# **Application Case Study: 630-ton Hydraulic Box Shear for an Integrated Scrap Metal Processing Center in India**

## **I. Market Background: Industry Consolidation Accelerates, Mid-Sized Processing Centers Seek Efficiency Breakthroughs**

With the continuous development of India's manufacturing sector and urban renewal, a wide variety of mixed scrap metals (including light-gauge scrap, medium-sized structural sections, pipework, and machining offcuts) are converging at regional integrated recycling centers. The core challenge for these centers lies in the fragmented and varied nature of the incoming materials. The traditional model of "sorting-classifying-cutting" involves lengthy processes and high labor intensity, leading to low overall processing efficiency and shrinking profit margins eroded by high operational costs.

Specific manifestations include:
* **Fragmented Processing Flow:** Light-gauge scrap, medium-sized profiles, and pipes require different equipment or methods, causing frequent production line switches and low equipment utilization.
* **High Preprocessing Costs:** Reliance on manual sorting and oxy-fuel cutting for rough processing is not only slow but also comes with persistent safety risks and high consumable costs.
* **Poor Product Consistency:** Output materials are irregular in size and specification, making it difficult to form stable, high-quality commercial products, weakening bargaining power with downstream steel mills or foundries.

The market is creating demand for a backbone piece of equipment capable of **one-stop, batch processing of various mixed scrap materials**, helping medium-sized recyclers find the optimal balance between scale and precision.

## **II. Client Pain Points: 50 Tons of Mixed Scrap Daily, Severe Production Line "Blockage"**

Our client is a sizable integrated scrap metal recycling plant near Delhi, India, receiving approximately 50 tons of various scrap daily from hardware markets, small dismantling shops, and manufacturing enterprises. Before introducing the new equipment, the production manager was troubled by the following issues:

1. **"Underpowered" and "Overkill" Situations Coexisted:**
* Processing light-gauge scrap with a baler was uneconomical, while small shears couldn't handle thicker materials. The production line had to "queue" different materials for different processes, **capping overall capacity at around 35 tons per day with no room for growth.**
* Significant time was wasted on secondary material handling and process switching.

2. **Sorting and Preprocessing Became a "Labor Black Hole":**
* To meet the feeding requirements of different machines, substantial manpower was required for pre-sorting and cutting mixed scrap, resulting in high labor intensity, low efficiency, and serious safety risks like metal cuts.
* "It felt like we weren't processing scrap, but managing a complex 'logistics distribution center'." — Client's original words.

3. **Difficulty in Enhancing Finished Product Value:**
* The final sheared scrap output was irregular in size and often contained inadequately processed oversize material, leading to frequent weight deductions or price reductions during sales.
* The inability to provide downstream customers with uniform, high-purity, premium sheared scrap limited brand image and market competitiveness.

## **III. Solution: The 630-ton Hydraulic Box Shear (The Versatile "Material Purifier")**

Addressing the client's core needs for **handling mixed materials, pursuing comprehensive processing efficiency, and achieving standardized output**, we proposed the **630-ton Hydraulic Box Shear** as the core upgrade for their production line. This machine is designed with the principles of "inclusivity" and "efficiency," aiming to simplify processes and boost overall output.

1. **Large Hopper & Powerful Shearing Force for Complex Material Types:**
* An **extra-large 2600mm x 1600mm feed opening** easily accommodates various irregular light-gauge scrap bundles, medium pipes, angle iron, channel steel, and even small-sized I-beams, significantly reducing pre-sorting work.
* **Dual shearing cylinders provide a total shearing force of 630 tons (3150KN x 2)**, sufficient to cleanly shear Φ150mm round bar, 120mm square bar, and 320mm high I-beams, covering over 95% of the client's incoming materials and achieving "multiple functions in one machine."

