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Eddy currents are electrical currents generated in conductive materials when they are exposed to a changing magnetic field. This physical phenomenon has various industrial applications and is particularly useful in recycling, where it enables non-ferrous metals, such as aluminium and copper, to be separated from other materials.

In a recycling plant, eddy current separators make it possible to recover metallic materials from mixed waste streams without having to manually sort each individual piece.

Their operation is based on electromagnetic induction: a magnetic rotor generates a changing magnetic field that produces a repulsive force on certain conductive metals, altering their trajectory and facilitating their separation.

What are eddy currents?

Eddy currents, also known as Foucault currents or induced currents, are electrical currents induced within a conductive material when it experiences a change in the magnetic field.

Unlike the electrical current flowing through a wire connected to a power supply, eddy currents are generated within the material itself through electromagnetic induction.

Their behaviour is explained by two physical principles:

  • Faraday’s law: a change in magnetic flux can induce electrical currents in a conductive material.
  • Lenz’s law: induced currents generate a magnetic field whose effect opposes the change that produces them.

When this phenomenon is applied appropriately, the interaction between magnetic fields can generate a force that moves the conductive material.

This principle is used in various industrial applications, including braking systems, material testing and metal separation equipment.

In the recycling industry, its main application is the recovery of conductive non-ferrous metals from mixed waste streams.

How does an eddy current separator work?

An eddy current separator is a machine that uses electromagnetic induction to separate conductive non-ferrous materials from other types of waste.

It generally consists of a conveyor belt and a high-speed magnetic rotor positioned near the discharge end. The rotor contains alternating-polarity magnets that generate a rapidly changing magnetic field.

When a conductive metal passes through this field, electrical currents are induced within it. The electromagnetic interaction generates a force that changes its trajectory compared with non-conductive materials.

The process can be divided into five stages.

1. Material preparation and feeding

Waste reaches the separator through a conveyor belt or feeding system.

To improve separation, the material should be distributed evenly, avoiding accumulations and overlapping that could prevent some particles from being exposed to the magnetic field.

Depending on the composition of the waste, preliminary shredding, screening or sorting operations may be necessary.

2. Preliminary separation of ferrous metals

Before using an eddy current separator, ferromagnetic materials, such as iron and certain types of steel, are normally removed.

Magnetic separators, including overband systems, magnetic pulleys and magnetic drums, are used for this purpose.

This operation improves the operating conditions of the eddy current separator and reduces interference from ferrous materials.

3. Generation of a changing magnetic field

The separator’s rotor spins at high speed, generating a changing magnetic field in the discharge area.

When conductive metal particles pass through this region, electrical currents are induced within them.

The strength of the response depends on factors such as the material’s electrical conductivity, mass, geometry and dimensions.

4. Repulsion and change of trajectory

The interaction between the induced currents and the rotor’s magnetic field produces a force on the metal particles.

As a result, conductive metals suitable for this process are propelled along a different trajectory from the one they would follow if they left the conveyor solely under the influence of gravity.

Non-conductive materials, such as certain plastics, glass or wood, do not experience the same repulsive force and follow a trajectory closer to their natural falling path.

5. Collection of separated fractions

A physical separation system, usually an adjustable splitter, is installed in the discharge area.

This component allows the propelled metallic materials and the rest of the mixture to be collected separately.

The result is a series of distinct fractions that can be sent to further sorting, conditioning or recovery stages.

It is important to note that the separator does not identify each type of metal individually or guarantee a fraction of absolute purity. Additional processes may be required to distinguish between alloys or separate certain metals from one another.

 

corrientes de Foucault

 

Which metals can be separated using eddy currents?

Eddy current separators are primarily used to recover non-ferrous metals with sufficient electrical conductivity.

The most common materials include aluminium, copper and certain alloys, such as brass.

Not all materials respond in the same way. Their behaviour depends on the relationship between their electrical properties, mass and geometry, as well as the equipment configuration.

Material Typical behaviour
Aluminium Responds well to induction and is one of the main metals recovered
Copper Can be recovered using eddy currents, although its higher density affects its trajectory
Brass Recoverable under certain conditions of size, shape and equipment configuration
Zinc and certain alloys Separation depends on the characteristics of the material and equipment
Iron and ferromagnetic steel Preferably removed through preliminary magnetic separation
Stainless steel Many types cannot be effectively separated using conventional eddy current equipment
Plastic, glass and wood Do not generate the same electromagnetic response and follow a different trajectory

Therefore, the purpose of this technology is not to separate any metal from any type of waste, but to recover specific conductive metal fractions under suitable processing conditions.

Difference between magnetic separation and eddy current separation

Although both technologies use magnetic fields, their operating principles and applications are different.

Conventional magnetic separation uses the attraction experienced by ferromagnetic materials when exposed to a magnet.

Eddy current separation, on the other hand, uses currents induced in conductive materials to generate a force that changes their trajectory.

Feature Magnetic separation Eddy current separation
Principle Magnetic attraction Electromagnetic induction and repulsive force
Typical materials Iron and ferromagnetic steel Aluminium, copper and other conductive non-ferrous metals
Equipment Overband separators, magnetic pulleys and drums Eddy current separators
Main function Removal of ferrous metals Recovery of non-ferrous metals
Typical position Preliminary stage Stage following ferrous metal removal

These technologies are complementary.

In a mixed waste recycling line, they are commonly combined to recover different metallic fractions and improve the quality of the material sent to subsequent processing stages.

Applications of eddy currents in recycling

Eddy current separation is used in various facilities where waste contains mixtures of metallic and non-metallic materials.

Municipal solid waste (MSW) treatment plants

Municipal waste may contain aluminium packaging and other metallic items mixed with plastics, paper, glass and organic matter.

After the necessary sorting and conditioning stages, eddy current separators can be used to recover non-ferrous metals present in the waste stream.

In municipal solid waste treatment plants, this technology can form part of a sequence of equipment designed to obtain different recoverable material fractions.

Industrial waste treatment plants

Industrial waste can have a heterogeneous composition and contain mixtures of metals, plastics, wood, paper and other materials.

Recovering non-ferrous metals reduces their presence in the remaining fractions and produces materials that can be sent to subsequent recycling processes.

In industrial waste recycling plants, Reverter Industries considers the integration of magnetic and eddy current separation systems alongside shredding, screening and sorting equipment.

Construction and demolition waste (CDW) recycling plants

Waste from construction and demolition activities may include concrete, aggregates, wood, plastics and various metallic components.

Following material preparation and sorting, eddy current separation can help recover certain non-ferrous fractions and reduce their presence in other recovered materials.

Its integration depends on the composition of the waste and the configuration of the construction and demolition waste recycling plant.

Scrap metal recycling facilities

When processing mixed scrap metal, metal separation is an important stage in obtaining fractions with suitable characteristics for recovery.

