Case Study: Application of Q43-120 Hydraulic Metal Shearing Machine in a Steel Recycling Plant in Peru

1. Market Background: The Need for Efficient Steel Scrap Recycling in Peru

The steel recycling industry in Peru has been witnessing rapid growth in recent years, driven by the increasing demand for recycled steel in construction, automotive, and manufacturing sectors. As Peru’s infrastructure expands and industries demand more raw materials, efficient steel recycling has become an integral part of the supply chain.

Steel scrap, especially from demolished structures, industrial manufacturing waste, and automotive scrapping, is a valuable resource for steel mills. However, the processing of large and mixed steel scrap into manageable pieces presents significant challenges. Efficient and high-performance machinery capable of handling various types of scrap metal is essential to maintain consistent supply to steel mills and maximize recycling operations.

The Q43-120 Hydraulic Metal Shearing Machine is designed to address these needs. This powerful machine provides the capacity and precision required to efficiently cut various steel scrap materials, including beams, pipes, and plates, and is ideal for steel recycling plants like our client’s in Peru.

2. Client’s Pain Points: Challenges with Existing Equipment

Our client, a steel recycling plant in Peru, was facing several operational difficulties with their previous shearing equipment:

• Limited Cutting Capacity: The older shearing machine could not handle the growing volume of steel scrap efficiently. As production demand increased, the existing equipment struggled to keep up, resulting in delays, backlogs, and inefficiencies.

• Inconsistent Cutting Quality: The previous machine struggled to deliver uniform cutting quality, especially when processing larger and more complex scrap materials like I-beams, round steel, and thick plates. This inconsistency in the cut size posed problems for downstream operations, as steel mills require uniform scrap sizes to optimize the melting process.

• High Maintenance and Downtime: Frequent breakdowns and maintenance of the old machine resulted in extended downtime, leading to reduced productivity and increased maintenance costs. The need for more reliable and efficient equipment was becoming urgent.

The client needed a machine that could increase throughput, improve cutting quality, and reduce maintenance costs while ensuring high efficiency and reliability.

3. Solution: Q43-120 Hydraulic Metal Shearing Machine

After carefully evaluating the client’s operational requirements and understanding their challenges, we recommended the Q43-120 Hydraulic Metal Shearing Machine, a heavy-duty shearing machine designed for cutting steel scrap of various sizes and types. This machine is capable of delivering high force cutting, precision, and durability.

Key Features of the Q43-120 Hydraulic Shearing Machine:

1. Powerful Cutting Force:

   • The main pressure cylinder (model YG160/100) provides a cutting force of 1200 kN (120 tons), making it capable of efficiently shearing a variety of steel scrap, including I-beams, angle steel, square steel, and steel plates. This powerful cutting force ensures high throughput and enables the machine to handle even the most challenging scrap materials.

2. Clamping Pressure Cylinder:

   • The clamping pressure cylinder (model YG80/50-325) has a maximum force of 200 kN (20 tons), which holds the material firmly during the cutting process, ensuring clean and accurate cuts. The high clamping force is critical for ensuring the stability of the scrap during shearing, particularly when processing large and heavy pieces.

3. Versatile Cutting Capabilities:

   

   • The Q43-120 is designed to handle a variety of materials and sizes, including:

     • Angle steel: 40x40x4mm (3 pieces)

     • Square steel: 30x30mm

     • I-beam: 100x68x4.5mm

     • Round steel: 35mm diameter

     • Steel plate: 14x125mm

   • The machine’s versatility makes it suitable for various scrap types commonly found in the steel recycling industry.

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4. Efficient Hydraulic System:

   • The machine operates at a working pressure of 21 MPa, powered by an YCY-25 oil pump with a rated pressure of 31.5 MPa and a flow rate of 63 r/min. This system ensures smooth, powerful operation and minimizes energy consumption during idle phases.

5. Fast Cycle Time:

   • The Q43-120 is designed to perform a cutting cycle in approximately 10 seconds (when empty load), ensuring high-speed processing and helping the plant achieve a high throughput rate without unnecessary delays. The quick cycle time is essential in maintaining a continuous, efficient production flow in busy recycling operations.

6. Compact and Energy-Efficient Design:

   • The electromotor (model YVF7.5KW-M) has a power rating of 7.5 kW with a rated speed of 1470 r/min, providing the necessary power for heavy-duty cutting while maintaining energy efficiency. The machine's compact design and energy-efficient operation help reduce operational costs, including power consumption, which is approximately 5.25 kWh per hour.

7. Durable and Low-Maintenance Construction:

   • The Q43-120 is built for durability, with high-quality components designed to withstand the rigors of continuous industrial use. The robust design helps reduce maintenance needs and downtime, ensuring that the plant can operate smoothly and maintain high productivity.

4. Client Feedback: Increased Productivity and Improved Quality

After the installation and successful commissioning of the Q43-120 Hydraulic Metal Shearing Machine at the client’s steel recycling facility in Peru, the client reported several positive outcomes:

• Increased Cutting Capacity: The Q43-120 significantly increased the plant’s cutting capacity, enabling them to process larger volumes of steel scrap in a shorter amount of time. The plant no longer faces bottlenecks in the cutting stage, allowing them to meet the increasing demand for processed scrap.

• Consistent and Precise Cuts: The machine’s powerful cutting force and precise control have ensured that the steel scrap is cut into uniform, manageable pieces. This consistency has improved the quality of the processed scrap, meeting the stringent requirements of steel mills and improving the downstream processing efficiency.

• Reduced Downtime and Maintenance Costs: The plant has reported fewer maintenance issues and less downtime since the installation of the Q43-120. The machine’s reliable performance has helped optimize production schedules and reduce the need for costly repairs.

• Improved Operational Efficiency: With its fast cycle time and efficient hydraulic system, the Q43-120 has improved the plant's overall operational efficiency. The plant has seen a reduction in energy consumption and improved productivity, which has led to cost savings over time.

The client summarized their experience with the Q43-120 as follows:

“The Q43-120 has exceeded our expectations in terms of both cutting capacity and quality. Our production efficiency has improved, and we can now handle more material with less downtime. This machine has proven to be a key asset in our steel recycling operations.”

5. Conclusion: The Q43-120 Hydraulic Metal Shearing Machine – A Solution for Steel Recycling in Peru

The Q43-120 Hydraulic Metal Shearing Machine has proven to be an ideal solution for our client’s steel recycling plant in Peru. By providing high cutting force, consistent quality, and energy-efficient operation, this machine has helped the client meet their increasing production demands and improve their overall efficiency.

This case study demonstrates the importance of selecting the right equipment tailored to the specific needs of the client. The Q43-120 offers the power, precision, and reliability necessary for high-volume scrap metal processing, making it an essential tool for modern steel recycling operations.

Jiangyin Huake Machinery Co., Ltd. continues to innovate and provide cutting-edge solutions that help recycling plants optimize their processes and achieve higher productivity and profitability in today’s competitive market.