Reducing wear and downtime in a recycling plant

In recycling, efficiency is essential. For Greenworld, a UK-based recycling company, sickle blades in their twin-shaft shredder were wearing out after just 500 hours. Each replacement meant two full days of downtime, affecting throughput and increasing maintenance costs.

To tackle the problem, Greenworld partnered with Welding Alloys. Our Integra™ services team, specialists in engineered wear protection, worked closely with them to develop a tailored hardfacing solution. Using our own manufactured cored welding wires, we refurbished several worn blades and returned them to service for a monitored trial.

After 242 hours of operation, the results were clear. The refurbished blades showed far less wear than the standard OEM versions. The original blade profile, especially at the tip, was well preserved, maintaining cutting performance throughout.

Keeping the blade shape intact is vital. When tips wear down, material often needs a second pass through the shredder, which slows production and uses more energy. By helping avoid this, the improved wear resistance supported both efficiency and reduced energy use – a win for both operations and the environment.

Fewer blade changes, less downtime and longer service life meant Greenworld could reduce maintenance costs and the total cost of ownership of their equipment, while maintaining high performance.

This project shows how our Integra™ team delivers durable wear protection in demanding environments. By combining technical expertise with our own consumables, we help customers extend the life of their equipment, reduce waste and energy use, and support more sustainable operations, while keeping performance high.

Request a quote with Welding Alloys today.