Tyre / Rubber
The ZXS shredders are single-shaft shredders with a powerful two-speed swing ram design that eliminates the risk of blocking and wearing of internal guide rails. The machine is very versatile and can be used for shredding of all types of input materials and is well suited for different industries. The 750mm diameter rotors ranging from 1500 to 3000mm widths are driven by two oversized gearboxes. The low speed of 45 rpm guarantees high torque and smooth operation. The hydraulic power-pack is integrated into the machine housing to save space and protect it from damage but is still easy to access or remove for maintenance. The proven E-rotor, blade holder and blade designs are taken to new dimensions to conquer the most demanding applications and challenges. The machines can be customised to various applications, with advanced controls and hydraulics, hard-facing and other wear options.
The ZXS shredders have been designed for the most demanding and high throughput applications in recycling industries. The input materials can be all types of plastics, wood, paper, cardboard, e-waste, post-consumer waste, rubber, etc. in various shapes and sizes. Typical input materials are: large lumps, large diameter pipe, baled material, tyres, pallets, drums, stretch film, etc. The output material size is defined by the installed screen, and except in RDF (refuse derived fuels) applications the output material needs to be processed further to achieve the desired final size. For the recycling of complete truck and tractor tires the ZXS-T model is configured with special wear protection and blades.
- Low speed, high torque gear drive
- Powerful two-speed hydraulic swing type pusher
- Heavy-Duty design & high throughput rates
- Suitable for very large and heavy parts
- Big diameter rotor (750 mm)
The ZTS and ZTTS single-shaft shredders are specially designed for the processing of complete or pre-shred tyres. Both machines feature a 750mm diameter rotor ranging in width from 1500 to 3000mm with oversized outboard bearings and twin gear drives.The tangential infeed ensures a optimal feeding of the input materials while eliminating the need for a hydraulic feeding system. All tyre shredders are equipped with a complete wear package including hard-facing, special blades and wear plates made from highly wear resistant steel. The two model ranges differ in the amount of stator blades and the screen sizes used. The modular design makes it easy to integrate either machine into existing installations.
The ZTS series with its single row of stator blades is used to pre-shred complete car tyres or large chunks of pre-processed tyres down to a size of approx. 150mm. The twin rows of stator blades and screen in the ZTTS series shredder enable it to take the tyre shreds down to a any required size > 20mm. The unique machine design combined with the variable cutting gap create an optimal separation of rubber and steel fractions when the machine is used with a 20mm screen. Steel can therefore be removed easily in the following process with magnetic separation equipment. Beside tyres, the machines are also used in the conditioning of RDF and other alternative fuel applications.
- Single large diameter rotor (750 mm)
- Proprietary blade design and material
- Variable blade gap to improve separation of steel and rubber
- Compact Heavy-duty design & high throughput rates
- Fast and easy tool change and maintenance
The heavy-duty granulators of the GSH-800 series offer a wide array of different rotor designs with widths ranging from 1200 to 2000mm with a diameter of 800mm. The completely welded heavy steel construction is designed to withstand the most demanding and universal applications. Rotor bearings, blade mounts and rotor shaft are oversized. The standard V-cut creates a high quality regrind with a very low percentage of fines in the output material. The removable third stator blade acts as a deflection wedge and allows the machine to be quickly adjusted to different application scenarios. Other standard features include easily replaceable wear plates in the cutting chamber as well as outboard bearings which reduce the risk of contamination.
The wide range of rotor and hopper designs allow the GSH machines to be customised to almost every application in the plastic recycling field, mainly with high throughput requirements. The GSH-800 series can be used to grind large thick walled parts down to a granule in one-step, or be used as a second-step granulator after a ZXS series shredder to reach very high throughput rates. When used to granulate light materials, such as bottles, the throughput can be greatly increased with the addition of a ZERMA force-feeding device. For abrasive, contaminated or highly filled materials the machines can be equipped with special wear protection, such as hard-facing of the rotor and housing and other critical parts manufactured from highly wear resistant steels.
- Blades are adjusted outside of the machine
- Specially developed deflection wedge
- Wide choice of rotors
- Well proven cutting chamber design
- Strong welded steel construction and oversized outboard bearings
Due to the increasing number of cars and trucks all over the world, used tires are available in large quantities at very low cost. With a bit of clever recycling, you can get a whole lot out of used tires: granule in various sizes, steel and profit. The sales income naturally depends on the quality of the output material a process that is as efficient as possible. ZERMA designed a system dedicated to tyre recycling, which ultimately produces very high-quality materials for recycling. Final products could be either shreds for thermal recycling, predominantly in the cement industry and crumb rubber of about 5 mm size used in various applications.
Shredding and metal separation
The first step is the newly developed ZERMA ZTS Tyre shredder which can shred passenger car tires of up to 800mm into strips and pieces of approx. 150 mm 300 mm.
ZERMA tire shredders are heavy duty single shaft shredders with gravity infeed specifically designed for the grinding of tires. They feature additional wear protection compared to other shredders. The machine is equipped with a flat rotor, made of highly wear resistant steel with added weld on hard facing for longer lifetime. The cutters used in these shredders are made from a newly designed, specialized material to ensure long life time and optimal performance. As opposed to other systems, the ZERMA system does not require the tires to be de-beaded. For larger truck tires we modified our proven ZXS Shredder. The so called ZXS T can shred truck tyres of up to 1500 mm into shreds of approx. 150mm 300 mm.
In both cases these shreds are discharged by a conveyor belt and transferred to the next ZTTS second stage tyre shredder. This shredder is than shredding the material into pieces of about 20 mm. This step helps to separate the tire rubber from the steel. A combination of cross belt magnetic separators and magnetic drums helps to split the various factions at this stage in the process. During metal separation we can take out about 99% of the total steel content. The steel free granule can than be packed and used as refuse derived fuel or transferred to the granulating process.
Granulating and sifting:
After shredding and steel separation the tyre shreds will be transferred to the granulation process. For granulating of the rubber shreds we are using our heavy duty GSH granulators with a special closed H-rotor to reduce the rubber down to a size of < 5mm in two steps. Throughout this process the material is classified on ZERMA CS screening machines and the last metal contamination is eliminated by additional magnetic drums.