Recover 11–13% more non-ferrous metals—simply through better screening
The throughput was right. The screening process quality was not.
This was exactly the situation facing the metal recycler Koslow. The drum screen being used did process the required amount of material. However, the classification of the input material by size was not precise enough: a significant amount of fine material and long parts unintentionally ended up in the target size range for the downstream sorting equipment.
Together with SPALECK, Koslow therefore analyzed its various input materials at the SPALECK Test Center for Recycling Technology. Subsequently, the trommel screen was replaced with a SPALECK Screening machine specifically designed to meet the requirements of metal recycling.
The result: Since then, Koslow has been recovering 11 to 13 percent more non-ferrous metals solely through the optimized screening process.
As an expert in metal recycling, Koslow processes more than 180,000 metric tons of metal-containing materials annually. These include, among other things, end-of-life vehicles, scrap iron, light and heavy shredder fractions, and waste electrical and electronic equipment. For further sorting, the company needs the input material to be precisely classified by size. This is exactly where the joint optimization of screening technology with SPALECK began.
Iwan Koslow GmbH & Co. KG, Germany
Metal Recycling / Non-Ferrous Metal Processing
Non-ferrous metals, such as aluminum, stainless steel, copper, brass, and alloys
Crushing, screening, and sorting of 180,000 metric tons per year
Replace the drum screen machine to optimize screening quality
IN ACTION
The ” Wertstoffsieb ” vibrating screen is specifically optimized for metal recycling at Koslow. As a result, the screen produces very precise screen sizes with virtually no cleaning required.
Koslow now has eight ActiveFEED units in operation. These units optimize the performance and cost-effectiveness of the sorting machines. As a result, the company is able to achieve higher throughput in less time and with better sorting quality.
Discuss the recycling project now
Learn more about optimized screening and material feeding for your existing or new metal recycling process. Let’s discuss your materials and process requirements. I’d be happy to show you some references and other examples of my work.
Koslow had reached a point where the quality of the downstream sorting could no longer be improved using the existing Screening technology.
In fact, the drum screen technology being used was having a negative impact on sorting quality and the material recovery rate in metal recycling.
Although the Trommel screen in use achieved the required throughput, the problem lay elsewhere: Due to the design and operating principle of the Trommel screen, large quantities of fine material and long parts fell into the target fraction as the material rotated.
Unlike with vibrating screens, it was not possible to guarantee a narrow particle size distribution here. In practice, the particle size distributions produced by the Trommel screen did not meet the requirements of the downstream sorting equipment.
Despite various adjustments to the drum screen, large quantities of fine material and numerous Long parts continued to end up in the target fraction.
As a result, the screening process became the bottleneck in the process: High-quality sorting technology was available—but the material did not arrive there in the desired classification.
“We had reached a point where we could no longer improve our sorting quality.”
Michael Kannengießer
Project Manager, Iwan Koslow GmbH & Co. KG
In the video, Christian Lake (SPALECK) and Michael Kannengießer (Koslow) provide detailed information about the screening technology used. They also discuss how Koslow, as a metal recycling company, is continuously optimizing the processing workflow in collaboration with SPALECK, a manufacturer of conveyor and separation technology. Thus, the video covers not only screening technology but also the topic of material feeding for sensor sorting.
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The significant improvement in screening was achieved, in part, by switching to a screening technology better suited for screening metals (recyclable materials screen).
Christian Lake: “A vibrating screen offers the advantage that there is no tumbling action with a drum. This means that fine particles and long pieces cannot fall vertically through the holes.”
However, simply switching to a vibrating screen is still not enough for metal recyclers to achieve optimal screening results.
The key advantage comes from the three-dimensional screening technology, combined with the machine’s optimally adjusted vibration characteristics and the use of custom screen liners tailored specifically to the customer’s material.
“This not only ensures the desired screening quality but also allows the recycler to benefit from virtually maintenance-free operation and high cost-effectiveness.”
Iwan Koslow GmbH & Co. KG, Deutschland
How do I find the right screening process to achieve my recycling goals?
At Koslow, extensive screening tests were the decisive step toward achieving more economically successful screening results.
