koueik, Sales Manager of the Recycling Division at Applied Machinery.
Together, they reviewed the production process, identifying key issues and exploring the best long-term solutions. They concluded the best path forward was to replace parts of the system with more reliable, better-engineered units, most notably, a new Genox Granulator retrofitted into the existing line.
“There were leakage points and dust factors inside our factory that we needed to get on top of,” says Josh.
“We looked at updating another couple of our units before we got this granulator and decided it would act as one unit, in a series of additional units, that will help JR Hammer achieve our long-term goals.”
He says operations have greatly improved since the installation of the Genox Granulator. One of the biggest differences is a reduction in downtime.
“Before the granulator, operations could be down for up to two weeks, depending on what needed to be done,” he says.
“A simple grid changeover that should be a five-minute job would usually take an hour.”
Much of that unreliability stemmed from the design of the previous granulator and its internal components, which, Josh says, were prone to damage.
In contrast, the new Genox system incorporates design improvements that prevent such failures.
Josh says the engineering extends beyond reliability, it’s also improved the day-to-day experience for JR Hammer’s workforce.
“The new granulator has electric hydraulic systems, which help our team open and close the machine by themselves without needing me there,” he says.
“That means they can now handle screen changes or blade adjustments on their own.”
The impact on throughput has been equally positive. Josh has noticed a significant decrease in downtime because there are no breakdowns.
The Genox Granulator has also played a key role in improving energy efficiency and overall sustainability, two priorities that underpin JR Hammer’s operations.
“The old granulator was out of balance, so it used more energy,” says Josh. “We had a diesel generator previously so the amount of diesel we are using has decreased. Because the new machine is more efficient and has a larger chamber, the material throughput is more consistent.”
Trusted partners
JR Hammer’s commitment to improvement doesn’t end there. The company has ordered an additional piece of equipment, not yet released to the market by Applied Machinery, as part of its ongoing investment program.
Building on lessons learned from previous systems, the team is now prioritising energy efficiency.
“Our current shredder system is a rebranded Genox model, but the wear and tear on that, plus my own early learning in maintenance, had deteriorated it quite significantly over many years,” says Josh.
“Our throughput and the types of cables we’re now recycling are far greater, so we needed something more suitable to manage heavier-duty cables.”
Applied Machinery has introduced JR Hammer to a new shredder that not only meets operational needs but also offers a chance to help bring the company’s offerings to the market.
Peter says the acquisition of future additional equipment will work in conjunction with the granulator.
When it comes to investing in untested equipment, trust in the supplier plays a pivotal role.
For JR Hammer, its relationship with Applied Machinery has provided that assurance.
“I have a great working relationship with Applied Machinery, so if they’re standing by it, then it must be good,” Josh says.
“They’ve supported us through every step of the process, from identifying problems to implementing solutions.”
For more information, visit: www.appliedmachinery.com.au
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