# **Application Case Study: 1400-ton Hydraulic Gantry Shear for a Large-Scale Scrap Metal Recycling Base in Vietnam**

## **I. Market Background: Infrastructure Construction Boom Drives Demand for Large-Scale Processing of Heavy Scrap**

Vietnam is in an accelerated phase of industrialization and urbanization. Large-scale infrastructure projects, port expansions, and the rise of high-rise buildings are generating enormous volumes of heavy construction scrap, demolition steelwork, large industrial equipment remains, and ship-breaking materials. These materials are generally characterized by large dimensions, thick cross-sections, and high strength, representing valuable secondary resources. However, the efficiency of their processing directly determines the core profitability of recycling enterprises.

Traditional processing methods face severe challenges:
* **Processing Efficiency Bottleneck:** Reliance on flame cutting or small shears is slow and energy-intensive, unable to handle large batches of heavy materials arriving in bulk, leading to congested yards and poor turnover.
* **High Processing Costs:** Significant consumption of oxygen and acetylene, coupled with continuously rising labor costs. The subsequent need for secondary processing of cut surfaces makes comprehensive cost control difficult.
* **Safety and Environmental Risks:** Open flame operations and the handling/securing of large materials pose high risks. The smoke, dust, and noise from cutting also face increasingly stringent environmental regulations.

Consequently, leading large-scale scrap recyclers are focusing on production line upgrades. By introducing heavy-duty, efficient, and automated pre-processing equipment, they aim to build large-scale, clean "steel resource processing centers" to establish market leadership in their regions.

## **II. Client Pain Points: 1000+ Tons of Heavy Scrap Daily, Traditional Lines "Can't Digest"**

The client in this case is a large, port-based integrated scrap recycling base in Southern Vietnam, handling ship-breaking, end-of-life construction machinery, and recycled building steel structures. Before the equipment upgrade, its pre-processing center faced immense pressure:

1. **Severe Capacity Shortage, Yard Severe Congestion:**
* The base receives approximately 800-1000 tons of various heavy scrap daily, including large quantities of steel plates over 150mm thick, round steel over 200mm in diameter, and large H-beams.
* Even at full capacity, the existing array of medium/small shears and multiple gas-cutting teams couldn't keep pace with incoming material, causing the yard to become increasingly bloated and slowing cash flow.

2. **Poor Processing Quality, Low Product Value:**
* Flame-cut surfaces were of poor quality with significant material thermal damage; small shears couldn't cut large cross-sections, forcing operators to "pick the low-hanging fruit."
* The resulting scrap was irregular in size and shape, suitable only for sale as low-grade mixed scrap, unable to enter the demanding premium steelmaking market, resulting in thin profit margins.

3. **High Operational Costs and Safety Pressure:**
* The large gas-cutting teams and costs for consumables and skilled labor accounted for nearly 50% of total processing costs.
* The multiple lifting, turning, and positioning processes for heavy materials were fraught with hazards, with safety incidents being a top management concern.

The Base Operations Director stated plainly during project justification:
> "Our yard had become a 'steel maze.' We need a true 'capital ship' that can crush all incoming materials head-on, turning them into standard, high-value 'industrial candy' on a conveyor line—not rely on a fleet of 'small boats' patching things up. Efficiency, safety, and finished product quality must be resolved at once."

## **III. Solution: The 1400-ton Hydraulic Gantry Shear (A "One-Stop" Shredding Center for Heavy Scrap)**

Addressing the client's ultimate needs for **ultra-large-scale processing capacity, the ability to handle extreme material types, and achieving continuous automated operation**, we provided the core solution: the **1400-ton Hydraulic Gantry Shear**. This machine is designed specifically for shredding heavy scrap, integrating powerful shearing force, an extra-long material box, and automated material handling.

1. **Dual-Cylinder, Thousand-ton Shearing Force, Designed for "Hard Bones":**
* **Dual shearing cylinder configuration delivers a total thrust of 12800KN (approx. 1400 tons force)**, easily shearing **round steel up to φ205mm, square steel 180×180mm, or steel plate 100mm thick x 1500mm wide**, covering the vast majority of heavy scrap types.
* **A 12-degree shear angle and 2040mm blade length** optimize the shearing process, reducing energy consumption and extending blade life while delivering immense cutting power.