Magnetic systems remove ferrous materials, while eddy current separators can recover conductive non-ferrous metals.

This technology complements other operations involved in the scrap metal recycling process, such as sorting, shredding and screening.

What factors influence separation efficiency?

The performance of an eddy current separator does not depend solely on the power or operating speed of the rotor.

The characteristics of the waste and the operating conditions of the entire processing line must also be considered.

Particle size and granulometry

Particle size affects the electromagnetic response and the trajectory of the material.

Highly heterogeneous fractions can make recovery more difficult. For this reason, some facilities include preliminary screening stages to process materials within more uniform particle size ranges.

Conductivity, density and geometry

Two metal pieces of similar size may respond differently.

The electrical conductivity, density and shape of each fragment influence the force it experiences and its behaviour when leaving the conveyor.

Therefore, it should not be assumed that all non-ferrous metals can be separated with the same efficiency.

Material distribution

Uniform feeding improves the exposure of particles to the magnetic field.

When waste arrives in piles or overlapping layers, some pieces may be hidden beneath others, making separation more difficult.

Dosing and feeding systems help maintain a more consistent material flow.

Conveyor speed and rotor configuration

The conveyor speed, rotor characteristics and rotor position influence the discharge trajectory of the materials.

These parameters must be adapted to the size, composition and behaviour of the fraction to be recovered.

Separator splitter adjustment

The position of the splitter determines where the material trajectories are divided.

Incorrect adjustment can result in the loss of recoverable metals or the inclusion of unwanted waste in the recovered metal fraction.

Moisture and the presence of impurities

Moisture, adhering materials and accumulations of fine particles can affect material distribution and separation.

Depending on the input conditions, additional cleaning, drying or conditioning stages may be appropriate.

Actual recovery performance must be assessed by considering the composition of the waste and the results obtained under representative operating conditions. There is no single efficiency percentage applicable to every installation.

How are eddy current separators integrated into a recycling plant?

An eddy current separator usually forms part of a larger waste treatment line.

Depending on the input material and recovery objectives, a typical configuration may include the following operations:

  1. Reception and dosing: regulation of the waste flow entering the facility.
  2. Shredding or size reduction, when necessary: preparation of the material to facilitate subsequent operations.
  3. Screening: classification into more uniform particle size fractions.
  4. Magnetic separation: removal of iron and other ferromagnetic materials.
  5. Eddy current separation: recovery of conductive non-ferrous metals.
  6. Additional sorting: further operations to improve the quality of the recovered fractions.

This sequence is illustrative. The final order and the need for each stage depend on the waste being processed and the requirements of the project.

For example, a facility receiving previously sorted materials may require fewer conditioning stages than one processing mixed industrial waste.

Likewise, recycling machinery should be selected according to processing capacity, waste composition and the plant’s recovery objectives.

At Reverter Industries, the integration of shredding, conveying, screening and separation technologies makes it possible to configure treatment solutions adapted to different industrial applications.

Advantages and limitations of eddy current separators

The main advantage of this technology is its ability to recover certain non-ferrous metals through an automated process, without relying exclusively on manual sorting.

Its benefits include the recovery of valuable materials, the reduction of impurities in other fractions and the possibility of integration into continuous processing lines.

However, it also has limitations.

Materials that do not generate a sufficient electromagnetic response cannot be effectively recovered using this system. Likewise, particle size, material distribution and waste conditions can reduce performance.

The separator does not replace every other sorting technology. Obtaining aluminium, copper or other alloy fractions with a specified purity may require additional equipment and processing operations.

For this reason, equipment selection should consider the entire treatment process, rather than the individual characteristics of the separator alone.

Frequently asked questions about eddy currents

What are eddy currents used for in recycling?

They are used to recover certain conductive non-ferrous metals present in mixed waste streams. Eddy current separators generate a changing magnetic field that induces electrical currents in metal particles, producing a force that changes their trajectory and facilitates their separation.

What materials can an eddy current separator recover?

Mainly aluminium, copper and certain conductive alloys, depending on particle size and characteristics. It is not a system designed to recover plastics, glass or wood, nor does it replace magnetic separation for iron and ferromagnetic steel.

Can eddy currents separate aluminium and copper from each other?

A conventional separator can recover different conductive non-ferrous metals together from the rest of the waste stream. However, it does not guarantee the individual separation of aluminium and copper. Additional sorting technologies may be required to obtain distinct fractions.

Why is a magnetic separator used before an eddy current separator?

Because it removes iron and other ferromagnetic materials beforehand. This reduces interference and helps protect the eddy current equipment, while also facilitating subsequent non-ferrous metal recovery.

What is the difference between an eddy current separator and a magnetic separator?

A conventional magnetic separator attracts ferromagnetic materials. An eddy current separator induces electrical currents in conductive materials, generating a repulsive force. Both technologies are used in a complementary way.

Can eddy current separators be integrated into existing facilities?

Yes, provided that the characteristics of the material flow and the conditions of the facility allow their integration. The equipment upstream and downstream, available space, feeding system and separation objectives must be evaluated.

Metal separation in recycling plants: an integrated solution

Efficient recovery of metallic materials requires combining different technologies according to the composition of the waste and the desired results.

Eddy current separators are an important tool for recovering non-ferrous metals, but their performance depends on material preparation and integration with the other equipment in the processing line.

Reverter Industries designs and integrates waste treatment and sorting solutions, combining conveying, shredding, screening and separation technologies according to the requirements of each facility.

If you need to assess the integration of separation systems or improve an existing plant’s processes, contact our technical team to evaluate the specific requirements of your project.

In a waste treatment line, a primary shredder and a secondary shredder do not perform exactly the same function. Primary shredding generally receives larger or more heterogeneous material and reduces it to a manageable fraction. Secondary shredding works on material that has already been conditioned in order to achieve further size reduction and, in many cases, a more controlled output particle size.

Not every facility needs both stages. The right configuration depends on the input waste, required throughput, maximum feed size and the final fraction that needs to be produced.

If you are comparing technologies for an industrial installation, see our range of industrial shredders for recycling.

What is a primary shredder?

A primary shredder is the machine responsible for the first significant size-reduction stage in many waste treatment lines.

Its main objective is generally not to produce a fine final material, but to prepare the waste for downstream processes. It therefore needs to handle relatively large pieces, variable compositions and, in some applications, bulky or difficult-to-handle waste.

Typical functions include:

  • Reducing waste volume.
  • Partially standardising feed size.
  • Making internal material transport easier.
  • Preparing waste for sorting, separation or screening.
  • Stabilising the feed to downstream processes.
  • Protecting downstream equipment from oversized pieces.

Depending on the application, primary shredding may use single-shaft, twin-shaft or other configurations. The technology should be selected according to the material and process objective rather than simply by shaft count or installed power.

What is a secondary shredder?

A secondary shredder operates after an initial size-reduction or preparation stage.

