A modern passenger car can contain up to 300 kilograms of plastic. Recycling these materials, however, is not easy. Different types of plastics are often combined with metal components and may need to be transported over considerable distances for further processing. This is why shredding plays an important role in reducing logistics costs and improving recycling efficiency. In a CASTULIK application trial, the DX160 twin-shaft shredder successfully processed one of the more challenging plastic components found in a vehicle – a plastic fuel tank.

Kia Slovakia's engine plant in Žilina is an example of highly automated and precise production, where an effective solution for processing technological waste becomes a key element of operational stability. The article shows how centralized crushing of steel chips in both continuous and single-shift operation contributes to higher safety, lower costs, better logistics and sustainable resource management within the Hyundai Motor Group.

Mechanical pre-processing of automotive production waste can significantly simplify downstream metal separation and plastic recycling. In this technical case study, we analyse the processing of a mixed waste stream containing polyamide components, steel inserts and springs. We evaluate how the individual components behave during shredding and demonstrate the conditions under which the material can be effectively prepared for magnetic separation.

Aluminium stamping offcuts often have a very low bulk density. Long strips tend to become entangled inside containers, creating large voids and making storage and transport inefficient. During a shredding trial, we evaluated how the material changed after processing in a twin-shaft shredder. The result was short, compact fragments with a bulk density of approximately 590 kg/m³.

Thanks to the CASTULIK DX160 shredder and a mechanical‑thermal processing technology, the company REPARAF from Zohor (Slovakia) transforms hundreds of tonnes of waste into recycled paraffin and alternative fuel.

Knife mills offer a precise and energy efficient alternative to traditional single shaft wood shredders. Thanks to their small cutting gap, high rotor speed, and the close positioning of the knives to the screens, they produce a fine, homogeneous output with minimal dust. On the other hand, single shaft shredders, excel in robustness and resistance to metal contamination, but they tend to perform worse with fine fractions, wet wood, or fibrous materials. The choice of technology therefore depends on the type of wood, the required output size, material purity, and performance demands. The optimal solution is best confirmed by practical testing of the specific material on both types of machines.

Shredding of hazardous waste significantly reduces storage and transportation costs. See the experience of DETOX (SK) with the twin-shaft shredder DX160.