Copper Wire Granulator: Trends, Technical Depth, and Industry Insights
Product:
Copper wire granulator |
Industry: Metal Recycling Equipment |
Market Segment: E-waste Recovery/Resource Regeneration
— Real-world Copper wire granulator installation view
The Copper wire granulator is a state-of-the-art waste management equipment specifically engineered for separating copper and plastic in scrap cables via mechanical granulation. With the global focus on sustainable resource utilization and the surging e-waste volume, copper wire granulators have become indispensable in the recycling supply chain, offering robust performance, high yield recovery, and eco-friendly operation.
1. Industry Trends & Market Data
Global e-waste volume reached
59.4 million tonnes in 2022, with waste cables accounting for roughly
12.2% (
Statista Report).
According to
Grand View Research, the
Copper wire granulator market is expected to grow at a CAGR of
7.5% from 2023 to 2030, fueled by stringent environmental regulations and copper price volatility.
- North America & Europe: Dominant users due to advanced recycling policies and mature scrap industries.
- Asia-Pacific: Fastest growing market, with China and India investing in large-scale cable waste recycling.
Global Copper Wire Granulator Market (2018-2025F)
2. Copper Wire Granulator Technical Parameters & Comparison
2.1 Main Technical Specifications
| Model |
Processing Capacity
(kg/h) |
Main Power
(kW) |
Separation Purity
(%) |
Applicable Wire Diameter (mm) |
Material Quality |
Standard Compliance |
| BN-400 |
150–300 |
14 |
99.6 |
0.1–20 |
Carbon Steel + CNC Components |
ISO9001, CE |
| BN-600 |
300–500 |
22 |
99.7 |
0.2–30 |
Stainless Steel 304 |
ISO9001, ANSI |
| BN-800 |
400–800 |
37 |
99.8 |
0.2–45 |
Steel + Wear Resistant Alloy |
ISO9001, SGS |
| BN-1200 |
800–1200 |
55 |
99.9 |
0.5–65 |
C45 Alloy Core |
ISO9001, CE, RoHS |
Model vs. Processing Capacity
2.2 Product Comparison Table
| Parameter |
Copper wire granulator BN-800 |
Main Competitor A |
Main Competitor B |
| Max Capacity (kg/h) |
800 |
700 |
900 |
| Purity (%) |
99.8 |
99.2 |
99.5 |
| Noise (dB) |
≤82 |
≤90 |
≤85 |
| Copper Recovery (%) |
98.5 |
97.1 |
96.8 |
| Electricity Consumption (kWh/t) |
41 |
54 |
48 |
| Warranty |
24 months |
12 months |
18 months |
| Certification |
CE, ISO9001 |
CE |
ISO9001 |
Percentage Distribution of Output by Copper wire granulator
— CNC processed blades for Copper wire granulator
3. Copper Wire Granulator Manufacturing Process Explanation
Raw Cable Input
➡️
Shredding/Size Reduction
➡️
Granulation in Granulator
[CNC abrasion-resistant cutters]
➡️
Vibration Separation
(Copper/Plastic Segregation)
➡️
Dust Filtration System
➡️
Final Copper/Plastic Output
- Key Material: All core parts including cutting chambers and screens are made from high-carbon alloy steel, processed via precision CNC machining for superior wear resistance and minimal tolerance.
- Manufacturing Process: Forging & CNC processing ensure dimensional stability, with all key points powder-coated for anti-corrosion. Electrical elements comply with IEC/CE/ANSI norms.
- Quality Inspection: Every Copper wire granulator passes ISO9001 full-process testing: weld seam ultrasonic crack detection, dynamic rotor balancing, running-in at max load, and copper/plastic purity sampling. Third-party SGS and CE certification documents are available.
- Durability: Average blade service life exceeds 1800 hours (industrial mixture feed), while key bearings use high-protection grease (IP66 rated) for 5+ years continuous operation.
- Electric/Control: Systems adopt Siemens/SCHNEIDER modular automation, emergency stop, PLC touch panel (Industry 4.0 ready).
— Copper wire granulator assembly in CNC-wired workshop
Manufacturing Workflow Illustration
- Raw Material Sorting: Select compliant waste cable, preliminary disassembly for oversized heads.
- Primary Shredding: Hydraulic feed to shredding chamber—cut to fragments 10-50mm.
- Secondary Granulation: Rotor/Knives granulate to 1-5mm granules; blades hardened above HRC61 (Rockwell scale).
- Vibratory Screening: Multi-deck vibration screens separate light plastic from heavier copper, using air airflow for dust/fiber removal.
- Final Inspection: Magnetic separator ensures no iron residue, online purity test per ISO 11424 (recycling cable purity grading standard).
— Workflow station of Copper wire granulator
4. Application Scenarios & Key Industry Advantages
4.1 Applicable Industries
- Petrochemical: Recovery of cables from decommissioned refineries/offshore rigs.
- Metallurgy/Energy: Reprocessing power transformer wiring, mine extraction cabling.
- Municipal/Water Supply: Recovery from city grid remodelling, public fiber-optic and water network cables.