To this end, Koslow utilized SPALECK’s free service to test its daily input materials on two large-scale systems equipped with feeding and screening technology. Working closely with the customer, the team examined how the materials could be screened and which screening technology could reliably produce the required fractions.
It was only after these trials that the decision was made to purchase the new machine. The drum screen was replaced by a SPALECK screening machine specially optimized for metal recycling.
Key customer benefit: Thanks to the SPALECK ModularDESIGN+ principle, the screening machine remains so adaptable that it can continue to be optimized and customized even years later.
This principle is useful not only in metal recycling, but also, for example, in slag processing, e-waste recycling, as well as in composting or municipal solid waste. The reason is simple: In day-to-day recycling operations, material compositions, the particle sizes of input materials, and even the recycler’s economic goals and opportunities are constantly changing.
The screening process at Koslow has been consistently optimized to meet the company’s process and processing objectives: high throughput and screening results optimized for downstream sorting.
The SPALECK recycling screen accurately and reliably separates a wide variety of input materials—such as light shredder fractions, heavy shredder fractions, auto shredder residue, and electronic scrap—into the particle sizes specified for the sorting process.
The selection of screen media is based on the material properties of the metal fractions. Modifications—such as those required when changing materials—can be made quickly and easily. With SPALECK, customers benefit from new developments and optimizations.
Trouble-free operation, optimal accessibility, and useful features such as SPALECK CONNECT technology and the LubricationCONTROL automatic central lubrication system support the operator and operating personnel and ensure highly economical operation.
The SPALECK screening machine could be easily integrated into the existing line through a retrofit. Thanks to our team-oriented approach and the understanding that optimal screening contributes to optimal sorting results, screening now plays a very important role in overall performance.
Would you also like to review or optimize your screening process, or would you like more information about our metal recycling projects? Then just get in touch with us. We’re always happy to help!
TRANSFERABILITY for Your Processing
If the recovery or sorting quality of an existing metal processing facility does not meet expectations, the cause may not lie in the sorting technology used. It’s worth taking a look at the material’s classification, especially when:
If even one item can be checked with “Yes,” you should determine whether a different screen machine or screen deck configuration would yield better results with the actual input material. The Koslow example shows just how significant the impact can be: an 11 to 13 percent increase in the amount of non-ferrous metals recovered—simply by optimizing the screening process. The result is specific to this project and cannot be generalized to other facilities. The underlying question, however, is this: Is your downstream sorting technology already getting the most out of the material—or is the screening process limiting the results?
Screening Technology for Your METAL RECYCLING
Would you like to improve your metal recovery, or are you not entirely satisfied with the classification performance of your existing screening equipment? Then let’s talk about your screening process and your material. I’d also be happy to show you more references for SPALECK screening machines.
Here are some questions about the SPALECK Activefeed feed hopper. We’d be happy to help you find the right solution.
The ActiveFEED feed hopper pays for itself from day one, as it significantly increases the recovery rate of non-ferrous metals in metal recycling, for example. In many cases, the payback period is less than half a year. We would be happy to advise you personally on this matter. Examples such as STENA Recycling and KMR Recycling show you exactly how this works.
Yes, you can easily retrofit the SPALECK ActiveFEED feed hopper. Many of our customers are replacing their standard batch sizes and, as a result, achieving significantly better and more profitable sorting results. Check out this feedback from our client STENA to see how easy the replacement process is.
Yes, the ActiveFEED is ideal as a feeding system for X-ray sorting technology, such as XRF or XRT sorting. In XRF and XRT sorting machines, it enables fully automatic, continuous material feeding. This allows recycling companies to use ActiveFEED to automatically feed their sorting machines with the optimal amount of material for each specific sorting machine and type of recyclable material. This increases both sorting efficiency and volume. In addition, sorting quality can be significantly improved through optimal feeding. See also the case study by STENA Recycling and the recycling expert Skrotfrag.
Testing your recycled materials at the SPALECK TestCenter is free of charge. This way, you can test high-performance recycling equipment such as the 3D COMBI screening machine or the SPALECK ActiveFEED feed hopper. Here’s how SPALECK’s conveying and separation technology can help you—at a glance.
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