Application of steel chip cake making machine in automobile manufacturing industry: Enpact helps companies realize greater value of scraps
Car manufacturing plants produce several tons of steel scraps in a day. These piles of steel scraps take up valuable space and cost a lot of money to transport. What's worse, sending it back for re-smelting will cause losses. But as long as a piece of machinery and equipment is introduced that can compress waste materials into ingots, this unfavorable situation can be completely reversed and break the dilemma.
How much of a headache does scrap steel shavings cause?
During the cutting, drilling and milling processes of engine blocks, transmission gears, and chassis parts, a large amount of loose iron filings will be produced. After a car is processed, the amount of waste generated is enough to fill two turnover boxes. At the same time, the waste also contains oil and liquid, and drips everywhere, causing the workshop floor to appear sticky.
The volume is used as the measurement standard when calculating transportation costs for loose iron filings. In this case, the tonnage that each transport truck can load is very small, resulting in the transportation cost exceeding the value of the scrap metal material itself.
When these materials are sent to the furnace for re-smelting, there will be a high burning loss rate, and the metal recovery ratio is only maintained at more than 60%. This is equivalent to consuming most of the profits that could have been obtained directly in the process of burning loss.
To what extent can a cake beater compress
The hydraulic cake crusher equipment supplied by Enpat uses its large-capacity and large-tonnage cylinder to compress the originally loose iron filings into cake-shaped objects with very strong density, reducing the volume of the materials to one-fifth of the original or smaller.
In the transportation process, machining iron filings are processed and recycled . Machined iron filings are processed and recycled . The application of machining iron filings processing and recycling steel chip cake beaters in the automobile manufacturing industry: Enpact helps companies realize greater value of scraps. Because the processed materials are more compact, the same transport vehicle can load several times the original quantity. Due to the substantial increase in loading volume, it directly leads to a significant reduction in logistics costs, which means that the original freight amount is significantly reduced.
By returning the pressed discus to the furnace, its burn loss rate has been significantly reduced from the original 30% to single digits, which has significantly improved the overall metal recovery rate.
Since the recycled metal market is now more accepting of finished cakes with high density characteristics, the sales price per ton of products can add hundreds of extra profit margins. This does not pose any practical problems, or is very easy to achieve.
How to deal with oil and liquid without breaking the law
The iron filings produced during automobile processing are mixed with cutting fluid and lubricating oil. If the compression operation is performed directly, it will be equivalent to suppressing the liquids that are hazardous wastes.
The cake crusher equipment under the Enpact brand is equipped with a special system for collecting and discharging liquids. It can separate the oil from the iron filings when the compressor is working, and carry out separate recovery and subsequent treatment of the separated oil.
The cutting fluid is recycled, which saves the cost of hazardous waste disposal, and at the same time, the environmental protection inspection can be passed smoothly. Starting from 2025, several provinces will have stricter regulations on oily waste liquids. This design plan is equivalent to solving compliance issues in advance.
Can the equipment withstand the production line's 24-hour turnaround?
Auto parts factories basically adopt a three-shift model, and the production assembly line runs non-stop. If equipment such as a cookie cutter always breaks down frequently, the subsequent accumulation of scrap will cause the entire production line to be forced to stop and wait for repairs. However, the company Enpat has successfully reduced the failure rate of the equipment to a very low level by using thickened steel plates and wear-resistant hydraulic components.
In terms of after-sales response, Enpact has deployed service outlets around the world, and commonly used spare parts can be issued and processed on the same day. For those automobile manufacturers with very tight production schedules, as long as they conduct specific calculations and accounting of the losses caused by downtime, they can clearly know how high the value of maintenance and support services is.
How to implement from single machine to whole line automation
Enpact can provide customized solutions based on the specific layout of the workshop, allowing the conveyor to bring together the iron filings formed in each production link, thereby implementing automated feeding operations, compression processing, and discharge of cake-like solids. The entire process does not require operator supervision at all times. Only one person is required to manage three pieces of equipment, which can significantly reduce labor costs.
Taking a medium-sized gearbox production line as an example, the daily amount of iron filings produced is about 1.5 tons. Under the original operation mode, two full-time personnel were required to clean the materials. After the introduction of automation technology, only one person is required to conduct inspections to meet the demand. Based on this calculation, the total labor cost saved in a single year is roughly equivalent to the cost of purchasing half of this type of equipment.
After settling the accounts, I realized that it was long overdue.
A cookie cutter costs hundreds of thousands of dollars, but after this money is spent, the freight is saved, the scrap price is also higher, the space freed up can be used to store two more machine tools, and the risk of environmental fines is gone. Most factories that make auto parts can get their principal back in about eight to twelve months.
The price of recycled metals will show an upward trend in 2026, and the advantages of high-density discus overflow will be more prominent. The sooner you intervene, the sooner you can get benefits. The longer the time drags on, the loose iron filings will continue to occupy precious space, and energy such as gasoline will be consumed to maintain the status quo. In the end, the losses will be real money.
Please tell me how much iron filings your factory can produce in a day? You can tell us in the comment area. Let me help you estimate how long it will take for that cookie machine to earn back the money and achieve the goal of repayment. If you also find this method useful, remember to like and forward it.
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