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Copper Wire Granulator | Efficient Scrap Recycling Solution

Copper Wire Granulator: Trends, Technical Depth, and Industry Insights

Product: Copper wire granulator | Industry: Metal Recycling Equipment | Market Segment: E-waste Recovery/Resource Regeneration

Copper Wire Granulator | Efficient Scrap Recycling Solution

— 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

For more technical details, refer to ANSI/ISA Standards and the ISO/TC 183 Copper, Lead, Zinc Standards.

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