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Bridging continents for wood recycling

wood recycling

HAAS Recycling from Germany has supplied solutions for wood and organics recycling for more than three decades. With installations and machines across the globe, its systems have also been used in Australia for over 10 years.

A recent installation at CUP Recycling, Germany, deals with up to 60,000 tonnes of waste wood.

Since 1997, CUP Recycling GmbH in Goldbach has been part of the WERNER group of companies (WERNER RC GmbH), a family-run company in the waste disposal industry.

CUP operates a processing plant for C&D waste, waste wood and green waste. These materials are professionally cleaned of impurities and shredded into all standard grain sizes. Valuable raw materials are returned into the economic cycle.

The new waste wood plant was needed to process an annual volume of 30,000-60,000 tonnes of all grades A to C.

Ralf Berninger, Technical Operations Manager at WERNER RC GmbH/CUP Recycling GmbH talks about the challenge.

“Our end-product specifications were, firstly, a high-quality chip 0-100mm for reuse in the chipboard industry, and secondly, a pre-shred 0-300mm for thermal recovery (generation of process steam and electricity). However, the processing building had already been built and the available space had therefore already been determined,” Ralf says. “The system is designed by HAAS in a way that we can process pre-shredded material separately, which means that the remaining part of the plant (almost 70 per cent) is not in operation during this time. This guarantees a minimisation of costs in terms of wear, maintenance and energy consumption.”

Several people and departments at HAAS are always involved in the planning of a technical concept. Taking the specific requirements into account, Sascha Kloft and Patrick Szubrin designed an individual layout. A technical design engineer then drew up the final drawing, which was optimised in further meetings with CUP.

The experienced mechanical engineers manufactured the individual plant elements from high-quality materials and components. All electrical and hydraulic installations were also completed in-house at HAAS. 

wood recyclingMaik Fischer, service engineer at HAAS, and his team installed the system within a couple of weeks.

“Every HAAS system is custom-made, adapted to the process specifications and the available space,” Maik says. “All components fit precisely, and subsequent welding or flexing on site is eliminated. In this plant, for example, we have integrated a large number of solid maintenance platforms so that access is possible to all relevant points. The construction on high platform pillars also ensures ground floor accessibility where needed, even with forklifts and lifting platforms.

“About 120 tonnes of steel and 100,000 screws are in this system.”

The TYRON 2000-E XL 2.0, equipped with fine tools 9/9-4, pre-shreds the waste wood. The following electric overband magnet separates the exposed coarse iron parts. A bi-directional conveyor transports the pre-shredded waste wood (0-300mm) either to the storage bay outside the building, or to the ARTHOS 1600-E hammermill for secondary shredding.

The ARTHOS shreds up to 40 tonnes of pre-shredded waste wood per hour to a size less than 100mm. The ballistic chute removes hard and heavy items and guarantees trouble-free operation, while protecting the hammermill. As such, downtimes are minimised.

A heavy chain conveyor equipped with an automatic chain tensioning and chain lubrication system transports the material to the non-ferrous separator. The reversible screw conveyor underneath the separator enables a special fraction to be discharged directly into processing building or, alternatively, the end-product to be transported onwards to the fully automatic storage bay filling. Finally, the end-product is transported with a movable conveyor belt to the required storage bay (in total five bays).

The entire plant is equipped with a dust suppression system. Misting technology binds existing dust.

The plant is controlled from a control room located in a container in the processing building. In addition, two mobile tablets enable flexible control and operation of the plant. During commissioning, the CUP Recycling team was trained in operation and maintenance of the system.

Michael Völker, of WERNER says it was perfect timing from HAAS.

“We at CUP were just starting the project planning for the new waste wood recycling plant when HAAS introduced itself to us. At that time, we were already in contact with other companies and had already received various plant concepts,” Michael says.

“Patrick Szubrin (Sales Manager Plant Technology) and Sascha Kloft (Managing Director) finally convinced us with the individual plant layout as well as various planning details. We visited a couple of already installed HAAS systems and were convinced of the performance of the systems. Already at that time, we have been impressed by the compact design and the construction. The performance of the systems was outstanding.”

In Australia, HAAS Recycling is partnering with CEMAC technologies, based in Melbourne. CEMAC closes the gap for all local requirements such as engineering, installation, service and repairs, as well as spare parts supply. 

For more information visit: www.cemactech.com

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