2. **Efficient Continuous Operation Reshapes Production Rhythm:**
* An **empty shear speed of 2-3 cycles per minute**, combined with automatic pushing and clamping systems, enables near-continuous flow-line operation.
* A **theoretical capacity of 8-10 tons/hour** easily boosts the client's daily processing capacity from 35 tons to the target of 50+ tons, with room to spare.

3. **Automated Control & Compact Design Reduce Operational Complexity:**
* **Fully automatic PLC control with remote operation** allows operators to control the entire shearing cycle from a safe distance, significantly lowering labor intensity and safety hazards.
* High level of integration; the main machine footprint is only about 6m x 2.7m, making it ideal for upgrades within existing sites without major construction work.

4. **Optimized Hydraulic & Cooling Systems Ensure Stable Operation:**
* A **total power configuration of 110kW** provides reasonable power for the capacity, avoiding excessive energy consumption.
* A **3800-liter large-capacity oil tank paired with industrial chiller cooling** ensures stable hydraulic system temperature and high reliability during long, continuous operation in India's high-temperature environment.

## **IV. Client Feedback: From "Chaotic Processing" to "Orderly Output," Profitability Significantly Improved**

Three months after commissioning, the client's production operations underwent a fundamental transformation:

* **Breakthrough in Comprehensive Processing Capacity:**
> "This box shear acts like the 'cornerstone' of our production line. Now, no matter what comes in—scrap rebar, scaffolding pipes, old window frames, or machine housings—it can almost all be fed directly in. Handling the daily 50-ton task is now effortless; the production line is finally 'unclogged.'"

* **Dual Reduction in Labor Costs and Safety Risks:**
* The number of workers required for the pre-sorting team was reduced by 60%. Employees moved from high-risk manual cutting positions to equipment monitoring and material handling roles.
* "The most noticeable change is that the harsh noise of gas cutting and the smoke have mostly disappeared from the workshop. Management pressure has dropped significantly." — Production Supervisor feedback.

* **Improved Output Quality and Sales Profit:**
* The sheared material is of uniform length (~400mm), with clean cuts and low contamination, making it a "hot commodity" in the market.
* Leveraging stable product quality, the client successfully secured a long-term supply agreement with a medium-sized steel mill, **achieving a sales price increase of about 8-12%** and significantly widening profit margins.

The client's负责人 summarized:
> "In the past, our competitiveness lay in 'daring to take in any kind of scrap.' Now, our advantage is 'efficiently turning whatever scrap we receive into a standard product.' This machine has evolved us from mere 'scrap collectors' into 'reprocessed raw material suppliers' with processing depth."

## **V. Summary: The Precise Market Positioning of the 630-ton Box Shear**

This case clearly demonstrates the unique value of the 630-ton Hydraulic Box Shear in the following scenarios:

* **Regional integrated scrap metal recycling plants** with daily processing volumes between **30-80 tons**, receiving complex material mixes and wishing to avoid investing in multiple single-purpose production lines.
* **As primary or secondary pre-processing equipment in large recycling bases**, used for initial crushing and volume reduction of mixed scrap, preparing it for subsequent sorting or baling.
* **Particularly suitable for processing "melting pot" materials** like social collection scrap, light structural steel, dismantling scrap, and manufacturing offcuts.

For recycling enterprises facing similar challenges, the upgrade path is as follows:

1. **Conduct a Material Audit:** Analyze the composition (type, size, thickness) of incoming materials over a week or month to identify the main bottleneck materials.
2. **Choose a Multi-functional Core Machine:** Prioritize equipment like the box shear with a **large feed opening, adequate shearing force, and high automation** to maximize process simplification and efficiency.
3. **Focus on System Synergy:** Evaluate how well the new machine integrates with existing material handlers, conveyors, and discharge systems to ensure smooth incorporation into the current workflow.

Choosing the right box shear is not just purchasing a machine; it's introducing a **"process optimization engine"** to your recycling business. By simplifying complexity, it helps companies build a reliable moat based on efficiency and quality in an increasingly competitive market.