In any pricing environment, scrap metal processors seek to minimise their operating costs to maintain a profit margin between the buying and selling of ferrous scrap.
Representatives from two companies that build, install and help maintain large shears and balers used by ferrous processing companies say one of their goals is to help recyclers make equipment choices that can help them maintain that margin.
Just as important as buying the right piece of equipment, they say, is reinforcing to their customers the key role maintenance plays in keeping operating and capital equipment costs in check.
WHO, WHAT AND WHEN
How a scrap yard maintains its shear or ferrous baler can depend on the size of the company that owns it, says Bob Pfeffer, who is based in the United States for Europe-based equipment provider Metso.
“If a company is large enough, I assume it will normally have a maintenance manager employed to oversee all the equipment and its staff of maintenance mechanics,” says Pfeffer. “The majority of companies will thus have direct employees for the equipment maintenance. The number of mechanics is subject to the facility size and amount of equipment in operation.”
Steve Weinberg, who works for Lefort America in the United States, a division of Belgium-based Lefort, says a scrap company typically has “a general manager at the location who sets a maintenance schedule for each machine based on hours used.” He adds, “The operators who are the direct users of the equipment should be responsible for adhering to that schedule, unless the company has an in-house maintenance department to do that.”
Scrap companies also can choose to use “outside contractors for maintenance, and most will use outside contractors for major work, including relines and rebuilds,” says Pfeffer. He says Metso/Lindemann offers “standard preventive maintenance contracts and also customised packages for our customers, as well as full service support for North America based from San Antonio, Texas. Most equipment manufacturers also supply a recommended daily, monthly, quarterly and annual list of required maintenance inspections or preventive maintenance requirements.”
For companies that perform their own maintenance, says Pfeffer, “A good maintenance mechanic should have good skills in basic electrical, hydraulic and mechanical systems.”
Having a maintenance schedule is one thing, but adhering to it is the task that takes ongoing effort. In busy times, production goals can override maintenance schedules, while in slow times tight cash flow can cause cuts in operations spending.
Despite business cycle pressures, “A lack of maintenance does affect the bottom line, whether in high-production or low-production periods,” says Pfeffer.
Comments Weinberg, “Management has to lay down the line on the use of the machine during busy or slow times. A daily report can be used and reviewed at the beginning of each day or shift that highlights the [maintenance] steps that need to be taken before operation.”
“Letting the equipment maintenance lapse only creates additional stresses, wear and potential damage to the equipment that could take additional parts, time and money to repair,” states Pfeffer. “The bottom line is that the manufacturer’s maintenance schedule must be adhered to under all conditions. This equipment is generally a large investment for the owners, and maintenance should be a priority when it comes to providing the maximum uptime for production.”
AUTOMATIC FOR THE PEOPLE
In the 21st century, automated controls have assumed a wider presence in shears and balers, prompting some changes to how maintenance is carried out. “Machines now have self-warning signals that alert the operators to any maintenance or service issues for immediate attention,” says Weinberg. “Some machines are equipped with self-lubricating systems to automatically do the job,” he adds, noting this makes it more likely that particular maintenance task will be completed during either busy or slow times.
“The newer technology provides the shear or baler operator much more information than most old technology,” says Pfeffer. “The diagnostic information provided to the operator and maintenance personnel can actually save them time as they trace a problem with the HMI (human machine interface) screens, which can provide information on the problem,” he adds.
Such information can include “details such as alarm conditions, pump tests, cylinder tests and other time-saving information,” says Pfeffer. “This compares to old technology, which often provided little or no troubleshooting information.”
Says Weinberg, “Automated controls are the present and future for this type of equipment. Because of the amount of stress and the environment in which it is being operated in, it really dictates that these controls are necessary for the cost-effective long-term operation of the machine. This allows the operator to free up time and keep on top of the necessary tasks that need to be done manually on a regular basis. Also with the ability ‘to look in’ via the internet, [an equipment maker] can direct the operator to complete necessary maintenance tasks in a pre-emptive manner.”
Despite the growing role of automation, an experienced hand (or eye) can still be critical. When it comes to replacing shear blades, “Usually, visual inspection of the blades is the best indicator,” says Pfeffer.
Tracking operating hours also is helpful, says Weinberg. “Guidelines for shear blade maintenance are dictated primarily by the number of hours in use and the material being sheared,” he comments. “On our machines, they can be rotated four times, every 500 hours, for a total of 2,000 hours of use.”
As Weinberg mentions, the material being processed is a key variable. Says Pfeffer, “Scrap varies in shapes, sizes and hardness, so a visual inspection daily is the best guarantee. A shear or baler operator with experience examining the blades can arrive at an estimate of life expectancy. However, even with a new set of blades, if the wrong material is processed, you could break or damage a new blade very quickly.”
Beyond blade change outs, “It is very important to keep the blade bolts tight to prevent blades from being loose and damaging the blade seats,” says Pfeffer. “Also, it is very, very important to keep the blade slide (crosshead) in proper adjustment. This helps to keep the required blade adjustment gap within the manufacturer’s recommended tolerance.”
FOR THE RECORD
Two additional aspects important to overall maintenance involve climate conditions for machines located outdoors and the preservation of records for a piece of equipment that likely will have a long lifespan.
To a great extent, says Weinberg, “The machines are manufactured to handle the heat, and the only issue would be the dust and dirt, which can be easily maintained with power washing as needed.” He says Lefort also offers “heaters for diesel engines and tanks for cold weather environments.”
Says Pfeffer, “In cold weather, the hydraulic oil needs to be kept warm enough (using tank heaters or a heated hydraulic room) and should be slowly cycled through the shear or baler system without any load until the equipment warms up. Lighter weight hydraulic oils can be used in cold applications.”
Metso/Lindemann, says Pfeffer, “uses panel heaters to help reduce condensation for cold applications, providing protection for the electrical components. These steps will help prevent premature wear and damage to systems in the cold. Also in the cold, it is important to consider the shear or baler lubrication systems. Again, the correct grease or oil for cold weather should be considered.”
Turning to the other extreme, Pfeffer remarks, “In hot environments, it is important to size the cooling system when the equipment is purchased to provide for adequate cooling. Providing shade for the coolers and hydraulic reservoir can also have benefits. Heavier weight hydraulic oil should be used.”
In “severely humid locations,” adds Pfeffer, the operator “can use special water-absorbing air breather filtration to minimise the moisture intake into the reservoir.”
No matter a shear or baler’s location, preserving maintenance records is recommended by both equipment providers. “There should always be a record of the past maintenance history on all machines, not only as a record of fact, but also for OSHA requirements,” says Weinberg, referring to the United States Occupational Safety and Health Administration, the agency that likely would investigate should a workplace accident occur in that nation.
“Accurate records should be kept on all equipment,” says Pfeffer. “Equipment manufacturers do provide suggested checks and procedures, and maintenance managers should build their own information reports for all shear and baler maintenance costs. This type of information, if recorded, can provide the managers with accurate costs of operation as well as providing the [knowledge base to decide upon] ongoing and future maintenance and relines or rebuilds. This recorded information also will signal the end of life of a shear or baler if the cost per ton is increasing due to equipment age.”
Weinberg offers the same perspective, saying, “These records can be used to determine patterns of performance of the equipment as well as the associated costs of operating and maintaining said equipment. When the yard owners have access to this detailed information, they can make logical and factual decisions that will determine their course of action as they budget for the coming year, including ongoing maintenance and repair costs versus [a potential] new equipment investment and the savings that will bring.”
The author is an editor with the Recycling Today Media Group and can be contacted at btaylor@gie.net.