GME Recycling and Bosch Rexroth: From the joint interest of two companies, “Ventiduedenti” is born - a revolutionary shredder that rewrites aluminium recycling history
High cutting precision, lower wear and reduced energy consumption. These three features make the machine conceived and designed by GME, in partnership with Bosch Rexroth, a one-of-a-kind item.
GME, the acronym for Gianni Mori Engineering, is a company based in Monza with a technical division in Voghera. Maurizio Mori, GME Marketing and Sales Manager, said, “We are active in two main sectors - aluminium recycling and lead battery recycling - and we create, design and draw machines and even entire lines in-house”. “We outsource our production - he adds, through a rigid control chain that fully covers the management of approximately 280 suppliers we resort to, in order to ensure the highest quality at all times.”
GME's way of working allows the company extreme flexibility, a condition that clients deem more and more essential. "In our case, this is possible," says Mori, because we take care of the machine layout and design, which can be modified and adapted based on the client's needs". In short, "We listen to the client's specifications, and the final project is the result of their specific needs and stringent requirements".
Mori said, "One of our two strengths is conceiving aluminium recycling systems because we are one of the very few companies that can completely cover the recycling value chain for this material; this means that we don't deal only with shredding and sorting of the scraps, but also with the melting part." "This is proven by the fact" - continues Mori - that "we design and develop decoating technologies in house, to eliminate organic matter and paint from cans and profiles, and we design and manufacture melting or holding furnaces, as well as foundry plant casting machines to produce aluminium bars or billets". GME's market comprises 98% of exports abroad, with its most relevant clusters being the European, MEA (Middle East and Africa) and Asia Pacific (India, China, Bangladesh and Pakistan) areas.
During the creation of a new aluminium shredder, GME reached out to Bosch Rexroth - a leading global company in the field of integrated industrial automation and mobile operating machine handling technologies. “We were looking for a partner - confirms Mori - that could support our will to create an updated production from a wear and maintenance standpoint, with high performances and greater flexibility”. In Bosch Rexroth, GME has found what it was looking for, and this was partially possible due to in-depth market analysis and, above all, to long-standing cooperation and a long history of mutual trust and reliability”. This is how “Ventiduedenti” was born, an aluminium shredder with revolutionary features, which is about to be launched on the market.
Mori explores the details of the new machine, highlighting the qualities that make it one of a kind.
Point 1, the precision of the cut. With these new blades, “teeth'' developed for this shredder “we have a precision that reaches a fraction of a tenth of a millimetre. In this way, we guarantee a clean cut with a controlled and homogeneous size of the scrap loaded; this feature is especially appreciated by clients, which deem having even output sizes essential. The profile control system is ensured, apart from the new tooth design; also by an additional unload check, which prevents any out-of-range piece from exiting, ensuring the complete shredding and evenness of the output product.”
Point 2, less wear. “The machine we designed has significantly lower maintenance needs. This is because the new rotor we designed here at GME features a scissor-cut coupling elliptical shape, with 22 offset teeth and Hägglunds hydraulic drive, ensuring the necessary cutting strength on profiles or scraps, even denser ones, generating a lower quantity of hydraulic peaks. Another essential aspect is the new Tooth design, with Quad-Cutting-Face technology, through which they can be rotated and tipped, to use the cutting faces four times before they need to be sharpened, with a blade duration in time four times longer than the previous product”. We have two substantial benefits. The first medium-long-term benefit is a reduced wear of the system mechanics and hydraulics, while the second is a greater blade and hydraulic motor longevity.
Point 3, greater performances. “The concept behind Ventiduedenti focuses on using the motor to optimize the productivity/energy consumption ratio. The shredder is built so as to adapt to different kinds of scraps with different shredding strengths, and, through its innovative cutting geometry, it reduces absorption peaks for the power installed so that they can only be reached in a fraction of a second during which the knocker shears the scrap. After which, the system undergoes a downward spiral, which means that the effort is not always at full regime, but it is instead divided and slowed down according to the actual needs. The motor is used in a less massive manner through the system described earlier. This translates into less machine wear in general and also greater adaptability to the type of scrap loaded into the shredder, designed to be extremely eclectic and versatile. At a glance: the need to carefully divide everything that is inserted in the shredder is not so stringent”.
The terms of the essential contributions to the “Ventiduedenti” project made by Bosch Rexroth are described by its Product Manager Giacomo Bosio: “With the Hägglunds product portfolio, we were able to satisfy GME’s requests in terms of quality, flexibility and reliability.
The quality of the finished product is also ensured by the performance of our components, which allows for improving the production process and increasing productivity.
Thanks to the flexibility of our solutions, we managed to meet the technological requirements of the machine fully.
Most importantly, our client knows they can count on the reliability of our Hagglunds systems, designed in order to provide a long service life, even in Heavy Duty continuous applications, with consequent maintenance reduction.
Moreover, with our control system, we are able to work in ‘power on demand’ mode, ensuring the correct size and use of the electric power installed, optimizing the productivity/energy consumption ratio.”
A concept reiterated by Davide Borroni, Bosch Rexroth Sales Representative: “The Hägglunds motor, applied to this kind of machines, offers great benefits: high starting power without any time limitation, and direct shaft assembly without interposed gearboxes; this reduces inertia, making the machine less sensitive to impacts, and protecting both the mechanical part and the drive system”.
Hägglunds started producing these systems in the 1980s and then constantly updated and improved them in step with technological developments.
The Swedish company is synonym with experience and success, “and this - says Bosio, from Bosch Rexroth – is truly important for the client because they know they can rely on an internationally-leading company that provides services and spare parts everywhere through the capillary diffusion of its operating branches”. “Furthermore, Hägglunds solutions are ‘plug & produce’ and turn-key. The system is assembled and tested by the manufacturing company. The client only needs to connect the components, install the motor on the shaft, and start the machine.
The drive is provided with a built-in control system - Spider II - that can fully manage the machine motion control by interacting with the most widespread communication protocols. It’s a simple parameter setting operation to make the commissioning easy and quick.”
Mori from GME adds: “This is a system 4.0 that reaches up to 10 tons/hour of loaded scrap, in a modular way, and with a precise cutting action, minimizing the production of fine particles and dust, and therefore aluminium loss compared to our standard systems, such as hammer mills; moreover, it prevents extremely noise environments, polluted by fine dust that hinder our operators’ health”.
Concerning the time required to complete the project, Borroni from Bosch Rexroth says: “We met in November to define the supply order and made the material available to the client by mid-February. This is another of our signature characteristics: we are able to provide an entire drive system (motor, hydraulic power unit and motion control) in approximately 14 weeks, while the supply of the motor only requires just 7 weeks”.
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