Aluminum castings (including engine blocks and transmission housings), machinery aluminum (mechanical component scrap), aluminum alloy wheels, cast aluminum scrap, and foundry returns such as runners and risers represent a class of feedstock that is bulky, hard, and heavily contaminated. These materials often contain embedded steel bushings, ferrous bolts, rubber seals, and surface oil or coatings. Direct melting results in severe oxidation loss, high energy consumption, and iron contamination that degrades the quality of secondary aluminum ingots. Haoxing Machinery provides complete aluminum castings and heavy aluminum scrap shredding and sorting lines, integrating dual-shaft shredders, aluminum hammer mills, magnetic separators, eddy current separators, chain plate conveyors, belt conveyors, and pulse dust collectors. The line efficiently reduces large, dense castings into clean aluminum granules (5–20 mm) in a single pass, while effectively separating ferrous metals, copper, plastics, rubber, oil, and coatings. Final aluminum purity reaches 98% or higher, delivering high-density, premium furnace feedstock for secondary smelters.
Addressing the large size, high hardness, and ferrous contamination of aluminum castings, Haoxing employs a robust "shredding + hammer milling + dual separation" process:
Aluminum Castings / Machinery Aluminum / Wheels / Cast Aluminum Scrap → Chain Plate Conveyor (Feeding) → Dual-Shaft Shredder (Coarse Shearing) → Belt Conveyor (Transfer) → Aluminum Hammer Mill (Fine Grinding & Granulation) → Belt Conveyor (Discharge) → Magnetic Separator (Ferrous Removal) → Eddy Current Separator (Aluminum Purification from Other Metals/Non-Metallics) → Dust Collection System (Purification) → Clean Aluminum Granules + Ferrous/Copper/Plastic Residues
Function: Smoothly transports heavy aluminum castings and wheels (individual pieces up to tens of kilograms) to the dual-shaft shredder inlet.
Features: Heavy-duty slat construction, slat thickness 8–10 mm, highly impact and abrasion resistant. Slat width 1200 mm, variable speed 0.5–15 m/min, interlocked with downstream load. Customizable length (8–15 m).
Recommended Model: LB1200×12m, 11 kW.
Function: Shears bulky castings and wheels into 50–120 mm chunks or strips, suitable for hammer mill feeding, while initially loosening embedded ferrous inserts and rubber.
Features: Two counter-rotating shafts, low speed (12–20 rpm), ultra-high torque. Blades made from high-chromium alloy tool steel (HRC 58–62) with four indexable cutting edges. Cutter shaft diameter 450 mm, working length 1000 mm, equipped with 48 moving blades. Effectively fractures casting structure and loosens steel bushings and bolts. PLC control with automatic reverse protection against unshreddable objects.
Recommended Model: HX-SS1000, 37 kW × 2, capacity 8–15 t/h.
Function: Pulverizes shredded chunks into dense, spherical aluminum granules (5–20 mm) via high-speed hammer impact, while completely liberating residual ferrous metals, oil, and coatings.
Features: Rotor diameter 1600 mm with 48 high-chromium alloy hammers (HRC 58–62) rotating at 800–1000 rpm. Material is repeatedly impacted and ground against high-manganese steel liners (ZGMn13). Bottom screen grate (10–20 mm aperture, interchangeable) controls output size. Oil and oxidation are stripped off and extracted by the dust collection system. Housing fabricated from 25–30 mm manganese steel plate with hydraulic lid opener. Feed opening 1600×1200 mm.
Recommended Model: HXPS1600 (heavy aluminum specific), 280 kW, capacity 12–18 t/h.
Function: Removes ferrous contaminants (steel bushing fragments, bolts, iron filings) from the crushed mixture, protecting downstream equipment and significantly improving aluminum purity.
Features: Permanent magnetic self-cleaning drum, field strength ≥8000 Gauss. Belt width 1000 mm, capacity 20–35 t/h. Ferrous material is automatically ejected, non-magnetic material proceeds to next stage. Iron removal efficiency ≥99%.
Recommended Model: CX1000, 4 kW.