Its role is to further reduce the material size and improve the consistency of the output fraction. As a result, feed size is normally more controlled than in primary shredding.

Secondary shredding can be used to:

  • Achieve a smaller particle size.
  • Homogenise material before recovery.
  • Liberate components to facilitate separation.
  • Prepare a fraction for granulation, screening or further sorting.
  • Adjust the product size to downstream process specifications.

Depending on the material, different technologies may be used, including multi-shaft shredders, mills, granulators and hammer-based systems.

The term “secondary” mainly describes the function of the machine within the process, not one specific shredding technology.

Differences between primary and secondary shredders

Criterion Primary shredder Secondary shredder
Position in the line First size-reduction stage Downstream size-reduction stage
Main objective Reduce volume and prepare material Further reduce size and control output
Input material Larger, irregular or heterogeneous Previously reduced or conditioned
Output size Generally coarser Generally finer and more uniform
Tolerance to large pieces High, depending on design Usually lower
Process function Pre-treatment Refining or intermediate/final preparation
Typical downstream equipment Screening, separation, conveying, secondary shredder Fine screening, separation, granulation, recovery

This comparison is indicative. In a real plant, the boundary between primary and secondary shredding depends on the material and the design of the full line.

When does a plant need only one shredding stage?

A single shredding stage can be enough when the main objective is volume reduction or when the resulting fraction does not require a tightly controlled particle size.

If the input material already falls within the machine’s feed limits and the output is suitable for conveying, sorting or recovery, a second shredding stage may add little value.

The decision should be based on the complete process. Installing two shredders by default does not necessarily produce a better line.

When are primary and secondary shredding used together?

Both stages are commonly used when there is a significant difference between the incoming size and the required final size.

A typical sequence may be:

  1. Reception and feeding.
  2. Primary shredding.
  3. Removal of contaminants or separation.
  4. Screening or classification.
  5. Secondary shredding.
  6. Final separation or classification.

This approach allows the work to be divided between different machines and each stage to be designed for a specific function.

It can also be useful when metals, fines or other components need to be removed between the first and second shredding stages. The secondary shredder then receives a more controlled material stream.

Which waste streams may require primary and secondary shredding?

Municipal solid waste (MSW)

MSW is a heterogeneous mixture that can contain fractions with different sizes, densities and compositions.

In some lines, an initial size-reduction stage helps open and prepare the material stream. Screening, magnetic separation, optical sorting, density separation and, where required, secondary shredding can then follow.

For background on this waste stream, see our guide to municipal solid waste.

Industrial waste

Industrial waste may include plastics, wood, cardboard, films, metals and other fractions generated by production processes.

When it arrives mixed or in bulky pieces, primary shredding can make the material easier to handle. If a smaller fraction is needed for separation or recovery, a second size-reduction stage can be added.

The system must be designed around the actual composition of the waste because industrial streams do not all behave in the same way during shredding.

RDF

In refuse-derived fuel plants, final particle size is an important process variable.

Primary shredding can condition the incoming waste, while secondary size reduction or granulation can bring the fraction closer to the specifications required for recovery.

Metal separation, classification or screening can be positioned between the two stages to improve the quality of the recovered fuel.

Wood and biomass

Wood can arrive as pallets, pruning waste, logs, industrial offcuts, boards or post-consumer timber.

Where large pieces are involved, primary shredding reduces the material to a manageable size. If the downstream use requires a more homogeneous fraction, further size reduction may be necessary.

Choosing an industrial wood shredder requires considering not only feed size, but also nails or other contaminants, moisture, throughput and target output size.

Tyres

Mechanical tyre treatment is another example of progressive size reduction.

An initial shredding stage transforms whole tyres into manageable pieces. Further stages can reduce the rubber size and help liberate steel and textile fibres.

Output particle size links primary and secondary shredding

One of the most common mistakes when sizing a line is to talk about “shredding” without defining the required output size.

The target particle size influences much of the design:

  • Type of shredder.
  • Blade, hammer or cutting-element configuration.
  • Number of stages.
  • Required power.
  • Processing capacity.
  • Screening systems.
  • Downstream separation equipment.

The greater the reduction required between feed size and final product, the more important it becomes to evaluate whether the process should be divided into several stages.

How to choose between primary and secondary shredding

1. Waste type and composition

Wood, rigid plastic, textiles, tyres and mixed MSW behave very differently during shredding.

Contaminants and foreign objects must also be considered.

2. Maximum feed size

Piece dimensions determine the shredding chamber, feeding system and whether an initial size-reduction stage is required.

3. Required throughput

The equipment must be sized according to the real throughput required by the facility.

Installed power alone is not enough. Performance also depends on bulk density, composition and material behaviour.

4. Required output size

This is one of the key criteria.

If primary shredding already produces the required fraction, a second stage may not be necessary. If a smaller or more homogeneous product is required, further size reduction should be evaluated.

5. Upstream and downstream equipment

A shredder should never be sized in isolation.

Feeders, conveyors, trommels, screens, magnetic separators, density separators and all other line equipment must be considered.

See our range of recycling machinery for technologies that can be integrated into a complete treatment line.

6. Operation and maintenance

Accessibility, wear, spare parts, downtime and ease of maintenance also affect equipment selection.

Primary shredder, secondary shredder or both?

A primary shredder may be enough when:

  • The input material is bulky and the main objective is volume reduction.
  • The resulting fraction is already suitable for the next process.
  • Fine or tightly controlled particle size is not required.

Secondary shredding may be recommended when:

  • A much smaller output size is required.
  • The final product must meet a specific particle-size target.
  • Materials need to be liberated before separation.
  • Intermediate sorting improves the stream before a second reduction stage.

There is no universal configuration. The correct solution balances throughput, required reduction, energy use, wear and the rest of the line.

Integrating shredders into a recycling plant

Shredder performance also depends on how the machine is integrated into the process.

A line may follow:

Feeding → Shredding → Screening → Separation → Secondary shredding → Final classification

or a completely different sequence depending on the waste.

For example, a magnetic separator between two shredding stages can remove metals before the material reaches the second machine. A trommel can separate by size so that only part of the stream requires further reduction.

Correct plant sizing therefore requires analysis of how all pieces of equipment interact.

If you are designing a complete treatment line, our guide on how to choose recycling machinery may also be useful.

Frequently asked questions

What is the main difference between a primary and a secondary shredder?

A primary shredder usually performs the first size reduction on bulky or heterogeneous materials. A secondary shredder works on conditioned material to achieve further reduction and a more controlled output.

Does every recycling plant need primary and secondary shredding?

No. Some facilities operate effectively with a single shredding stage. A second stage depends on feed size, required output size, throughput and the rest of the treatment process.

Is a pre-shredder the same as a primary shredder?

The terms can overlap in some applications because both may operate at the beginning of the line. The exact terminology depends on the manufacturer, technology and the machine’s process function.

