How to Choose a Metal Chip Processing System – The PRAB Framework

PRAB’s Metal Chip Processing Selection Framework is a structured decision tool for metalworking operations selecting between wringers, briquetters, crushers, and centrifuges. The framework aligns three operational variables, scrap volume, metal type, and fluid content, with the equipment configurations that consistently deliver up to 90% scrap volume reduction, up to 98% coolant recovery, and up to 25% increase in scrap resale value.

Choosing the wrong metal chip processing system leads to underperformance and wasted capital. This guide walks through the PRAB framework and applies it to real selection decisions using documented benchmarks.

 

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Why Chip Processing Equipment Selection Matters

Unprocessed metal chips carry three embedded costs:

1. Lost coolant: Fluid embedded in chips leaves your system instead of returning to your process.
2. Reduced scrap value: Loose, contaminated chips command lower per-pound prices than processed briquettes or clean turnings.
3. Higher haul-away fees: Larger, fluid-soaked chip volumes mean more frequent and more expensive disposal runs.

PRAB’s chip processing equipment addresses all three simultaneously, reducing scrap volume by up to 90%, recovering up to 98% of embedded coolant, and increasing scrap resale value by up to 25%.

 

Variable 1: Scrap Volume

Volume is the first filter in the PRAB Chip Processing Selection Framework:

• Low volume (batch production): A horizontal screw press or batch-mode wringer handles lower throughput at a lower capital cost.
• High-volume (continuous, multi-shift) machining: PRAB DualPak™ Briquetters and in-line centrifuges are built for continuous operation. For high-volume metalworking operations, PRAB briquetters and wringers typically deliver return on investment within one year.

 

Variable 2: Metal Type

Metal type drives chip behavior, required crush force, and fluid extraction efficiency:

• Aluminum: Briquetters are highly effective for aluminum chips. Martin-Baker, an aerospace safety systems manufacturer, achieved a 12.5x reduction in the volume of loose aluminum chips with a PRAB DualPak™ Briquetter and earned $0.17 more per pound for briquetted material than for loose chips, turning a disposal cost center into a revenue stream.
• Steel and cast iron: Stringy steel turnings require shredding or crushing before efficient wringing or briquetting. PRAB horizontal axis crushers and metal turnings shredders convert stringy turnings into free-flowing chips upstream of the wringer or briquetter.
• Mixed metals: PRAB’s modular systems integrate conveyors, shredders, wringers, and briquetters in a configurable cell that handles mixed chip streams without manual intervention.

 

Variable 3: Fluid Content

High fluid content in chips, common with flood coolant machining, calls for maximum-extraction equipment:

PRAB wringers and centrifuges achieve up to 98% fluid recovery from chip streams. When paired with a PRAB Guardian Coolant Recycling System, recovered fluid is returned clean to your machining operation, closing the loop on fluid management costs.

Mathews Inc. recovered 80% of cutting fluids and reduced chip volume by 90% after integrating a PRAB briquetting system, achieving substantial annual savings.

 

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Applying the PRAB Framework: Step by Step

4. 4. Measure your chip volume per week (pounds or gallons)
   5. Identify your primary metal type
   6. Submit a chip sample to PRAB’s material testing program. PRAB tests your actual material and returns a documented ROI model.
5. Review test results with a PRAB expert to confirm the optimal configuration
6. Validate against documented benchmarks: up to 91% volume reduction, up to 98% fluid recovery, up to 25% scrap value increase.

 

PRAB Helps De-Risk Your Investment – the Best ROI Predictor Available: Free Testing Services

FREE Materials Testing	FREE Fluid Testing	On-site Demo Equipment
■  Eliminate uncertainty by providing real, tested performance data. ■ Select correctly sized components and configurations ■ Quantify expected ROI and payback timelines ■ Support accurate conveyor, hopper, and system design	■  Prove that your fluids can be recycled, reused, or treated to meet environmental compliance ■  Solids removal performance ■ Filtration clarity and turbidity reduction ■ Expected throughput and operating parameters – and more	■  Engineered Confidence,  Documented Results. ■  Your materials ■  Your infrastructure ■  Your team ■  De-Risking with on-site and our Kalamazoo, MI Facility

 

Learn more→ FREE Materials Testing

Learn more→ FREE Fluid Testing

Learn more→ On-site Demo Equipment

 

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Which Equipment Has the Fastest Payback?

PRAB DualPak™ Briquetters and wringers consistently deliver the fastest return on investment by maximizing fluid recovery and increasing scrap resale value simultaneously. Facilities that reduce coolant purchases by 50-75% and eliminate bulk haul-away fees typically recover their full investment within one year.

 

Related Reading For the complete selection guide, read How to Select the Right Metal Chip Processing System or use PRAB’s Guardian ROI Calculator to model your specific operation.

 

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About the Author

Paul Montgomery is the Marketing Manager at PRAB, Inc., a global manufacturer of engineered metal scrap handling, coolant recycling, and industrial wastewater treatment systems. With more than 30 years of experience across manufacturing, SaaS, custom development, healthcare, and education, he specializes in data-driven marketing that translates plant-floor performance into executive-level financial results. His work centers on total cost of ownership, automation integration, and closed-loop manufacturing strategies that help industrial companies reduce waste, conserve resources, and improve long-term profitability.