Chip Processing Machines

How to reap the operational and financial rewards of shredders, crushers, and briquetters

Effectively managing metal turnings and coolant-coated scrap is a challenge for metalworking manufacturers.

But companies can transform metal scrap from a storage and disposal issue into a profit-generating asset by implementing chip processing systems that efficiently dry turnings, separate reusable fluids, and reduce waste volumes. This optimizes production efforts and creates new revenue streams through cost savings—but it all comes down to investing in the right equipment.

Here is how to choose the optimal system—and incorporate a briquetting process—to enhance production efficiency and achieve faster ROI at your metalworking operation.

1. Match the System to Your Metal Scrap Characteristics

The type of scrap and the volume being handled will determine which 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-size scrap volumes.
Briquetters compress processed metal chips from shredders or crushers into dense briquettes. This reduces storage needs, simplifies transportation, and often earns higher rates from recyclers.

2. Prioritize Coolant Recovery

Coolant fluids are critical—and expensive—components in 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 in 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 a faster ROI.

Beyond providing reusable coolant, these systems can help substantially reduce haul-away expenses, storage, and new fluid purchases, potentially providing complete ROI within a year.

3. Leverage the Benefits of Briquetting

In addition to helping with coolant recovery, briquetting brings several operational and financial benefits:

Volume Reduction: Briquetting can reduce metal scrap volume by up to 90%, significantly decreasing required storage space 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, prolonging the lifespan of your entire scrap management program.

4. Optimize Operational Efficiency and ROI

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

Shredders handle high scrap volumes efficiently with minimal maintenance, 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.

5. Integrate New Equipment 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.

Proven, Data-Driven Solutions

PRAB’s chip and fluid testing services precisely analyze your materials, and our on-site demo equipment lets you confidently predict performance and ROI. Designed for easy service and durability in harsh environments, our chip processing equipment integrates with your existing systems for long-term reliability.

By choosing systems tailored to your scrap features, you can maximize coolant recovery, reduce storage and transportation costs, and accelerate ROI to within a year.

The PRAB Advantage

With more than 70 years of industry experience, PRAB has the depth, knowledge, leadership, and innovative spirit to ensure expert solutions tailored to your needs.

Need help finding the right equipment for your needs? Contact a PRAB expert today.

Selecting the Right Chip Processing System