2000 Scrap Aluminum Profile Crusher Project Case Study

Project Overview

Gaozhou Zhongliheng Metal Industrial Co., Ltd. (hereinafter “Zhongliheng”) specializes in aluminum profile production and recycled aluminum resource utilization, offering construction profiles, industrial profiles, and aluminum alloy ingots to manufacturing industries across western Guangdong and neighboring provinces. As the volume of scrap aluminum profiles recovered by the company continued to grow, efficiently and cleanly processing long profiles containing attachments (plastic inserts, iron fittings, rubber seals) became a core pain point in its pre-treatment process before melting.

Unlike clean, regular industrial scrap, Zhongliheng’s typical feedstock consists of mixed construction and industrial obsolete aluminum profiles. These materials can reach 1–3 meters in length and often carry plastic corner brackets, iron screws, rubber strips, and even some dirt. Feeding such material directly into a melting furnace caused:

• High melt loss: Bulky, loose profiles increase surface oxidation and entrap slag.

• Safety hazards: Plastics and rubber generate dense black smoke upon combustion; iron parts may jam the furnace bottom or cause explosions.

• Deteriorated furnace conditions: Large pieces pile up, extending melting time, raising energy consumption, and shortening furnace lining life.

Previously, Zhongliheng purchased pre-processed clean aluminum scrap, but the cost was high and supply unstable. In-house crushing with a simple crusher led to heavy dust, high noise, rapid blade wear, and ineffective removal of iron attachments and plastics.

Solution: Haoxing 2000 Heavy-Duty Scrap Aluminum Profile Crusher

In September 2025, after on-site inspections and material trials with several equipment manufacturers, Zhongliheng selected the Model 2000 Heavy-Duty Scrap Aluminum Profile Crusher manufactured by Gongyi Haoxing Machinery Factory (hereinafter “Haoxing”). This crusher serves as the core processing unit – no conveyor included – and is specifically designed for Zhongliheng’s mixed profile stream:

• Large feed opening & powered infeed system: Opening dimensions of 2000×1500 mm accept 1–3 m long profiles without pre-cutting. A hydraulic assisted infeed roller automatically pushes long profiles into the chamber, eliminating manual feeding hazards.

• High-torque twin-shaft shearing rotor: Forged from high-strength alloy steel, the rotor features staggered discs with an optimized medium-speed, high-torque profile. It efficiently shreds long profiles, shears and crushes to separate plastics and rubber from aluminum, while breaking iron screws and other small attachments.

• Intelligent anti-wrapping & overload protection: Equipped with an electronic reversing system and a fixed-blade cleaning device. If abnormal torque is detected, the rotor automatically reverses to clear wrapped material and then resumes forward rotation, drastically reducing manual cleaning downtime.

• Three-stage alloy cutting tools & wear liners: Tools made of high-chromium alloy with hardfacing technology, geometry optimized for soft/ductile aluminum – balancing sharpness and impact resistance. Liners can be reversed to extend service life by approximately 40% compared to ordinary crushers.

• Integrated iron separation port (optional): A magnetic separation zone in the crushing chamber attracts and directs small iron particles (screws, broken bracket fragments) to a dedicated iron discharge port, keeping iron content in the output aluminum below 0.5% – meeting melting requirements.

The crusher is installed in Zhongliheng’s pretreatment workshop. Feed is done by forklift to the feed platform, directly into the crusher. Discharged crushed aluminum (controllable particle size, typically 30–80 mm) falls into a collecting bin or pit below the discharge hopper, then transported by forklift to the furnace charge area. The entire process has no additional conveying equipment – simple and direct.

Operational Benefits

Since commissioning in December 2025, the Model 2000 crusher has operated for nearly five consecutive months, processing over 8,000 tonnes of scrap aluminum profiles with remarkable results:

1. Significantly reduced melt loss: Uniform particle size and increased bulk density after crushing cut melting time by about 18%, reducing aluminum melt loss from the previous 8–10% to 5–6%. Based on an annual output of 15,000 tonnes, this saves millions of RMB worth of aluminum metal per year.

2. Improved furnace conditions & emissions: Most plastics and rubber are stripped and fragmented during crushing; even if a small amount enters the furnace, its fine size allows complete combustion with roughly 70% less black smoke. The iron separation port greatly reduces iron impurities in the furnace charge, lowering slag viscosity.

3. Stable operation, easy maintenance: Haoxing’s anti-wrapping design works effectively – the chamber needs inspection for wrapping only about once a week, far less than the previous 2–3 times per week. The tools have not yet required replacement; only one scheduled flip/adjustment was performed, keeping consumable costs below expectations.

4. Safer & cleaner working environment: The crusher features a heavy-duty sound enclosure and a dust extraction port; workshop dust levels are below national limits. The hydraulic infeed roller eliminates manual long-profile feeding risks – no lost-time injuries have occurred.

Core Equipment Advantages (Model 2000 Scrap Aluminum Profile Crusher)