By combining the PRAB Dualpak Briquetting system with an upstream crusher, the company was able to significantly and efficiently reduce the bulk density of its scrap material. Instead of dumping the contents of the hopper directly into an external container, the forklifts now deposit the scrap material into the briquetter, which uses dual-compression technology to transform it into a “puck” that is almost 90% solid — the highest-density puck in the industry.
Aerospace
Briquetters
Guardian Coolant Recycling Systems
Tramp Oil Separators
Paper Bed Filters
Previously, the company’s scrap removal process involved collecting material saturated with cutting fluid from its gantry mill and discharge conveyor in a self-dumping hopper. A forklift would then pick up the full hopper and transport it to a larger hopper or lugger box outside, where the recycler would haul it away.
The primary problem with this process was that it didn’t result in a truly full hopper or lugger box. Only about 12,000–18,000 pounds of loose material, especially aluminum, can fit into a container that typically accommodates 40,000 pounds, or what a recycler considers a full truckload by weight, not volume. Hauling away as much as 28,000 pounds of air, rather than scrap, per load is far from ideal for both the manufacturer and the recycler.
The company was aware of the benefits a PRAB Dualpak™ Briquetter system could bring to its operation, as it had achieved success with similar installations at several of its other facilities throughout Canada. That success included an ROI on the equipment expenditure in approximately 18 months and payback on the company’s coolant costs in approximately 8–10 months.
Still, each specific facility and operation is different. PRAB collaborated with the manufacturer’s corporate engineers to conduct a comprehensive site review and a thorough audit of the company’s existing system and other environmental variables. The results of this investigation confirmed that implementing a system comprising a briquetter, crusher, and Guardian Coolant Recycling unit at the company’s Pacific Northwest facility could yield results similar to those achieved at its plants in Canada.
By combining the briquetter with an upstream crusher, the company was able to significantly and efficiently reduce the bulk density of its scrap material. Instead of dumping the contents of the hopper directly into an external container, the forklifts now deposit the scrap material into the briquetter, which uses dual-compression technology to transform it into a “puck” that is almost 90% solid—the industry’s highest-density puck. In the process, cutting fluid is squeezed out of the scrap and collected in a bottom recovery pan. Next, the fluid is pumped from the pan to the filtration unit, where tramp oils and suspended solids are removed. The filtered coolant is then pumped back to the machines for reuse, improving tool life.
As the pucks come off the briquetter, they are placed in a Gaylord box, a 4’x4’ lined, corrugated cardboard box that fits on a skid. The high-density, boxed briquettes can now be loaded onto trucks at full 40,000-pound capacity, satisfying the recycler’s preference for maximum weight and reducing haul-away visits.
Another reason the company opted for the briquetting scenario is that pucks offer greater potential for in-house remelting of solid scrap. While recyclers typically specialize in this type of work, this manufacturer now has the option to add a remelting furnace to its plant and gain even more value from its scrap by minimizing material loss compared to remelting loose chips.
| ROI Chart | Loose, Wet | Briquette |
| Circa: 2017 | ||
| Weight of scrap/mo (lb from customer (shipping) | 500,000 | 500,000 |
| Enter the contained coolant from the test data | 15% | 15% |
| Metal scrap generated / From customer (calculated) | 425,000 | 425,000 |
| Enter residual coolant from test data | 15% | 3.50% |
| Weight of scrap shipped out | 500,000 | 439,875 |
| Recoverable metal | 425,000 | 425,000 |
| Enter price per pound as shipped (dealer) | $0.35 | $0.40 |
| Enter processing fee (Deduction) (dealer) | $0.02 | $0.01 |
| Material Value | $140,250 | $168,795 |
| Coolant Replenishment cost/mo | $1,200 | $1,200 |
| Coolant Saving | $0 | $920 |
| Total Revenue from Scrap | $140,250 | $168,795 |
| Expenses of Process | ||
| *Electrical | $0 | $2,100 |
| Miscellaneous Additional Expenses | ||
| Cost of Gaylord Boxes | $200 | |
| Freight | $1,200 | |
| Total Expenses | $2,126 | $3,500 |
| Summary | ||
| Revenue | $140,250 | $168,795 |
| Expenses | $2,126 | $3,500 |
| Net | $138,124 | $165,295 |
| Difference per Month vs. Loose, Wet | $27,171 | |
| Difference per Year | $326,052 | |
| System Cost = $450,000.00 | ||
| *Est. $.06 to $.12 per kwH (Foundry Series x 2) Pay Back = 12.89 months | ||
All told, the crusher/briquetter/recycling system enabled the manufacturer to see substantial benefits consistent with those achieved at its Canadian facilities as well as by other aerospace manufacturers who implemented a similar system:
0-pound load of scrap that briquettes make possible)
|
Application Information |
|
|
Material Handled |
Aluminum |
|
Chip Configuration |
95% chips, 5% turnings |
|
Volume of Material |
2,000 lbs/hr |
|
Bulk Density of Material |
Varies |
|
Tramp Metal Solids |
2 to 3 per year 2” to 8” |
|
System to be Fed By |
Up to 3 cubic yard self-dumping hoppers |
|
System Location |
Inside plant |
|
Plant Power Supply |
480VAC/3/60 |
|
Power Consumption |
126 total amps, 108.3 total H.P. |
|
Fluid |
Fuchs Ecocool water soluble coolant |
|
MSDS Supplied |
No |
|
Number of Machines Sumps |
31 |
|
Sump Sizes |
The largest sump is 450 gallons (1), then 405 (2), 300–200 (4), 200–100 (5), <100 (19) |
|
Total Sump Capacity |
4,300 gallons |
By briquetting its solid waste, this company turned its scrap and spent fluid from a loose, flowing waste stream into a 90% solid commodity that is released from its coolant and can now be processed, reused, or even sold for value. The reclaimed cutting fluid also contributes to a revenue stream by reducing the need to purchase pure coolant concentrate, which costs between $20 and $30 per gallon. Ultimately, this solution not only represents a new approach to processing equipment but also a new way of thinking that many aerospace manufacturers are adopting: scrap and spent fluids are part of what they produce and can be turned into real dollars that directly impact their bottom line.
PRAB Dualpak™ Briquetter by Neff Model MX50-100M
Discharge Conveyor – 2½” Pitch Steel Belt
PRAB Filtration System Summary
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