Case Study: Application of Y83-315 Hydraulic Metal Briquetting Machine in a Bulgarian Recycling Facility

1. Market Background: The Growing Need for Efficient Metal Scrap Recycling in Bulgaria

Bulgaria has experienced significant growth in its manufacturing and metal processing sectors, with the automotive, construction, and steel industries driving demand for recycled metal materials. As the volume of metal scrap, especially metal swarf, increases in industries like machining, casting, and stamping, the need for efficient briquetting machines has become more pressing. The ability to efficiently compact scrap metal into uniform, high-density briquettes ensures that these materials can be transported, stored, and processed more effectively in smelting operations.

In response to this demand, the Y83-315 Hydraulic Metal Briquetting Machine was introduced to a Bulgarian recycling facility to enhance the efficiency and capacity of their metal scrap recycling operations. This machine is designed to convert various types of metal scrap into compact, dense briquettes, which can then be fed directly into melting furnaces or transported for further processing.

2. Client's Pain Points: Operational Challenges with Existing Briquetting Equipment

The client, a leading Bulgarian recycling plant specializing in metal scrap, faced several challenges with their previous briquetting equipment:

• Limited Processing Capacity:
  The older machine struggled to meet the increasing volumes of metal scrap generated at the plant, resulting in slow production rates and processing bottlenecks. As the plant's demand for briquettes grew, the existing equipment became inefficient and inadequate.

• Inconsistent Briquette Quality:
  The previous briquetting machine produced inconsistent briquette sizes and densities. The lack of uniformity led to issues in handling and transporting the briquettes. Inconsistent briquettes are particularly problematic for smelting, as they may not melt evenly or fit into furnace charge requirements.

• Frequent Maintenance and Downtime:
  The plant experienced frequent breakdowns with the older machine, which led to increased maintenance costs and reduced operational uptime. These disruptions impacted production schedules, resulting in lost revenue and lower efficiency.

The client sought a high-performance, reliable briquetting machine capable of processing larger quantities of metal scrap more efficiently, producing consistent briquette quality, and reducing maintenance and downtime.

3. Solution: Y83-315 Hydraulic Metal Briquetting Machine

To address these challenges, we recommended the Y83-315 Hydraulic Metal Briquetting Machine. This robust machine is designed to process metal swarf, scrap, and shavings into high-density briquettes that are suitable for melting in steel mills, reducing the need for bulky storage and improving logistics. The Y83-315 offers a range of features that allow it to handle a variety of metal materials with ease.

Key Features of the Y83-315 Hydraulic Metal Briquetting Machine:

1. High-Pressure and Powerful Cylinders:

   • The main pressure cylinder (model YG360/220) provides a nominal force of 3150 kN (315 tons), ensuring effective and efficient compaction of metal scrap into dense briquettes. This high-pressure capability is particularly beneficial for processing large volumes of scrap.

   • The enhancing cylinder (model YG125/80) delivers 300 kN of force, providing additional pressure to ensure uniform briquette formation.

2. Versatile Cylinder Configuration:

   • The machine is equipped with charging and pre-press cylinders (model YG110/75), each delivering 237 kN, and the briquette pushing cylinder (model YG140/80), providing 380 kN of force. This multi-cylinder design ensures smooth material feeding and consistent compression.

3. Efficient Hydraulic System:

   • The MCY80 hydraulic pump, with a rated pressure of 31.5 MPa, ensures the hydraulic system operates efficiently, reducing energy consumption and improving overall machine performance. The hydraulic system is optimized for stable operation during prolonged use.

4. High-Quality Briquettes:

   • The machine’s press box chamber (￠120×200 mm) ensures that each briquette has a diameter of ￠120 mm and a thickness of approximately 7 cm. This size is ideal for transport and further processing in melting furnaces.

   • With a briquette density of ≥1800 kg/m³, the Y83-315 produces high-quality, compact briquettes that are uniform in size and density, ensuring consistency in downstream processes.