2. **Super-Long Material Box & Automatic Pusher System for Continuous Flow Operation:**
* A giant **8m (L) × 1.98m (W) × 1.2m (H) material box** can hold a large volume of material at once, especially suitable for processing long structural sections.
* A **hydraulic motor-driven chain pusher system** with a 7.8m stroke automatically and steadily feeds material to the shear point. Working with dual clamping cylinders (1530KN x 2) to secure the material, it enables a cyclic operation of "loading-clamping-shearing-discharging," achieving an **empty cycle speed of 2.5-3 times/minute**.

3. **Fully Hydraulic Drive & Intelligent Control System for an Efficient, Stable Production Line:**
* A robust **456.2kW total power system** (10 sets of 45kW motor-pump units) provides ample power reserve for continuous heavy-duty operation, ensuring stable pressure output.
* An **intelligent PLC control system** integrates control over all movements (pushing, side pressing, clamping, shearing). Operators can manage the entire process from the control room, significantly improving safety and process control.

4. **High-Efficiency Cooling & Thermal Management System for 24/7 Operation:**
* A **70㎡ plate-type oil cooler paired with a 100T cooling water tower** forms a powerful hydraulic oil cooling circuit, effectively dissipating the massive heat generated during sustained high-intensity operation. This is key to enabling 24-hour continuous operation.

## **IV. Client Feedback: An Efficiency Revolution Where "One Machine Transformed a Whole Park"**

Upon commissioning, the machine rapidly became the core source of competitive advantage for the recycling base. The client reported transformative changes across multiple dimensions:

* **Exponential Growth in Processing Capacity:**
> "This gantry shear operates like a 'steel-devouring beast.' Now, the daily 1000+ tons of incoming material are 'consumed' and 'regurgitated' as sized scrap in an orderly fashion. The yard has transformed from a static 'warehouse' into a dynamic 'front end of the conveyor line,' more than doubling our capital turnover speed."

* **Optimization of Both Product Mix and Profit Structure:**
* The clean, sized heavy scrap produced is highly sought after by premium domestic and international steel mills for its superior quality and uniform dimensions, **commanding an average sales price increase of 15%-25%.**
* The complete elimination of flame cutting drastically reduced the labor and consumables share of processing costs, **significantly increasing gross profit per ton processed.**

* **Inherent Production Safety & Environmental Compliance:**
* Remote-controlled "man-material separation" fundamentally eliminated the risk of physical injury during heavy material handling.
* The smoke-free, flame-free, low-noise operation environment has made the base a benchmark for industrial environmental protection locally, enhancing its social image and operational license security.

The General Manager of the base summarized its strategic value in one sentence:
> "It's not just a machine; it's the 'keystone' of our entire business model. Before, we were 'scrap iron collectors.' Now, we are 'suppliers of heavy recycled steel raw materials.' **This gantry shear has given us the ability to define product standards, transforming us from price-takers into value-setters.**"

## **V. Summary: The Strategic Positioning and Selection Insights for 1400-ton Gantry Shears**

The success of this Vietnam project marks the 1400-ton gantry shear as **the standard core equipment for large-scale scrap recycling bases handling 10,000+ tons annually**. It is particularly suitable for:

* **Large port-based scrap recycling bases, ship-breaking centers, or regional scrap collection and processing hubs** with daily processing needs **exceeding 800 tons**, primarily consisting of heavy, large-dimension scrap.
* **Businesses involved in dismantling large quantities of construction machinery, bridge steel structures, etc.**, requiring the processing of ultra-high-strength, large irregular cross-section materials.
* **Enterprises targeting the high-end market**, committed to stably supplying premium heavy shred or qualified furnace-ready charge to large domestic and international EAF steel mills.

For recycling enterprises aspiring to become regional leaders, investing in such equipment requires systematic strategic consideration:

1. **Capacity Planning First:** Based on source material aggregation capability, site logistics, and target market share, scientifically calculate the required processing capacity, allowing for a reasonable capacity buffer.
2. **Focus on System Integration:** The gantry shear is the core of the pre-processing line, but its effectiveness depends on synergy with front-end loading (grapples) and back-end sorting or baling equipment. Integrated production line design is crucial.
3. **Focus on Full-Lifecycle Value:** When evaluating suppliers, prioritize their design capabilities (e.g., hydraulic system thermal balance design, structural stress analysis), the brand and durability of key components (pumps, valves, blades), and their ability to provide localized, responsive technical service and support.

Investing in a 1400-ton gantry shear is the critical leap for a scrap recycling enterprise transitioning from a "labor-intensive trader" to a "technology-intensive resource processor." It is not merely a tool to increase current capacity but a strategic asset for building a moat in resource acquisition, cost control, and product competitiveness for the next decade.