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The Hidden Costs of Metal Turnings – Why Shredding Is Essential

Increase the Resale Value of Metal Turnings Using Advanced Metal Chip Processing Techniques

Metal Turnings before Shredding - Metal Chip Processing | PRABMetal turnings—those long, tangled byproducts of machining operations—can be deceptively challenging for manufacturers. While they might seem like harmless scrap, untreated metal turnings can rack up hidden costs. From increased handling and transportation expenses to safety hazards and inefficient recycling, the consequences can quickly pile up.

Shredding metal turnings is a crucial first step in transforming this potential liability into a valuable and manageable resource. In this blog, we’ll explain the hidden costs of untreated turnings and why shredding is an essential process for modern manufacturing facilities.

What Are Metal Turnings?

Metal turnings are curly, often tangled metal fragments produced as waste during machining processes like lathing, turning, milling, and drilling. They are a form of metal swarf—the material removed during cutting operations—and may appear as long, stringy pieces or in shorter segments.

In their raw form, metal turnings can be challenging to handle, store, and recycle, resulting in inefficient and costly management.

Learn more about metal turnings shredders here.

The Hidden Costs of Untreated Metal Turnings

  1. Storage Challenges
    • Loose metal turnings take up excessive space, often necessitating large containers or bins.
    • This drives up operational costs and eats into valuable floor space that could be used for production.
  2. High Transportation Costs
    • The low density of bulky turnings makes them inefficient to transport.
    • More trips are required to haul loose turnings, which increases fuel costs and carbon emissions.
  3. Inefficient Recycling
    • Recycling facilities struggle with untreated turnings due to their awkward shape and residual oils.
    • These factors lower the material’s value and increase recycler processing costs.
  4. Safety Hazards
    • Tangled, sharp turnings pose significant risks to workers during manual handling.
    • Loose turnings can clutter the workspace and create tripping hazards.

How Shredding Metal Turnings Reduces Costs

Shredding involves cutting bulky metal turnings into smaller, more manageable pieces. This simple step solves many challenges posed by untreated turnings:

  1. Volume Reduction
    • Shredding compresses metal turnings, reducing their volume by up to 80%.
    • This frees up storage space, letting manufacturers use their floor space more effectively.
  2. Improved Transportation Efficiency
    • Shredded turnings are denser, requiring fewer trips to transport.
    • This reduces hauling costs and minimizes environmental impact.
  3. Higher Recycling Value
    • Uniform, smaller pieces are easier to process, making them more appealing to recyclers.
    • Shredding also helps recover fluids trapped in the turnings, improving material cleanliness and overall value.
  4. Enhanced Workplace Safety
    • Shredded turnings are safer to handle, as they eliminate sharp edges and tangled hazards.
    • A cleaner, more organized workspace boosts worker productivity and safety.

Explore PRAB’s metal turnings shredders.

Case Studies: Shredding in Action

Ingersoll Tillage

Ingersoll Tillage was struggling with the challenges of handling and transporting loose metal turnings. After integrating a PRAB horizontal axis crusher and shredder system, they achieved:

  • 80% reduction in turnings volume.
  • Improved scrap handling efficiency.
  • Enhanced worker safety through automated shredding.

Read the full Case Study:

Aerospace Components Manufacturer

A leading aerospace manufacturer implemented shredders to process titanium and aluminum turnings. The results included:

  • Higher recycling rates due to cleaner materials.
  • Significant savings on waste transportation costs.
  • Better compliance with environmental regulations.

Learn more about their success story.

Designing an Efficient Shredding Process

When setting up a shredding system, here’s what manufacturers should consider:

  1. Material Type
    • Different metals, like steel, aluminum, and titanium, may require specialized shredders.
  2. Volume and Throughput
    • High-capacity shredders are ideal for facilities producing large quantities of turnings.
  3. Integration
    • Shredders can be paired with conveyors, briquetters, and fluid recovery systems for a seamless scrap management process.
  4. Maintenance
    • Regular maintenance keeps shredders operating efficiently and reduces costly downtime.

Discover PRAB’s integrated shredding solutions.

Financial and Environmental Benefits of Shredding

  1. Cost Savings
    • Reduced transportation and disposal costs can result in substantial annual savings.
    • Higher scrap value from shredded turnings creates an additional revenue stream.
  2. Sustainability
    • Shredding encourages recycling, thereby reducing the amount of waste sent to landfills.
    • Enhanced fluid recovery reduces environmental contamination.
  3. Regulatory Compliance
    • Shredding helps manufacturers meet ISO 14001 standards for environmental sustainability and waste reduction.

Shredding as Part of a Comprehensive Metal Scrap Management System

Metal turnings shredders are often the first step in a larger scrap management strategy. When paired with technologies like wringers, briquetters, and fluid recycling systems, shredding can:

  • Maximize resource recovery.
  • Streamline operational efficiency.
  • Create a cleaner, safer workspace.

Explore PRAB’s full range of scrap processing solutions.

Conclusion

While metal turnings might seem minor, their hidden costs can add up quickly. Shredding addresses these challenges by reducing volume, enhancing recycling efficiency, and creating a safer work environment. Manufacturers can unlock significant financial and environmental benefits by incorporating shredding into a comprehensive scrap management plan.

Learn how shredding can optimize your operations with PRAB’s Metal Turnings Shredders.