5. Fast Cycle Time and High Output:

   • The machine features a single cycle time of about 18 seconds when empty, producing 3 briquettes per minute. With an average production rate of 216–255.6 kg per hour, the Y83-315 ensures high throughput, making it suitable for large-scale recycling operations.

6. PLC Control for Easy Operation:

   • The machine is equipped with a PLC automatic control system, which allows operators to easily monitor and adjust the briquetting process. The system is user-friendly and includes a remote control option, enhancing convenience and ensuring consistent machine operation.

7. Energy-Efficient Motor and Hydraulic System:

   • The Y83-315 operates with a 30 kW electric motor (model Y225L2-4) that provides reliable power for the briquetting process while maintaining energy efficiency. The motor runs at a speed of 1440 rpm, which is ideal for consistent performance over extended periods.

8. Customizable Features:

   • The Y83-315 can be customized with a conveyor system for automatic scrap feeding and an air cooler for enhanced hydraulic system cooling. These options allow the client to further optimize their production process, improving overall operational efficiency.

4. Client Feedback: Enhanced Productivity and Consistent Briquettes

Following the installation and commissioning of the Y83-315 Hydraulic Metal Briquetting Machine, the Bulgarian client reported significant improvements in their metal scrap recycling operations:

• Increased Throughput: The new briquetting machine enabled the plant to handle larger volumes of metal scrap more efficiently. The fast cycle time and high production capacity allowed the plant to keep up with the growing demand for briquettes.

• Consistent Briquette Quality: The machine produced consistent, high-density briquettes, which met the specifications required for smelting. This consistency improved the efficiency of downstream processes and reduced material waste.

• Reduced Maintenance Costs: The client reported a significant reduction in maintenance costs and downtime, thanks to the machine’s reliable design and efficient hydraulic system. Fewer breakdowns allowed the plant to operate smoothly and meet production targets.

• Energy Efficiency: With the Y83-315’s energy-efficient motor and hydraulic system, the plant was able to reduce electricity consumption, leading to lower operating costs over time.

The client summarized their experience with the Y83-315 as follows:

“The Y83-315 has revolutionized our operations. We are now able to produce high-quality briquettes at a faster rate, with much less downtime and maintenance. This machine has exceeded our expectations and is now a key asset in our facility.”

5. Ideal Materials for the Y83-315 Hydraulic Metal Briquetting Machine

The Y83-315 Hydraulic Metal Briquetting Machine is particularly well-suited for compacting various types of metal scrap, including:

• Metal Swarf: Small, fine metal chips produced during machining operations.

• Steel Scrap: General steel scrap, including cuttings, shavings, and trimmings.

• Aluminum Scrap: Shavings, filings, and small pieces of aluminum.

• Copper Scrap: Copper chips and small metal pieces from electrical wire production.

• Cast Iron Scrap: Pieces of cast iron from machining and other processes.

• Non-Ferrous Metals: Other non-ferrous metal scrap, such as zinc, lead, and magnesium.

The machine’s versatility and powerful hydraulic system make it ideal for handling a wide range of scrap types commonly generated in metalworking, machining, and manufacturing industries.

6. Conclusion: The Y83-315 Hydraulic Metal Briquetting Machine – A Solution for Metal Recycling in Bulgaria

The Y83-315 Hydraulic Metal Briquetting Machine has proven to be an excellent solution for the Bulgarian recycling plant, addressing their challenges with higher production capacity, consistent briquette quality, and reduced maintenance costs. This powerful and efficient briquetting machine has enhanced the plant’s ability to process metal scrap efficiently, while meeting the increasing demand for high-density briquettes in the steel and manufacturing industries.

This case study highlights the importance of selecting the right briquetting machine for metal scrap processing. The Y83-315 offers the necessary force, efficiency, and precision required for handling a wide range of materials, making it a valuable asset in modern metal recycling operations.

Jiangyin Huake Machinery Co., Ltd. continues to provide innovative solutions that help recycling plants optimize their processes, reduce costs, and improve productivity in today’s competitive industrial landscape.