Innovative Hardfacing Solutions from Welding Alloys Extend Life of Recycling Shredder

Welding Alloys was recently approached by JTC Welding & Engineering for technical expertise and support in carrying out a critical task- the repair of an industrial shredder, a key component used in the recycling of household waste. The shredder was in a poor state, and the customer recognised that they would need advanced welding wires to carry out the repair. They were aware that Welding Alloys was well-positioned to offer an effective solution but required guidance in choosing the right product to suit the specific needs of the shredder. Welding Alloys was invited to visit the site and assess the situation in person, and on arrival, the issue was made clear. The shredder had suffered extensive damage throughout, more specifically, to the blades attached to the main body. Over time, the abrasive action of waste particles and the corrosive effects of its acidic residues culminated with the total disfiguration of the blades, ending in a drastic decrease in the shredder’s overall efficiency and service life.

Initially, several competitors attempted to address the problem through various onsite repairs. Unfortunately, these efforts were inadequate and superficial, involving welding that only masked the visible issues on the surface of the blades without addressing the root cause. This approach merely postponed the inevitable, allowing the underlying problem to worsen.

Due to this issue being left unmanaged for so long, the problem persisted, transforming the base of the blades from rectangular and sturdy into a thin, unstable V-like structure. This change caused unshredded waste to collect and circulate in the space at the base instead of being shredded as intended, causing irreparable damage to the gearbox and as a result, severely escalating the final repair costs and overall downtime of the machine.

Recognising the need for a more robust solution to their problem, JTC Welding & Engineering decided to collaborate with Welding Alloys. The proposed solution involved a complete rebuild of the shredder, starting with the complete removal of the old blades from the shaft using a mixture of air arc gouging and oxy fuels to remove worn parts from the shaft. JTC Welding & Engineering ordered new fabricated blades and tooling from a UK manufacturer. Welding Alloys provided support in supplying the most suitable hardfacing wire for the task. ROBODUR K 650, one of our best-selling seamless copper-coated wires, was identified as the ideal consumable for this application to protect the shredder from wear. The hardfacing was performed using the ROBODUR wire, significantly improving abrasion resistance and offering an effective solution to withstand the demanding operating conditions of the shredder. Additionally, for all the V-prepped fillet welds, the customer applied Welding Alloys’ ROBOFIL R 71+ seamless flux cored wire, to ensure the highest integrity and quality of each weld required for the repair. While this comprehensive rebuild required a larger initial investment than the previous patchwork repairs, the result promises a variety of long-term benefits such as an extended service life and a drastically reduced Total Cost Ownership (TCO).

This project highlights both the effectiveness of Welding Alloys’ products and the importance of addressing equipment wear and tear with appropriate, high-quality solutions. By opting for a complete rebuild with advanced materials, JTC Welding & Engineering is setting a precedent for maintaining critical recycling infrastructure and ensuring operational efficiency for years to come.