We sell solutions!

We provide our customers with customized solutions for their area of application, with which you can optimize your entire recycling process and thus work more economically efficiently. We claim that our customers experience longer service lives, less downtime and thus enormous time savings thanks to the supplied CUTMETALLL quality. In doing so, we place our focus on the entirety of the recycling process and at all times, in cooperation with our customers, we try to respond to prevailing circumstances, special requirements and needs and to deliver coordinated solutions and concepts.

We rely on our experience, our expertise and our know-how, which we can offer our customers directly and completely from our company. From development to testing and control to the production of all components - we guarantee everything from a single source.

The special challenge
In Germany, private households generate around 5.2 million tons of plastic waste annually. The majority of this waste ends up in yellow bags and bins for kerbside collection designated for recycling. This waste includes mixed materials such as soft and hard plastics, plastic packaging and foils, but also aluminium and other materials. Materials may still be co-mingled in the bales in which pre-sorted plastic waste is delivered to the disposal companies for recycling. Although the respective composition of the input material is extremely varied, the plastics recycler must succeed in producing an output material from it that meets the precise specifications of his customers. To ensure this, the machines have to be stopped frequently to load them with the knives and sieves designed to process the particular input material. However servicing the machines is time-consuming.
Typical problems
There are four problems that waste management companies often face when recycling plastic waste:

1. Plastic waste is damp. Because the bottles and containers usually contain residual liquids contaminating the plastics. These include substances such as WC cleaners which react chemically with other liquids. The acids and vapours which form in the process cause the machine parts to rust.

2. Machines in the plastics sector reverse more frequently. This means that the knives operate in one direction for a few minutes and then in the opposite direction for a few minutes. As a result of the frequent change of direction, the fixing screws of the knife holders wear down more quickly. This makes it more difficult to loosen the knives.

3. The input material is varied. This requires the use of different machine knives and screens, which are matched to the respective input material. An example: Slicing stretch films with unsuitable knives results in larger parts of the film being torn off but not cut. The result is an output of lower quality. This is because the larger parts turn out to be a problem for the downstream processing of the plastic granulate.

4. Incorrect feeding of pre-sorted plastic bales into the plastic mill by the machine operator will cause problems. Especially if the bales have not yet been freed from the wires that hold them together.
Advantages of CUTMETALL products
CUTMETALL offers its customers effective solutions for each of the problems described.

1. Rusty machine parts
To remedy this situation, CUTMETALL has developed repair kits. These are sheets of metal that can be welded in without having to take apart a large part of the machine.

2. Reversing machines
For these machines CUTMETALL designed knife holders in which the screws are better protected. .

3. Versatile input
CUTMETALL plus Carbide Germany GmbH has developed special solutions for plastics recycling: Industrial knives with one-piece or multi-piece brazed carbide cutting edges, designed for shredding particularly abrasive materials.

The base material of these extremely wear-resistant carbide knives is a specially tempered tool steel.
The inlays are hard brazed.
This keeps the basic structure flexible, while the blade body is resistant to heavy loads.
In addition, CUTMETALL plus processes the machine knives using the diamond grinding method.
This surface treatment enables a high cutting durability even under intensive use.

Equipped with highly wear-resistant rotor and stator knives (cutting crowns, block, granulating and flat knives) as well as particularly wear-resistant screens, the machines deliver a homogeneous cut over a long period of time.
At the same time, the reduced number of required knife changes minimises the downtime of the machines. This results in higher production utilisation, increased output quality and constant bulk densities.

But the machines themselves also benefit from CUTMETALL products:

Their use reduces machine vibrations, lowers the noise level, reduces energy consumption, decreases temperature development, reduces dust exposure and extends maintenance intervals.

4. Problems with plastic bales
CUTMETALL does not only offer products. If problems occur at the customer's premises, for example when processing plastic bales, specialists from the company analyse the work processes on site and then provide the customer with targeted advice.

But CUTMETALL's range of services does not end there.
If a customer has recurring problems with a machine type, specialists develop solutions either independently or together with the customer to eliminate the problem and optimise the work process.

In doing so, the company responds specifically to customer wishes and designs individual configurations to meet the special requirements of the waste disposal company.
For example, CUTMETALL has created knives with a modified geometry for machines in plastics recycling.
The tips have been turned out deeper, which enables a more aggressive feeding behaviour.v Due to this geometry the shredders run more freely and better.
They also do not clog so quickly.

Last but not least, those responsible at CUTMETALL know that many plastics recyclers use several machines from different manufacturers. For this reason, the company has an extensive product portfolio available for them. At CUTMETALL, customers can obtain all necessary spare and wear parts from one source. In various degrees of hardness, sizes and geometries.
Information about the plastics recycling industry
The recycling of plastic waste is booming. There are three reasons for this*: 1) The sharp rise in the volume of packaging waste for years, 2) the increasing proportion of microplastics in the oceans, and 3) the extensive ban on imports of plastic waste imposed by China. In order to get a grip on the problems, the EU Commission developed a plastic waste strategy which came into force in 2018 and which regulates the handling of plastics in a new way. An essential part of this strategy is to increase the so-called material recycling rate of plastics from private households.

This requires knowledge: There are three common methods of plastics recycling:

Mechanical recycling
33 percent of all plastic waste in Germany is materially processed. This means: disposal companies shred, clean and sort the old plastic. The plastic parts are then melted at high temperature and reprocessed. Only thermoplastics are suitable for this method, i.e. plastics that can be formed within a certain temperature range.

Energetic recycling
At 44 percent, energy recycling accounts for the largest share of plastics recycling. The old plastic is incinerated and the energy released is used. In particular, soiled and mixed materials can be effectively recycled in this way.

Raw material / chemical recycling
The share of raw material recycling in reuse is only one percent. In this method, chemical processes are used to break down complex molecules (polymer chains) in the plastic. This produces simple molecules (monomers), oils and gases which can be processed into new plastics.

With its plastics waste strategy, the European Union aims to make plastics recycling a worthwhile business: New rules on packaging aim to improve the recyclability of plastics and increase the demand for recycled plastic, called recyclate. As more plastic is also collected, better and larger recycling plants will be set up. In parallel, an improved standardized system for the separate collection and sorting of waste throughout the EU will be created.

*Sources: Karlsruhe Institute of Technology KIT / PLASTIC ATLAS 2019 of the Heinrich Böll Foundation and the Bund für Umwelt und Naturschutz Deutschland (BUND), both Berlin / Federal Environment Agency, Dessau-Roßlau