Function: Precisely separates aluminum granules from other non-ferrous metals (copper, zinc, stainless steel) and non-metallic impurities (plastics, rubber) in the magnetic tailings, producing high-purity aluminum product.
Features: High-speed rare-earth NdFeB magnetic rotor (0–3000 rpm adjustable) generates high-frequency alternating magnetic field. Aluminum particles are ejected by eddy current repulsion into a dedicated collection bin, while other metals and non-metallics fall freely into separate chutes. Processing size 3–100 mm, separation purity 96–99%.
Recommended Model: ECS1000, 7.5 kW, capacity 8–12 t/h.
Function: Transports material between processing stages.
Features: Tear-resistant nylon belts (EP200), width 800–1000 mm, with self-aligning idlers and spring scrapers. Configurable for horizontal, inclined, or curved layouts.
Recommended Model: B1000×12m/15m, 5.5–7.5 kW.
Function: Captures airborne dust, oil mist powder, and light impurities generated during shredding and crushing, ensuring clean workshop air and regulatory compliance.
Features: Sealed negative-pressure ducting, filtration area 200 m², airflow 15,000 m³/h. Pulse-jet cleaning, filtration efficiency ≥99.9%. Exhaust vented via 15 m stack.
Recommended Model: DMC-200, 15 kW.
Automotive Engine Blocks / Transmission Housings: Contain embedded steel bushings and bolts. Dual-shaft shredder pre-breaks structure; magnetic separator effectively removes ferrous. Aluminum recovery ≥97%.
Aluminum Alloy Wheels (with steel valve stems/inserts): Shredding + crushing followed by magnetic separation removes steel components; eddy current purification delivers aluminum purity ≥98.5%.
Machinery Aluminum (Mechanical Component Scrap): Complex shapes with oil contamination. Hammer milling strips oil and coatings; dust collector extracts residues, yielding clean aluminum granules.
Cast Aluminum Scrap / Foundry Returns: High hardness, large pieces. Dual-shaft shredder provides enhanced coarse reduction; hammer mill equipped with high-chromium hammers for 30%+ longer wear life.
Mixed Aluminum Casting Scrap: The complete line simultaneously processes various casting types. Eddy current separator further recovers copper, zinc, and other non-ferrous metals.
| Equipment | Recommended Model | Power | Capacity | Key Parameter Notes |
|---|---|---|---|---|
| Chain Plate Conveyor | LB1200×12m | 11 kW | 30–50 t/h | Slat width 1200 mm, thickness 8–10 mm, VFD |
| Dual-Shaft Shredder | HX-SS1000 | 37 kW × 2 | 8–15 t/h | Cutter shaft φ450×1000 mm, 48 blades (4-edge indexable) |
| Aluminum Hammer Mill | HXPS1600 | 280 kW | 12–18 t/h | Rotor φ1600 mm, 48 hammers, screen 10–20 mm |
| Belt Conveyor | B1000×12m/15m | 5.5–7.5 kW | Matches crusher | EP200 nylon belt, trough idlers |
| Magnetic Separator | CX1000 | 4 kW | 20–35 t/h | ≥8000 Gauss, self-cleaning drum |
| Eddy Current Separator | ECS1000 | 7.5 kW | 8–12 t/h | Tray width 1000 mm, rotor speed 0–3000 rpm |
| Pulse Dust Collector | DMC-200 | 15 kW | 15,000 m³/h | Filtration area 200 m², pulse-jet cleaning |
Haoxing Machinery's aluminum castings and heavy scrap shredding and sorting lines are operating reliably at numerous large-scale secondary aluminum smelters, ELV dismantling facilities, and aluminum processing scrap recovery centers worldwide. Whether processing high-hardness engine blocks or ferrous-contaminated wheel castings, we provide customized turnkey solutions tailored to your feedstock characteristics, throughput targets, and site constraints—empowering you to produce cleaner, higher-value aluminum furnace feedstock at a lower processing cost and maximize the value of your aluminum scrap resources.
Haoxing Machinery HXPS1600 Aluminum Casting Crushing and Sorting Processing Video：
HXPS1600 Aluminum Casting Crushing and Sorting Processing Test Machine Video:
