Inadequate waste control measures in workshops are costly, and with labour and material costs on the rise, a system for processing scrap is critical.
The latest product from Dimac Australia, the Australian-made Swarf Crusher, is a unique system designed to reduce the floor area required to store swarf by compacting metal shavings into billets. Meanwhile, the recovery of cutting fluid from this process allows companies to gain a better price from the sale of swarf.
The system works by loading the swarf into a hopper where two horizontal augers and one vertical auger feed the swarf into a chamber. From there it is compressed into billets of 53 mm in diameter. Dimac say the length can be varied to suit the material you are processing.
Once the metal shavings have been compressed into billets they are then transferred to an elevator and up into a collection drum. During the compressing process, cutting fluids are squeezed out and are recovered in a tray underneath the machine.
From here, they can either be pumped directly back into the machine tools tank or into a separate holding container.
The robust yet compact design of the system allows it to be installed either underneath the swarf conveyer of a machine tool or as a stand-alone unit to service a number of machines by using individual bins on wheels.
"When the swarf is compacted into billets its sale value increases as part of the metal merchants processing has already been taken care of," said Managing Director, Paul Fowler.
"Also, billets are smaller so you can afford to keep them inside and avoid rust issues that can erode profits. It also reduces transport costs by having less pick ups by the metal merchant.
"This is not only an economically sound solution is also an environmental one," added Paul, "with both cutting oils and metals recycled as a result."
Other savings include less burning of material, no more leaking oils down drains and a severe volume reduction of scrap by up to 70 per cent.
"Swarf Crusher is such an easy system to implement in any workshop. Without a doubt one of the greatest benefits of the system is that expensive floor space is no longer taken up by large scrap bins," he said.
Suitable for both ferrous and non- ferrous materials, around 95 per cent of coolant from the material is extracted during the compressing process.
Dimac say Swarf that used to take up five bins; will now fit into one bin, and all with fewer disruptions to work flow.
"A considerable amount of thought has gone into the usability of the system, which has a reliable microprocessor with fault detection, auto power off and totally CE compliant features," adds Paul.
The system comes with a swarf height sensor to turn the machine on and off depending on the amount of swarf in the hopper.
Swarf crusher is available in two models – standard and high speed, with an output of 50kg per hour for steel on a standard machine and 90kg per hour on a high speed model.
Customers have the option of a bin loading systems, which can make using Swarf Crusher even more cost effective.
"By having your specially designed bin under the machine tool conveyor you can easily load up the machine with the push of a bottom, even while its working," concluded Paul.