Large-volume scrap metal recycling in pre-wired, modular sections for installation in weeks.
Complete, large-volume scrap removal systems for volume reduction, fluid separation, weighed transferring and load-out in automotive/transportation, aerospace, defense, heavy-industrial, and large tiered-supplier operations. Modular sections are skid-mounted, pre-wired, and designed specifically to simplify the installation process- allowing for maximum metal scrap processing within weeks.
PRAB’s modular system reduces installation time and costs and provides portability and flexibility to meet changing plant requirements. Large-volume scrap collection and chip processing systems traditionally have taken months to install. Equipment comes in random order, floor layout takes time and labor resources, and electrical wiring and controls need to be installed and programmed. PRAB helps manufacturers overcome these installation delays by engineering and manufacturing full production scale, pre-assembled, modular scrap collection and metal recycling systems.
Advantages of a Modular Chip Processing Scrap System include:
All PRAB modular chip processing systems are engineered to meet the specific capacity needs of each individual facility and are fully automated to process metal scrap for recycling, collecting fluids for reuse, and weighing material for efficient container loading. Each of the 4 modular sections within the complete system are skid-mounted and pre-wired for quick installation, allowing for maximum metal scrap collection and processing within weeks.
Modular Sections within the system include:
Each of the 4 modular sections within the complete modular chip processing system are skid-mounted and pre-wired for quick installation, allowing for maximum metal scrap processing within weeks. Sections include scrap metal separation and process, fluid separation and collection, weighed dry scrap transfer, and drag conveyor load-out.
Includes Feed Hopper Assembly and Screw Conveyor
Includes Horizontal Shaft Chip Wringer Assembly and Coolant Collection and Recovery
Includes Weigh Belt Assembly
Includes Drag Conveyor
Walk Through of a Complete PRAB Modular Chip Processing System
Ron Chapman, Systems Sales Manager, PRAB
Today I want to introduce to you the latest in modular chip system technology. My name is Ron Chapman, I’m the Systems Sales Manager at PRAB globally headquartered in Kalamazoo Michigan. Let’s Begin. This full automated and complete chip processing line will dramatically improve the way you process metal scrap and reclaim expensive cutting fluids. As you can see this system has full access platforming, which is very convenient when it comes to service and access for visual inspection.
Model 1 – Scrap metal separation and process main feed hopper with integral screw conveyor modules are prewired for installation in a matter of weeks. Hydraulic chip Cart Dumper automates scrap feed into the main hopper. PRAB Screw Conveyor transfers material to a PRAB Drag Conveyor. Integral separator removes parts and solids that are discharged into ta central collection point.
The first part of this system is of course the PRAB Feed Hopper assembly. This is a Modular Feed Hopper in that it has main hopper assembly itself with a PRAB Screw Conveyor at the bottom. All as a single module that is completely prewired and ready to go. Now, the significance of that is this is something that will not be installed in a matter of two months, but rather in a couple of weeks and this is true with the entire system. This particular system is for a large automotive plant that will be producing engine blocks both heads and blocks and of course machining aluminum material. There are two points of introduction. The PRAB Industrial Dump Station with chip carts and the other is an auxiliary Dump Station that they can come up and bring with a forklift to dump this material. Both solids, chips, and coolant into this main PRAB Feed Hopper. The material as it’s dumped will of course pass across this grate. The grate has means of being a vibratory grate assembly so that it can vibrate allowing the chips and allow the coolant to pass through the grate and down into the auger system, as you can see below. The blocks and heads for intense, would not be able to pass through as their larger than the grate assemble. They would be picked up off the side by an operator. As the material discharges out of the hopper, it’s transferred by a PRAB Screw Conveyor and that Screw Conveyor discharges the material into the PRAB Heavy-Duty Steel Drag Conveyor. From the elevating Drag Conveyor when see the material will enter into a secondary separator. The chips as they exit the Drag Conveyor will enter into the separator. The separator will allow the chips and coolant to pass into the PRAB Wringer System directly below me. While the heavy parts and solids will pass down a shoot down into a container directly below.