- Telecommunication/IT disposal: Data center/telecom cable upgrades producing large volumes of high-grade wire waste.
- Construction & Demolition: Scrap during building demolition and infrastructure renewal projects.
— Typical Copper wire granulator in petrochemical and mining
4.2 Core Advantages (Case-Proven)
- High Separation Accuracy: Ensures 99.8% purity for copper granules and 99.5% for plastics.
(Source: Factory Acceptance Reports, 2023, OWRecycling Tests)
- Energy Saving: Modular motors (IE4/IE5 grade) reduce power usage by up to 19% compared to legacy granulators.
- Corrosion/Service Life: Full anti-corrosion paint & protected bearings increase operational life by 28.7% (third party test, 2022).
- Custom Modularization: Plant-matched design with options (dust control, multiple outputs, PLC remote control) per client site.
- Compliance: Copper wire granulator products obtained ISO9001 full manufacturing coverage, with select models passing RoHS (EU Restriction of Hazardous Substances) for global export.
Case Study: Recovery Plant, UK
- Installed Copper wire granulator BN-800 for 12h/day operation, replacing two legacy lines and boosting copper recovery by +5.1%.
- Reduced total system noise to <82dB, earning local eco-platinum award in 2023.
- 3 years operation, sponsored technical service and predictive maintenance rating 4.8/5 (client feedback, Recycling Product News).
Case Study: Cable Manufacturing, India
- Industrial application in wire rod mill—granulated scrap cable returns directly to smelting line, achieving annual copper resource recycling of ~1860 tons (2023).
- Selected for anti-dust filtration design, zero formal complaints on purity.
5. Manufacturer Comparison & Custom Solutions
| Factor |
OWRecycling |
Competitor A |
Competitor B |
| Core Technology |
3-stage CNC blade + air separator |
Single-stage |
Dual-stage, manual mixing |
| Blade Material |
Hardened Alloy, HRC61-63 |
Steel, HRC55 |
Alloy, HRC57 |
| Certification |
ISO9001, CE, SGS |
CE |
ISO9001 |
| Automation |
Full PLC (remote support) |
Manual |
Partial PLC |
| Customization Level |
High (site-specific) |
Low |
Medium |
| After-sales Service |
24/7 global, 36-month core warranty |
Office hours, 12 months |
Regional, 18 months |
| References |
100+ plants globally |
30+ |
70+ |
Custom Solution Flow
- Pre-sale audit: On-site cable type & volume assessment—process simulations provided.
- Proposal & Customization: Turnkey set or modular line. Options such as dust collector, noise suppressor, reject bin, IoT diagnostics.
-
Installation & Training: Factory acceptance test (FAT) compliance per ISO 20607 (Machinery Safety). Local team/remote video guidance.
-
Ongoing Support: Preventive maintenance kits, software updates, hotline troubleshooting.
— Modular Copper wire granulator solution delivered to client
6. Delivery, Warranty & Customer Service
- Lead time: Standard delivery in 30–35 days (custom lines: 45–60 days).
- Warranty: All Copper wire granulator lines include 24–36 months core parts warranty, with lifetime paid support for core components.
- Support: 24/7 online tech support (support@owrecycling.com), on-site service for North America, EU, SE Asia, AUS.
- Spare parts: >6000 parts in stock globally, 48h rapid shipment guarantee.
- Traceability: Each machine with unique QR code for digital manuals, service logs, OEM calibration trace.
Certified to ISO9001, CE, SGS, RoHS
7. Professional FAQ: Technical FAQs for Copper Wire Granulator
Q1: What is the main blade material and its benefits?
A1: Blades are forged from high-carbon chromium alloy (HRC61) via CNC. This ensures exceptional wear resistance, sharpness retention, and supports high-throughput granulation cycles with minimal downtime.
Q2: What cable diameters are supported?
A2: The Copper wire granulator accommodates wires from 0.1mm up to 65mm (model dependent), making it suitable for fine electronics through to power/utility-grade cables.
Q3: Which installation standards are followed?
A3: Equipment is built to comply with IEC 60204-1 (Electrical Safety), CE Machinery Directive 2006/42/EC, and relevant ANSI standards for North American deployments.
Q4: What are typical output purities for copper and plastic?
A4: Output copper purity is typically 99.5–99.9%; plastic fraction ≥99.2%. Both are validated by random sampling in accordance with
ISO 11424.
Q5: How are environmental dust and noise managed?
A5: All granulators are equipped with sealed dust collectors (efficiency ≥97.5%) and advanced damping pads. Noise levels are suppressed to ≤82dB in compliance with EU workplace regulations (Directive 2003/10/EC).
Q6: What is the expected lifespan under typical usage?
A6: Average mechanical lifetime exceeds 60,000 hours given scheduled maintenance per ISO9001; blades can last 1800–2500 hrs (copper-heavy feed), with affordable replacement options.
Q7: How are granulators tested before shipping?
A7: Each unit undergoes FAT (Factory Acceptance Test) including no-load/batch operation, output sampling, noise and dust emission checks, and compliance verification, with results documented and sent to client prior to dispatch.
8. References & Further Reading
