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Product News Time-Consuming Handling and Risk of Injury: Installation of Shredder on Zinc Die Casting Machine Minimizes Space Requirements and Logistics Costs

From Johanna Erbacher

Zinc die casting products are versatile, but the disposal of production residue poses a problem. ERDWICH Zerkleinerungs-Systeme GmbH offers a solution for this with its M600 single-shaft shredder, as well as its RM1350 ripper and the M465 and M(H)480 twin-shaft shredders with electro-mechanical and hydraulic drives. A small-scale model of the RM1350 will be presented at EUROGUSS 2022 in Nuremberg.

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The RM1350/2 ripper is designed for large parts up to complete body structure components in automotive manufacturing.
The RM1350/2 ripper is designed for large parts up to complete body structure components in automotive manufacturing.
(Source: Erdwich Zerkleinerungs-Systeme GmbH)

Products manufactured using the zinc die casting process can be found in vehicles as well as in toys or medical technology products and can take on a wide variety of forms. Not only is the process particularly versatile, but there is also no need to worry about material losses, as the zinc residues can be remelted and further processed without any loss of quality, which benefits the environment. However, disposal is a problem: The often bulky production residues require a lot of space and usually have to be removed manually at short intervals, which hinders production processes. The sharp-edged surfaces also increase the risk of injury to the responsible personnel. A solution for this is offered by the M600 single-shaft shredder from ERDWICH Zerkleinerungs-Systeme GmbH, which can be installed directly on the die casting machine. It minimizes space, logistics, and time requirements and makes manual handling obsolete. For components of different sizes, ERDWICH also offers the RM1350 ripper and the M465 and M(H)480 twin-shaft shredders with electro-mechanical and hydraulic drives.

The zinc die casting process has established itself in mass production: Depending on the size of the product to be manufactured, parts in the three- to four-digit range can be produced with just one die casting mold - per hour. Particularly in the production of parts for the automotive industry or in mechanical engineering, sprue spinning, punch burrs or defective workpieces can cause full scrap containers within a very short time. If these are not replaced quickly enough by empty containers, this results in a considerable impediment to operating processes - in the worst case, the production speed has to be throttled. "In many companies, removal for remelting is often still carried out manually," explains Harald Erdwich, Managing Director of ERDWICH Zerkleinerungs-Systeme GmbH. "The personnel are then not only exposed to noise and heat, but there is also an increased risk of accidents and injuries due to the sometimes very sharp-edged die cast parts."

Efficient On-Site Shredding of Production Residues of Different Sizes

How can these difficulties be avoided during the production of the die cast parts already? ERDWICH has developed shredders for different sizes for this purpose, which can be installed directly at the die casting plant. In this way, the scrap parts are shredded to a more manageable size even before they are stored in the containers provided for this purpose. The M600 single-shaft shredder, which is available in various cutting unit lengths, is suitable for this application. This was designed for shredding small die cast parts weighing up to 2 kg and can significantly reduce the volume of the parts by up to 60 percent. "With our systems, we always make sure that they fit the specific requirements of our customers," Erdwich reports. "That's why we offer the M600, as well as most of our shredders, with different cutter sizes and drive capacities."

The compact machine dimensions are another advantage, as the plant takes up a space of just 1.5 m2, depending on the version. This means that operation is possible even in confined spaces. In addition, the company attaches great importance to the longest possible service life and ease of maintenance: the completely through-hardened knives, which can be re-grinded several times, ensure the longest possible uninterrupted operation of the shredder.

Fully Automated Solutions for Integration into Production Lines

"In addition to the M600, we also offer systems that are suitable for shredding larger scrap parts," explains Erdwich. "These include the M465 and M(H)480 twin-shaft shredders and the RM1350 ripper, which can efficiently shred and break down parts weighing up to 10 kg or even complete car body structural components. Each shredder meets our high safety standards and is designed for long operating times." All systems can be connected directly to the casting station or die casting machine and, as fully automated solutions, can also be retrofitted into existing production lines. To ensure optimal integration of the shredders into the line, ERDWICH offers on-site appointments at the customer's premises. There, the company's experts get an overview of the conditions and subsequently work out a constructive solution that optimally utilizes the available space and provides the necessary plant size.

After shredding by the ERDWICH shredders, the handy metal parts can be collected in containers via conveyor belts or transported directly back to the furnace systems. This ensures that the shredded material is returned to the production process as quickly as possible. The volume of the castings is reduced by 50 to 60 percent. This optimizes the entire intralogistics process and eliminates the need for space-consuming and cost-intensive intermediate storage of the scrap material and, as a result, also accident-prone manual handling. Shredding also reduces the energy consumption of the melting furnaces, as the small parts can be melted down more easily and, above all, more efficiently. In this way, the resource-saving reprocessing of scrap parts becomes an essential production step in an energy-efficient and cost-saving manufacturing cycle.

At EUROGUSS 2022 in Nuremberg, ERDWICH will provide information on the complete range of its shredder portfolio for castings. A model (in small-scale format) of the RM1350 will also be on display directly at Booth 9-257 in Hall 9. There, Managing Director Harald Erdwich and his colleagues will be available for initial discussions and specific inquiries.

What: EUROGUSS 2022
When: 08 - 10 June 2022
Where: Nuremberg Exhibition Center, Hall 09, Booth 9-257
Contact: Harald Erdwich (Managing Director)
Further information: www.erdwich.com

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