Model 2 – Fluid Separation
Wringer pulls up to 900 g-force and produces 98% dry chips. Coolant is discharged out of the bottom of the Wringer to a central collection point. An estimated 300-600 gal/day for this system in coolant savings. Fines are recycled back through the Wringer. Controls are prewired using Alan Bradley, or customer standard, with HMI interface.
The first module was our hopper assembly. The second module is the heart of the system, which is the wringer assembly. This is the PRAB Diagonal Shaft Wringer System. As I mentioned, chips and coolant will enter into the main housing of Chip Wringer and the Chip Wringer will remove the coolant from the chips by centrifugal force. We are polling as much as 900 g’s force on the material to remove the coolant from the chips. You’ll notice on this chip wringer it is a horizontal mount. In that the shaft runs horizontally, two bearings on each end very easily accessible. Access to the wringer is very simply in that you can just open these wing nuts and open the unit up and expose the inside. It’s easily maintained. Easily serviced. There are two points of discharge on the PRAB Horizontal Chip Wringer. The first being, chips only discharge into this Drag Conveyor, as you see here. Coolant on the other hand, discharges out of the bottom and into this fluid recovery tank. Again, we accumulate her in the recovery tank when we get to a certain level the coolant will be pumped over by two pumps over to this destination. Now what we will have here are two plastic totes that the customer will use to accumulate all the fluid that is going to recover, and we could anticipate 300 to 600 gallons a day of coolant that’s going to be collected from our Wringer System. Fines on the other hand will be dredged out of the bottom of this conveyor elevate to a Drag Conveyor and into this Screw Conveyor. The Screw Conveyor will take the material over, discharge back into the Drag Conveyor here, which is the main Drag Conveyor that feeds the Wringer System. So, we are redistributing the fines back into the material flow and eventually that material works out with the good material. That whole assembly is mounted as one module and again is completely prewired and ready to install. Also, the panel is part of module 2 which is completely integrated and prewired in the system. This panel is Alan Bradley controlled with HMI interface. All components are complete prewired and ready to go. Again, to simplify the installation process.
Module 3 – Weighed Dry Scrap Transfer Weight belt conveyor carries the dry scrap to a transfer conveyor, weighting the material as it travels to prevent over-filling of the downstream trailers.
Dry chips are discharged into the Drag Conveyor and are elevated into our third module and that is the weigh belt system The weigh belt will weigh the material as it’s passing across belt and monitor the weight and fill, so that we do not over fill the downstream equipment, which happens to be the customer’s semitrailer.
Module 4 – Load-Out System
Engineered sections in the conveyor allow for flow diversion and even fill of the trailer.
This is our final module for our system. This particular module is our Drag Conveyor, which is going to distribute material from the to the customer’s trailer. You’ll notice on the bottom there is a drag flighting that will take material and transfer it across the bottom of this Drag Conveyor. Segmented sections on the bottom of this drag will allows us to open or close however we want it to, so to optimize trailer fill. All PRAB Chip Processing Systems have a 100% guarantee. This module system that I presented to you today is just a portion of what PRAB can do for you. Our application team would like to sit down and meet with you to review your specific requirement. Thank you again for giving us this opportunity to show you our equipment and we look forward to earning your business.
Product Brochure: Chip Processing Systems
Case Study: Chip and Fluid Recovery at Mathews, Inc.
Download Conveyors Still Operating in the Field After 57 Years Exclusive Bolt-Free Connections for Staying Strong Under Grueling Conditions Every part of this rugged chain driven conveyor is designed for handling severe duty, highly abrasive, wet metal chips, fines and swarf. The heavy-duty, abrasion-resistant flight bars feature an exclusive bolt-free connection for staying strong under grueling conditions. The […]
CHALLENGE Kalamazoo, Mich., July 20, 2014 – Featured in Modern Machine Shop Magazine. Mathews, Inc is a manufacturer of Bows and Archery Equipment. The company has been in business since 1992 starting with 26 people, growing to now over 400 full-time employees. Another recent expansion to a new 56,000 sq ft facility provided the added capacity necessary to […]
Automated Systems and Software Platforms Exist that Can Ease an Operation’s Transition to the Industrial Internet of Things Introduction Smart technology has become a common, if not essential, part of our daily lives. Most people are familiar with smart technology—which is an acronym for Self-Monitoring, Analysis and Reporting Technology—in the form of various consumer […]