Is a secondary shredder always a granulator?

No. A granulator may operate as a secondary size-reduction machine, but not every secondary shredder is a granulator.

What determines the final size of shredded material?

Shredding technology, blade or hammer configuration, screens, operating speed, waste characteristics and the number of reduction stages can all influence final particle size.

Design shredding as part of the complete process

The difference between primary and secondary shredding is not simply a matter of using a larger or smaller machine. Each stage must perform a specific function within the plant.

Correctly defining the input material, throughput and required output size makes it possible to determine whether one reduction stage is enough or whether the work should be divided between several machines.

At Reverter Industries, we analyse the complete process to integrate shredding, feeding, conveying, screening and separation according to each project’s requirements.

See our range of industrial shredders for recycling or contact our team to discuss your application.

A paper and cardboard recycling plant needs five blocks of equipment: feeding and dosing, shredding, screening by size, density separation and conveying between stages. The specific configuration of each block depends on the input material —corrugated cardboard, office paper, mixed fraction or packaging— and on the throughput in tonnes/hour the line has to process.

This guide runs through each stage, the equipment involved and the criteria that determine its sizing.

Overview: the complete line at a glance

Stage Function Equipment
1. Feeding Regulate the input flow and avoid load peaks Dosing systems
2. Shredding Reduce volume and homogenise particle size Shredders / hammer mills
3. Screening Separate by size and remove fines and contaminants Trommels
4. Separation Split light (paper, film) from heavy (metals, inerts) Density separators
5. Conveying Connect stages and feed sorting cabins Conveyor belts and apron conveyors

1. Feeding and dosing: the bottleneck almost no one sizes correctly

Paper and cardboard arrive at the plant in bales, in bulk or mixed with other fractions. If that input is not regulated, the shredder receives load peaks that spike consumption, accelerate blade wear and force the line to stop.

Dosing systems solve this problem: they store the material and release it at a constant rate through flow regulation with frequency-controlled units. In practice, a well-sized doser is what allows the rest of the line to run at a stable rate rather than in fits and starts.

Sizing criterion: hopper capacity large enough to absorb the full discharge of a truck without stopping the feed downstream.

2. Shredding: reduce volume before sorting

Paper and cardboard are light, bulky materials. Shredding them before sorting multiplies their bulk density, reduces the cost of internal transport and makes subsequent screening possible.

For these materials the reference equipment is the hammer mill, designed to fragment light, brittle materials into fine particles. Single-shaft or multi-shaft industrial shredders are used when the input fraction arrives mixed with rigid plastics, wood or metals.

A specific case is the industrial paper shredder, aimed at the secure destruction of confidential documentation as well as at preparing the material for recycling. If the plant handles archives from companies or public authorities, this equipment covers two needs with a single investment.

Sizing criterion: the target output size determines the choice of blades and the power. The finer the output, the higher the consumption per tonne.

3. Screening: separate by size with a trommel

After shredding, the material passes through a perforated rotating cylinder that classifies it by particle size through continuous screening. Screening trommels process everything from paper and cardboard to refined organic fractions, and on a paper line they perform two functions at once:

  • Remove fines: paper dust, loose staples, fragments below the usable size.
  • Split the flow: separate the coarse fraction (corrugated cardboard) from the fine one (paper), which follow different recovery routes.

Sizing criterion: the drum diameter and length determine the residence time; the mesh aperture defines the particle-size cut.

4. Density separation: remove what is not fibre

This is the stage that makes the difference between a recovered material of commercial quality and one penalised for contaminants. Density separators divide light materials from heavy ones by means of an air stream, isolating the paper and cardboard fibre from metals, inerts, glass and rigid plastics.

Air separation technology achieves efficiencies of over 99% on solid waste, and it is what makes it possible to reach the contaminant levels that paper mills demand.

Sizing criterion: the airflow and the chamber geometry are adjusted to the density difference between the fractions to be separated.

5. Conveying: the line that connects everything

Material has to be moved between each stage, and in a paper and cardboard plant conveying is not an accessory: it defines the entire layout and the accessibility for maintenance.

  • Belt conveyors cover the horizontal and inclined sections and feed the manual sorting cabins.
  • Apron conveyors are used on steeply inclined sections or with abrasive material, where a rubber belt would suffer premature wear.

Sizing criterion: belt width according to throughput, speed according to the sorting time required in the cabin.

How the line changes according to the input material

Not all paper and cardboard plants are configured the same way. The input material determines which stages are critical:

Input material Critical stage Recommended configuration
Large-format corrugated cardboard (OCC) Shredding High-capacity shredder + coarse screening
Office paper and archives Secure shredding Industrial paper shredder + fine screening
Mixed fraction from selective collection Separation Trommel + reinforced density separation
Paper and cardboard with light packaging Separation Multi-stage density separation

How to size a paper and cardboard recycling plant

Before selecting specific equipment there are three variables that condition the entire design:

  1. Input throughput (t/h): it determines the power of the shredder and the width of the belts. Oversizing raises the investment; undersizing turns a stage into a permanent bottleneck.
  2. Material composition: the percentage of contaminants defines how much separation capacity is needed. Clean material of industrial origin requires fewer stages than municipal collection.
  3. Required output quality: the final destination —national paper mill, export, RDF— sets the admissible level of contaminants and, with it, the sophistication of the separation.

From those three figures the rest is calculated: floor area needed, installed power, number of operators in the cabin and return on investment.

Why integrate the whole line with a single manufacturer

Buying separate equipment from different suppliers creates a recurring problem: each machine works to specification, but the complete line does not reach the expected performance because the stages are not synchronised with one another.

At Reverter Industries we have been manufacturing machinery and installing plants across Europe for more than 75 years, and we design each paper and cardboard recycling plant from scratch according to the material to be processed and the input volume, integrating shredding, sorting, density separation and automated control into a single line.

In-house manufacturing in Spain, direct technical service and the ability to work on any stage of the installation without relying on a third party.

👉 Explore our paper and cardboard recycling plants or tell us about your project and we will study the right configuration.

Frequently asked questions

What machinery does a paper and cardboard recycling plant need? Five blocks of equipment: dosing systems to regulate the feed, shredders or hammer mills to reduce volume, trommels to screen by size, density separators to remove contaminants and conveyor belts to connect the stages.

Can paper and cardboard be recycled without shredding it first? Technically yes, but performance drops. Unshredded paper and cardboard have a very low bulk density, which raises the cost of internal transport and prevents subsequent screening by particle size.

What is the difference between a trommel and a density separator? The trommel separates by size through rotary screening; the density separator separates by density through an air stream. In a paper and cardboard plant they are used in a complementary way: first the material is split by size and then the heavy contaminants are removed.

How much floor area does a paper and cardboard recycling plant need? It depends on the input throughput and on whether storage of input material and finished product is considered. The sizing is calculated from the tonnes/hour to be processed and the days of stock planned.

