How to Select the Right Metal Chip Processing System

Shredders, Crushers, and the Benefits of Briquetting

Metalworking manufacturers can find it challenging to manage metal turnings and scrap coated in coolant fluid. Effective chip processing systems help clean turnings, separate reusable coolants, and reduce waste volumes, optimizing recycling efforts and creating new revenue streams.

Selecting the right system and incorporating briquetting can further enhance efficiency and ROI. Here’s how to choose the ideal solution for your operations.

1. Match the System to Your Metal Scrap Characteristics

The metal scrap and the volume being handled will determine which metal chip processing system is right for you:

• Shredders are excellent for reducing large, bulky turnings and swarf, tearing them down for more manageable handling. They’re ideal for high-volume scrap.
• Crushers use compressive force to break down denser materials suitable for small to medium-sized scrap volumes.
• Briquetters compress processed metal chips from shredders or crushers into dense briquettes, reducing storage needs, making transportation more efficient, and often earning higher rates from recyclers.

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Insights for Your “Metal” Industry:

Machining | Die Casting | Stamping | Forging | Scrap Yards | Finished Parts

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2. Prioritize Coolant Recovery

Coolant fluid is an expensive part of metalworking operations. When performed efficiently, chip processing can yield a significant volume of recoverable coolant:

• Shredders and crushers are the first step in reducing scrap size, making it easier to drain coolant.
• Briquetters offer a notable advantage for coolant recovery by compressing the chips and extracting nearly all trapped fluids. This process can achieve up to a 98% reduction in residual oils, which allows for reuse and an enhanced ROI.

 

3. Unlock the Benefits of Briquetting

In addition to coolant recovery, briquetting brings several technical and financial benefits:

• Volume Reduction: Briquetting can reduce metal scrap volume by up to 90%, significantly decreasing the space required for storage and lowering transportation costs.
• 12% Increase in Scrap Value: Briquetted metal chips are more valuable than loose chips. Their uniform, dense shape makes them easier to handle and more desirable for recyclers, who often pay more for briquettes. Recent updates show a 12% increase in the rate paid for metal briquettes.
• Lower Environmental Impact: By reducing the frequency and cost of coolant disposal and decreasing the carbon footprint associated with shipping loose chips, briquetting contributes to a more sustainable operation.

• Extended Equipment Life: Handling dense briquettes instead of loose scrap reduces wear on equipment like conveyors and transport vehicles, enhancing the lifespan of your entire scrap management system.

 

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Proven Solutions – Backed by Data

Our chip and fluid testing services precisely analyze your materials, and our on-site demo equipment lets you confidently predict performance and ROI.

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4. Optimize Operational Efficiency and ROI

The right combination of chip processing equipment—shredders, crushers, and briquetters—can maximize efficiency and deliver a compelling return on investment:

• Shredders handle high scrap volumes efficiently with minimal maintenance, which is ideal for initial material reduction.
• Crushers provide reliable performance for reducing smaller, denser metal scrap, ensuring efficient downstream processing.
• Briquetters offer both space-saving and cost-saving benefits, increasing metal scrap value, reducing disposal costs, and enhancing coolant reuse. PRAB’s briquetting systems can provide a complete ROI within a year due to significant savings in coolant buying, storage, and transportation.

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What equipment do I need?

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5. Integrate with Your Existing Systems

Your chip processing system should integrate with your material handling and coolant recovery infrastructure for optimal effectiveness. Modular solutions, such as PRAB’s integrated metal scrap conveyors, separators, and briquetters, streamline scrap management, reduce handling time, and maximize coolant recovery.

 

Enhanced Productivity and Profitability

Selecting the right chip processing system and incorporating briquetting can transform metal scrap from a disposal issue into a profit-generating asset.

 

The PRAB Advantage:

PRAB equipment integrates with your systems for long-term reliability and is designed for easy service and durability in harsh environments.

By choosing equipment tailored to your scrap features, maximizing coolant recovery, and reducing storage and transportation costs, you can achieve substantial cost savings and accelerate ROI.

With over 7 decades of experience, PRAB has the experience, knowledge, leadership, and innovative spirit to ensure expert solutions tailored to your needs.

 

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.