Scrap Aluminum Profile Shredding and Sorting Line: Complete Solutions from Bulky Extrusions to Clean Aluminum Granules
Scrap aluminum profiles—including waste aluminum doors and windows, curtain wall extrusions, thermal break aluminum, decorative trims, and industrial extrusions—are a vital feedstock for secondary aluminum production. These materials are typically long, irregularly shaped, and contaminated with plastic thermal strips, rubber seals, ferrous hardware, and paint coatings. Direct melting results in high oxidation loss, excessive energy consumption, and poor aluminum purity, degrading the quality of recycled ingots. Haoxing Machinery provides complete scrap aluminum profile 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 profiles up to several meters in length into clean aluminum granules (5–20 mm) in a single pass, while effectively separating plastics, rubber, ferrous metals, and paint. Final aluminum purity reaches 98% or higher, delivering premium furnace feedstock for secondary smelters.
1. Core Process Flow for Scrap Aluminum Profiles
Addressing the length, contamination, and plastic content of aluminum profiles, Haoxing employs a proven "shredding + hammer milling + dual separation" process:
Scrap Aluminum Profiles / Thermal Break Windows → Chain Plate Conveyor (Feeding) → Dual-Shaft Shredder (Coarse Shearing) → Belt Conveyor (Transfer) → Aluminum Hammer Mill (Fine Grinding and Granulation) → Belt Conveyor (Discharge) → Magnetic Separator (Ferrous Removal) → Eddy Current Separator (Aluminum-Plastic Separation) → Dust Collection System (Purification) → Clean Aluminum Granules + Waste Plastic/Rubber
2. Equipment Functions and Key Parameters
1. Feeding: Chain Plate Conveyor
Function: Smoothly transports long aluminum profiles (up to 6 meters) to the dual-shaft shredder inlet.
Features: Heavy-duty slat construction, impact and abrasion resistant. Belt 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.
2. Coarse Shredding: Dual-Shaft Shredder
Function: Shears long profiles into 50–150 mm strips or chunks, suitable for hammer mill feeding.
Features: Two counter-rotating shafts, low speed (15–25 rpm), high torque. Blades made from high-chromium alloy tool steel (HRC 58–62) with four indexable cutting edges. Effectively liberates plastic thermal strips and rubber seals during shredding. PLC control with automatic reverse protection against unshreddable objects.
Recommended Model: HX-SS1000, cutter shaft φ450×1000 mm, 37 kW × 2, capacity 8–15 t/h.
3. Fine Grinding: Aluminum Hammer Mill
Function: Pulverizes shredded strips into dense, spherical aluminum granules (5–20 mm) via high-speed hammer impact, while completely liberating residual plastics, rubber, and paint.
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. Paint and oxidation are stripped off during crushing. Housing fabricated from 25–30 mm manganese steel plate with hydraulic lid opener. Feed opening 1600×1200 mm, optional forced feed rollers.
Recommended Model: HXPS1600 (aluminum profile specific), 280 kW, capacity 12–18 t/h.
4. Magnetic Separation: Magnetic Separator
Function: Removes ferrous contaminants (hardware, screws, iron filings) from the crushed mixture, protecting downstream equipment and 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.
5. Non-Ferrous Separation: Eddy Current Separator
Function: Precisely separates aluminum granules from non-metallic impurities (plastic thermal strips, rubber seals, foam) 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 non-metallics fall freely. Processing size 3–100 mm, separation purity 96–99%.
Recommended Model: ECS1000, 7.5 kW, capacity 8–12 t/h.
6. Material Handling: Belt Conveyors
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.
7. Environmental Control: Pulse Jet Baghouse Dust Collector
Function: Captures airborne dust, paint powder, and light fluff 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.
3. Adaptability to Different Aluminum Profile Types
Standard Aluminum Door/Window and Curtain Wall Profiles: Standard configuration (shredder + hammer mill + magnetic separator + eddy current separator). Output purity ≥98.5%.
Thermal Break Profiles (with PA66/PVC Strips): Optimized eddy current separator settings for efficient aluminum-plastic separation. Aluminum recovery ≥97%.
Profiles with Ferrous Attachments: Magnetic separator effectively removes hinges, screws, corner brackets, and other iron hardware.
Painted or Laminated Profiles: Hammer milling strips over 95% of coatings; dust collector extracts paint particles simultaneously.
4. Reference Scrap Aluminum Profile Shredding and Sorting Line Configuration
| Equipment | Recommended Model | Power | Capacity | Key Parameter Notes |
|---|---|---|---|---|
| Chain Plate Conveyor | LB1200×12m | 11 kW | 30–50 t/h | Slat width 1200 mm, VFD, impact-resistant |
| 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 scrap aluminum profile shredding and sorting lines are in operation at numerous secondary aluminum smelters and large-scale aluminum recycling facilities worldwide. Whether processing standard window profiles or highly contaminated thermal break material, 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.
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