Can an existing plant be expanded by adding stages? Yes, as long as the original layout allows it. The most common expansions are adding a density separation stage to improve output quality or increasing shredding capacity.

There are six parts to a conveyor belt: the frame or load-bearing structure, the belt itself, the pulleys (drive and return), the rollers (carrying, return and impact), the drive system (motor, gearbox and variable frequency drive) and the auxiliary components for tensioning, alignment, cleaning and safety.

Each component performs a specific function, and its selection determines the load capacity, durability and operational continuity of the equipment. In recycling plants, where the material is abrasive and irregular, choosing a single component poorly translates into unplanned downtime and premature wear across the whole system.

Conveyor belt components: summary table

Component Main function Materials or variants
Frame Supports the load and stabilises the conveying path Carbon steel, stainless steel
Belt Conveying surface in contact with the material PVC, rubber, polyurethane, stainless mesh
Drive pulley Transmits motor power to the belt Rubber or ceramic lagging
Return pulley Guides the empty belt and increases the wrap angle Steel, no drive force transmitted
Rollers Reduce friction and absorb impact Carrying, return, impact
Geared motor Converts revolutions into starting torque Three-phase motor + gearbox
Tensioners and guides Maintain belt tension and tracking Manual, automatic, self-aligning

The frame: the load-bearing structure

The frame is the metal skeleton that supports every component and keeps the conveying path stable under load.

  • Carbon steel: withstands the weight under standard industrial conditions.
  • Stainless steel: mandatory in the food and chemical sectors due to hygiene requirements.

It is completed with lateral fixing elements: railings that anchor the structure to external columns and clamps that join the modular sections of the frame, allowing the installation to be extended or reconfigured without rebuilding it.

The conveyor belt: materials and tension

The belt is the working surface that interacts directly with the waste. Its selection defines the capacity and service life of the entire system.

Materials by application

  • PVC: lightweight packaging and processes requiring simple cleaning.
  • Rubber: withstands the abrasive wear of plastics and inert material; reinforced rubber prevents punctures from sharp loads.
  • Polyurethane: wet and greasy environments.
  • Stainless steel mesh: processes involving intensive washing. Its open design aids drainage and prevents the build-up of organic matter.

Smooth or cleated surface

Smooth surfaces are used for general horizontal conveying of loose material. Cleats prevent the load from sliding on inclined sections.

Why tension is critical

Insufficient tension causes the belt to slip on the pulleys and lose efficiency. Excessive stretching accelerates the wear of the internal bearings. Both extremes end in line stoppage.

At Reverter Industries we configure the belt according to the waste to be processed, from packaging and stretch film to RDF/SRF, batteries and municipal solid waste.

Cintas Transportadoras de Banda

Drums and pulleys: how movement is transmitted

Drive pulley

This is the cylinder that transmits the motor’s rotational power to the belt. Its surface is lagged with rubber or ceramic to maximise friction and prevent slippage. Effective traction is what keeps the conveying speed constant.

Return and deflection pulleys

Located at the opposite end or at strategic points, the return pulley guides the empty belt back to the loading point without transmitting drive force. It keeps the path correct and can increase the wrap angle on the drive pulley, optimising traction in long or complex installations.

Types of conveyor belt rollers

  • Carrying rollers (upper run): support the weight of the material. They reduce friction between belt and structure, enabling smooth rotation that consumes less energy. They must be robust enough not to deform under stress.
  • Return rollers (lower run): support the weight of the empty belt and stabilise the return run, preventing vibration and misalignment.
  • Impact rollers: installed where material drops from hoppers. Made up of spaced rings, they absorb the force of the fall and protect the belt from punctures and premature wear.

The electrical drive system

Motor and gearbox

The electric motor, generally three-phase, is the primary source of power. The gearbox converts high revolutions into an adjusted speed and high torque, multiplying the force available to move heavy loads. The combination allows a soft start and protects the system against sudden blockages.

Variable frequency drives

They adjust motor speed in real time according to the load present. They optimise energy consumption, smooth out starts and stops, reduce mechanical stress on every component and extend the service life of the equipment.

Tensioning and alignment systems

Manual versus automatic tensioners

Manual systems require periodic intervention using adjustment screws. Automatic ones use counterweights or compressed air to keep tension stable in the face of thermal or load changes, reducing machine downtime.

Self-aligning rollers

They correct minor deviations by pivoting slightly on their axis. They straighten the belt autonomously, prevent rubbing against the structure and ensure uniform wear at the edges.

Lateral guarding

Fixed or adjustable guides that keep the material centred. They prevent the belt from running off its axis and protect both the mechanical components and personnel safety during loading.

Cleaning and safety components

  • Return-run scrapers: remove waste stuck to the inner face of the belt. They prevent build-up that would unbalance the pulleys or contaminate the downstream process. Installed near the discharge points, they deliver maximum effectiveness.
  • Transfer tables and heads: ease the passage of material between stages, reduce direct impact on the belt and prevent packaging or fragile fragments from breaking.
  • Presence and level sensors: detect the actual load in order to start or stop the motor, optimising consumption and protecting the machinery from overloads.
  • Emergency stops: mandatory under safety regulations. Their series design allows activation from any accessible point in the event of entrapment risk or mechanical failure.

Component maintenance

Constant friction at the support points degrades the shafts. Periodic lubrication of the bearings with high-quality greases reduces the heat generated and extends the life of the moving parts.

Preventive inspections avoid unexpected downtime: keeping tension and alignment correct reduces energy consumption and optimises the plant’s daily operating costs. Read our complete guide to conveyor belt maintenance to set up an inspection plan.

Frequently asked questions about conveyor belt parts

What are the main parts of a conveyor belt?

The frame, the belt, the drive pulley, the return pulley, the carrying, return and impact rollers, the geared motor with variable frequency drive, the tensioning and alignment systems, and cleaning and safety components such as scrapers and emergency stops.

What is the difference between the drive pulley and the return pulley?

The drive pulley transmits the motor’s power to the belt and is lagged with rubber or ceramic to maximise friction. The return pulley transmits no drive force: it guides the empty belt and can increase the wrap angle on the drive pulley to improve traction.

What types of rollers does a conveyor belt have?

Three. Carrying rollers, on the upper run, support the weight of the material. Return rollers, on the lower run, support the empty belt. Impact rollers sit beneath the discharge points from hoppers and absorb the force of the fall.

Which belt material is best for a recycling plant?

It depends on the waste: reinforced rubber for abrasive or sharp material, PVC for lightweight packaging, polyurethane in wet and greasy environments, and stainless steel mesh in processes with intensive washing, thanks to its drainage and hygiene.

What happens if the belt does not have the correct tension?

Insufficient tension makes the belt slip on the pulleys and reduces efficiency. Excessive tension accelerates bearing wear. Automatic tensioners with a counterweight or air keep the adjustment stable on a continuous basis.

Every component, designed for your process

Knowing the parts of a conveyor belt is the first step; the second is configuring them according to the material, the throughput and the conditions of your plant. Discover our belt conveyors, see the types of conveyor belts and their applications or talk to our technical team to design a tailor-made solution within your recycling machinery line.

A ballistic separator is an essential machine in modern recycling plants. Its main function is to classify municipal solid waste, lightweight packaging, paper, cardboard, plastics, wood, or construction waste according to their shape, size, and behavior during the separation process.

Thanks to this technology, treatment plants can improve the quality of recovered materials, increase sorting efficiency, and reduce the amount of waste sent to landfill. As a result, the ballistic separator has become a key solution for moving toward more automated, profitable, and sustainable waste management.

Separador balístico

What Is a Ballistic Separator?

A ballistic separator is a machine designed to divide waste into different fractions using the oscillating movement of an inclined surface made up of paddles or screens. This movement allows materials to be separated according to their physical characteristics.

The equipment generally distinguishes between:

  • Flat or 2D materials, such as paper, cardboard, or plastic film.
  • Rolling or 3D materials, such as bottles, containers, cans, or rigid packaging.
  • Fine fraction, made up of small particles that pass through the screens.

This classification facilitates the subsequent treatment of waste and improves the performance of other plant equipment, such as optical sorters, magnetic separators, shredders, or compactors.

How Does a Ballistic Separator Work?

The operation of a ballistic separator is based on the alternating movement of its inclined paddles. When waste enters the machine, each material behaves differently.

Flat materials tend to move in one direction, rigid or rolling objects move in another, and small particles fall through the perforations in the screen. This system enables fast and accurate separation without the need for constant manual intervention.

In addition, many models allow the inclination and speed to be adjusted to suit the type of waste being processed and improve the purity of the recovered fractions.

Main Components of a Ballistic Separator

To choose the right machine, it is important to understand its most relevant components.

Adjustable Chassis

The inclinable chassis allows the working angle of the separator to be modified, adapting the sorting process to different materials. This adjustment improves performance without the need to completely stop the process.

Classification Shafts and Paddles

The shafts generate the oscillating movement of the machine, while the paddles or screens drive the separation of waste. Their resistance is essential when working with heavy, wet, or abrasive materials.

Interchangeable Screens

Screens make it possible to separate the fine fraction from the rest of the materials. Models with bolted or easily accessible screens simplify maintenance and reduce downtime.

Feeding System

A regular and well-dosed feeding process improves the efficiency of the separator. That is why it is usually integrated with conveyor belts and other automated systems in the plant.

Types of Ballistic Separators by Application

Not all ballistic separators are designed for the same type of waste. The choice of model will depend on the material to be processed, the required capacity, and the necessary level of robustness.

Separators for Paper, Cardboard, and Lightweight Packaging

These machines are designed for light and dry materials. They are commonly used in packaging sorting plants, paper recovery centers, and recyclable waste treatment lines.

They allow paper, cardboard, flexible plastics, bottles, cans, and other packaging materials to be separated efficiently.

Separators for Municipal Solid Waste and Industrial Waste

These models are designed to work with more complex and heavier material flows. They are suitable for mixed municipal waste, plastic fractions, compacted packaging, or non-hazardous industrial materials.

Their structure is usually more resistant and prepared for intensive use.

Separators for Construction and Demolition Waste

When working with rubble, wood, bulky materials, or heavy impurities, more robust machines are required. These separators are prepared to withstand impacts, abrasion, and heavy workloads.

They are especially useful in construction and demolition waste recycling plants.

Advantages of Ballistic Separators in Recycling Plants

Installing a ballistic separator in a treatment plant offers important benefits:

  • Improves the quality of recovered materials.
  • Increases the efficiency of the sorting process.
  • Reduces dependence on manual sorting.
  • Optimizes the performance of other recycling equipment.
  • Reduces operating costs and downtime.
  • Supports compliance with recycling and sustainability targets.

By enabling greater automation, it also helps plants become more productive and competitive.

How to Choose the Best Ballistic Separator

Before selecting a ballistic separator, it is advisable to analyze several technical and operational factors.

Type of Waste to Be Processed

Sorting paper and cardboard is not the same as processing mixed municipal waste or construction materials. The type of waste will determine the required robustness, screen size, and configuration.

Processing Capacity

The machine must match the volume of waste processed by the plant. Insufficient capacity can create bottlenecks, while oversized equipment can lead to unnecessary costs.

Available Space

Some plants have limited surface area. In these cases, it is worth considering compact models, modular configurations, or systems that allow several separation stages to be integrated into less space.

Ease of Maintenance

Access to screens, shafts, paddles, and wear areas is key to reducing downtime. A good maintenance-friendly design improves the service life of the machine and reduces long-term costs.

Integration with Other Equipment

The ballistic separator must work in coordination with conveyor belts, optical sorters, magnetic separators, shredders, and compacting systems. Proper integration improves the overall flow of the plant.

Automation and Technology in Ballistic Separation

Modern ballistic separators can incorporate control systems, sensors, and monitoring tools to improve process performance. These solutions make it possible to adjust parameters, detect incidents, and optimize sorting in real time.

Automation is especially important in plants with high volumes of waste, where precision and process continuity are essential.

Ballistic Separators and Sustainability

The use of ballistic separators has a direct impact on the circular economy. By improving waste sorting, they make it possible to recover more materials and reintroduce them into new production cycles.

This reduces the extraction of virgin raw materials, decreases the amount of waste sent to landfill, and improves the environmental efficiency of recycling plants.

Frequently Asked Questions About Ballistic Separators

What Materials Can a Ballistic Separator Separate?

It can separate paper, cardboard, lightweight packaging, bottles, cans, plastics, wood, municipal waste, and certain industrial or construction waste, depending on the installed model.

What Is the Difference Between a Ballistic Separator and a Trommel?

A trommel mainly sorts materials by size using a rotating drum. A ballistic separator, on the other hand, sorts by shape, density, and material behavior, separating flat, rolling, and fine fractions.

Where Is a Ballistic Separator Installed?

It is installed in recycling plants, municipal solid waste treatment plants, packaging lines, industrial waste plants, and construction and demolition waste treatment centers.

What Maintenance Does It Require?

It requires periodic inspections of screens, paddles, shafts, bearings, and transmission systems. Proper preventive maintenance prevents breakdowns and extends the service life of the equipment.

Conclusion

A ballistic separator is a key machine for improving waste sorting in recycling plants. Its ability to separate flat, rolling, and fine materials makes it an efficient solution for processing packaging, paper, cardboard, plastics, municipal waste, industrial waste, or construction waste.

Choosing the right model depends on the type of material, processing capacity, available space, and required level of automation. With proper integration and maintenance, a ballistic separator can increase material recovery, reduce operating costs, and support more sustainable waste management aligned with the circular economy.

Recycling Machinery at Reverter Industries

At Reverter Industries, we design and manufacture recycling machinery adapted to the needs of each treatment plant. If you need to improve waste sorting, shredding, separation, or recovery, our team can help you find the most efficient solution for your project.

Discover our recycling machinery solutions and optimize the performance of your plant with specialized industrial technology.

Waste treatment is a key process for efficiently managing the waste generated by human activities. Its main objective is to reduce environmental impact, recover valuable materials, and promote a more sustainable model based on the circular economy. Through proper waste classification and treatment, many of these materials can be transformed into new resources.

Classification and Origin of Waste

Waste can be classified according to its origin and characteristics. Among the most common types are household, commercial, and industrial waste, as well as organic bio-waste, construction debris, and sanitary or hazardous waste.

Each type of waste requires specific treatment to minimize its environmental impact and facilitate recycling or reuse. Proper separation at the source helps improve the efficiency of waste management processes and reduces the amount of waste that ends up in landfills.

Processes and Methods in Waste Treatment

Various techniques are used in waste treatment. Preparing materials for reuse allows products to extend their lifespan through cleaning, repair, or refurbishment.

Biological treatments are mainly used for organic waste. Composting converts organic residues into natural fertilizer, while biomethanization generates biogas through the anaerobic decomposition of organic matter.

Mechanical treatments include processes such as shredding, sorting, and separating recyclable materials like metals, plastics, and paper. There are also thermal treatments, such as incineration and gasification, which allow energy to be recovered from certain types of waste.

Integrated Management in Treatment Plants

Recycling plants and treatment centers play a fundamental role in managing waste efficiently. These facilities incorporate automated sorting technologies, material shredding systems, and biological or energy recovery processes to valorize waste.

In addition to technical processes, integrated waste management includes services such as selective collection, specialized treatment of hazardous waste, and environmental education programs that encourage sustainable habits.

Regional Context: Waste Management in La Rioja

In La Rioja, several initiatives have been developed to improve waste management and promote recycling. Source separation, the expansion of treatment infrastructure, and the adoption of new technologies have increased the recovery of materials.

Recycling plants in the region use methods such as composting, mechanical recycling, and energy recovery treatments to reduce the volume of waste and make better use of resources. Cooperation between governments, companies, and citizens is also essential to move toward a more sustainable model.

Conclusion

Waste treatment is a fundamental element in protecting the environment and optimizing the use of resources. Proper waste classification, the development of recycling technologies, and efficient management in treatment plants help reduce environmental impact and recover valuable materials. Moving toward sustainable waste management is essential to strengthen a circular economy model that transforms waste into new resources and contributes to a more responsible future.

An industrial scrap metal shredder reduces the size and volume of metal waste to facilitate its transport, sorting, separation, and subsequent recovery. These machines are used in recycling plants to process materials such as iron, steel, aluminum, shavings, and other metal waste, adapting the shredding system to the material and size of the input. Proper shredding improves the process flow and facilitates the recovery of the metals.

Types of Scrap Shredders

In the recycling sector, there are different types of shredders adapted to each material and need.

  • Shredders for ferrous scrap are designed to process iron and steel, using high-resistance blades and hydraulic systems that allow large metal blocks to be efficiently shredded.
  • Pre-shredders are used in the initial stage of the process to reduce bulky pieces before final treatment, improving workflow efficiency.
  • Industrial shears are used to cut aluminum profiles and large metal parts, facilitating their preparation for shredding.

There are also specific shredders for shavings and electronic waste, adapted for lighter or more delicate materials. For solutions applicable to other waste and processes, see our range of industrial shredders for recycling.

Key Components and Control Systems

  • The performance of a shredder largely depends on its blades, motors, and hydraulic systems. High-strength steel blades require regular maintenance and sharpening to ensure durability.
  • High-performance industrial motors provide the power needed to process large volumes of scrap, while hydraulic systems apply the appropriate force in each operation.
  • Automation and electromechanical control systems improve efficiency, optimize energy consumption, and increase operational safety.

Benefits of Using Shredders in Recycling

The use of scrap shredders offers significant advantages:

  • Reduces the volume of metal waste, optimizing storage and transportation.
  • Improves the quality of recycled material by facilitating impurity separation.
  • Increases efficiency in recycling plants.
  • Supports the circular economy by enabling the reuse of metals such as steel, aluminum, and iron.

Additionally, by reducing the need to extract new raw materials, environmental impact and energy consumption are significantly lowered.

New or Used Scrap Shredders

When acquiring a shredder, it is important to evaluate whether to choose new or used machinery.

New shredders offer greater warranty coverage, advanced technology, and a longer service life. Used machines may involve a lower initial investment but require a thorough technical inspection to avoid unexpected costs.

In both cases, preventive maintenance is essential. Regular inspection of blades, hydraulic systems, and electrical components ensures safe and efficient operation.

Conclusion

Scrap shredders are fundamental in metal recycling. They reduce volume, improve the quality of recovered material, and optimize industrial processes. Proper selection, maintenance, and automation not only increase productivity but also strengthen sustainability and support the development of a more efficient and responsible circular economy.

Metal recycling is a fundamental practice for sustainability and the circular economy. It helps reduce the extraction of raw materials, lower pollution, and make the most of resources that can be reused multiple times without losing quality. Metals such as aluminum, steel, and copper have high industrial value, and their recycling represents significant energy and environmental savings.

Importance of Metal Recycling

Recycling metals significantly reduces energy consumption and pollutant emissions associated with mining and primary production. For example, recycling aluminum can save up to 95% of the energy required to produce it from raw materials.

In addition, recycling helps to:

  • Reduce waste in landfills
  • Lower waste management costs
  • Boost employment in the sector
  • Promote a more sustainable industryTodo ello refuerza un modelo económico más eficiente y respetuoso con el entorno.

All of this strengthens a more efficient and environmentally responsible economic model.

Metal recycling

Recycling Processes and Technologies

The process begins with the collection and sorting of metals. Afterwards, techniques such as the following are applied:

  • Shredding to reduce size
  • Magnetic separation for ferrous metals
  • Eddy current separation for non-ferrous metals
  • Smelting and refining to obtain reusable ingots

New technologies, such as automated systems and high-efficiency machinery, are improving material recovery rates and reducing environmental impact.

Types of Recyclable Metals

Among the main recyclable metals are:

  • Aluminum, used in packaging and automotive industries
  • Copper, essential in electricity and electronics
  • Steel, widely used in construction
  • Nickel, key in batteries and alloys

Their nearly infinite recyclability makes them strategic materials for the circular economy.

Current Challenges

Metal recycling faces challenges such as waste contamination, transportation costs, market price fluctuations, and a lack of public awareness. In addition, complex alloys make efficient separation more difficult.

Overcoming these challenges requires technological investment, infrastructure improvements, and environmental education.

How to Participate in Metal Recycling

At an individual level, it is important to properly separate metal waste and use appropriate recycling containers or collection centers.

Companies can implement internal recycling programs, collaborate with authorized waste managers, and train employees in environmental best practices.

Conclusion

Metal recycling is a key element in moving toward a more sustainable and efficient economic model. It helps save energy, reduce the extraction of natural resources, and lower pollution, while also driving industrial development and technological innovation. Active participation from both citizens and businesses is essential to maximize its impact and strengthen a circular economy based on responsible resource use.

Organic waste disposers are devices designed to break down biodegradable waste into small particles, making disposal easier and improving waste management in both households and professional environments. Their use contributes to better hygiene, reduces unpleasant odors and pests, and promotes more sustainable practices in the treatment of organic waste.

How organic waste disposers work

The operation of an organic waste disposer is based on a blade system that grinds food scraps with the help of water. The waste is transformed into fine particles that can be easily flushed through the drainage system. Modern models incorporate technologies that improve efficiency, reduce noise, and increase safety during use.

In addition, they include protection systems that prevent blockages, overloads, or accidental activation, making them safe even in domestic environments.

Organic waste disposer

Types of organic waste disposers

There are disposers designed for different needs. Domestic models are compact, easy to install under the sink, and suitable for common food waste. On the other hand, professional and industrial disposers are intended for restaurants, hotels, and businesses, offering greater power and capacity to handle large volumes of waste.

There are also special low-energy-consumption units and wash stations with integrated grinding systems, which further optimize the process and reduce environmental impact.

Advantages of using an organic waste disposer

Using a disposer offers multiple benefits. It improves hygiene in kitchens and workspaces by quickly eliminating organic waste, reduces the appearance of bad odors and pests, and simplifies daily waste management.

From an environmental perspective, disposers help reduce the amount of waste sent to landfills and support processes such as composting and organic recycling. In the long term, their durability and low maintenance make them a cost-effective and efficient investment.

Key aspects to consider when choosing a disposer

When choosing an organic waste disposer, it is important to consider power, capacity, and the types of waste it can process. Available installation space, noise level, and ease of maintenance are also determining factors.

It is also advisable to evaluate the warranty, technical support, and value for money, as a good choice can lead to economic savings and greater efficiency over time.

Prices and most common brands

Prices vary depending on the type of disposer. Domestic models are usually more affordable, while professional and industrial options require a higher investment. Well-known brands stand out for their reliability, efficiency, and ease of installation, offering solutions adapted to different budgets and needs.

Conclusión

Organic waste disposers are a practical and sustainable solution for improving waste management in homes and businesses. They facilitate the disposal of organic waste, improve hygiene, reduce environmental impact, and optimize processes such as composting and recycling. Choosing the right model and using it correctly helps save time, reduce waste, and move toward a more efficient and environmentally responsible waste management model.

An industrial wood chipper reduces the size of pruning waste, pallets, stumps, boards, and post-consumer wood to facilitate its transport, processing, recycling, or composting. Depending on the type of waste and the required output, different chipping technologies can be used. Equipment selection should consider the input material, its size and composition, the necessary processing capacity, and the desired final size.

What is a wood chipper?

A wood chipper is a machine that reduces the size of plant waste (branches, boards, pallets, stumps, or post-consumer wood) to facilitate its transport, recovery, or composting. It should be distinguished from a wood chipper: while a wood chipper produces uniform chips from logs and branches, a shredder is more geared towards shredding and reducing mixtures of wood, leaf litter, or heterogeneous materials.

“Less volume, more value: wood ready for recycling or recovery.”

Types of wood shredders (and when to choose each one)

  • Types of wood chippers (and when to choose which one)
    Ideal for high volume (pruning, stumps, mixed green waste). Offers systems to limit projections and improve safety on site.

  • Drum/rotor shredder
    Fixed versions for plants and mobile versions for construction sites or waste parks. Versatile in input sizes and outputs controlled by screens.

  • Industrial shredders for recycling
    At Reverter Industries, we develop specific solutions for wood within our line of industrial shredders and wood recycling plants, which can be integrated into existing lines.

“The right type depends on the material, the volume, and your output goal.”

Key benefits for your operation

  • Volume reduction: fewer trips, lower logistics costs.

  • Size standardization: feeds biomass boilers, presses, or sorting lines.

  • Real circular economy: you turn waste into a resource (wood chips, mulch, recovered solid fuel).

  • Safety and regulatory compliance: equipment and procedures in line with current regulations (see safety section).

How to choose a wood chipper (essential checklist)

  1. Input material: green prunings, pallets with nails, boards, stumps?

  2. Capacity and continuity: actual tons per hour and peak loads.

  3. Desired particle size: defines screens or blade/hammer configuration.

  4. Mobility: fixed plant vs. mobile equipment.

  5. Energy and consumption: installed power and estimated consumption by material and shift. (Consumption varies significantly depending on the type of biomass and operating conditions).

  6. Safety and regulations: UNE-EN requirements for chippers/shredders and INSS(T) best practices.

  7. Integration into your line: belts, metal separators, suction, electrical control.

Take a look at our wood shredder solutions or ask us for a custom design.

Security: what you can’t overlook

UNE-EN 13525:2020 (wood chippers) establishes safety requirements (design, guards, emergency stop, feed zones, etc.). In Spain, INSST NTP 1182 summarizes foreseeable hazards and control measures (projections, entrapments, ejections). Working with compliant equipment and procedures reduces risks and downtime.

Operation and maintenance that extend service life

  • Clean up after each day: this prevents dust/shavings from accumulating (fire hazard) and keeps the feed clear.

  • Lubrication and inspection of moving parts: reduces wear and vibration.

  • Spare parts plan: blades, hammers, screens, and transmission components.

  • Electrical and safety check: emergency buttons, guards, interlocks.

Common use cases

  • Municipal management of pruning and green waste → preparation for composting.

  • Carpentry, logistics, and e-commerce → reduction of pallets and post-consumer wood.

  • Energy recovery → pretreatment for biomass or RDF.

  • Construction and demolition → preparation of wood containing foreign objects (nails/staples) prior to sorting.

Discover our wood recycling plants

Why Reverter Industries?

With over 75 years of experience designing, manufacturing, and integrating recycling machinery and plants, at Reverter Industries we optimize what you already have and incorporate what you need to close the cycle: crushing, transport, separation, control, and after-sales service. Learn more about us.

Conclusion

In short: choosing the right wood chipper depends on the type of material you process, the actual volume of work, and the output particle size you need. With a good selection—and a simple maintenance plan—you reduce logistics costs, improve safety, and turn waste into value.

At Reverter Industries, we accompany you from start to finish: sizing, integration into your line (conveyor belts, separators, control), commissioning, and after-sales support. If you like, we can review your case and I can suggest the optimal configuration.

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