Wear Parts for Recycling Machines – Creausabro Components and Ready-to-Install Welded Assemblies

From Wear Plate to Ready-to-Install Assembly

As part of a long-standing collaboration with a manufacturer of mobile and stationary recycling machines, UnionStahl has continuously expanded the scope of its services. What began with the supply of Creusabro® wear plates and cut-to-size parts has gradually evolved into a comprehensive manufacturing partnership.

Today, UnionStahl not only supports its customers by ensuring a reliable supply of materials, but also handles various processing and manufacturing steps, including the production of ready-to-install wear parts for recycling machines and welded assemblies.

This allows customers to obtain wear parts and assemblies from a single source—from selecting the appropriate materials to cutting and machining, all the way to the finished assembly.

Vertical integration for high-performance wear parts for recycling machines

The partnership began with the supply of wear-resistant sheets and flame-cut parts for heavily stressed components in recycling machines. As demands on manufacturing capacity and production processes increased, the partnership was continuously expanded.

In addition to supplying materials, UnionStahl now handles additional manufacturing steps:

• Flame cutting
• Laser cutting
• Chamfering
• Mechanical finishing
• Welding
• Manufacturing of ready-to-install welded assemblies

By combining expertise in materials and manufacturing, the individual process steps can be coordinated with one another. This creates a seamless solution from material procurement to the finished component.

Examples from Manufacturing

Tool Discs

Tool discs are components subject to heavy wear in the comminution process and are manufactured from Creusabro® 8000. The material is cut to size according to the required geometry and further processed.

A welding robot is used for production. The robot-assisted process ensures reproducible welding and consistent manufacturing quality.

Quick-Change Cassettes

The quick-change cassettes are robust welded assemblies designed for the efficient replacement of wear-prone machine components. They are manufactured from S355J2+N structural steel and are also robot-welded.

The production-optimized design and coordinated manufacturing processes support reliable integration into the recycling machines.

Post-cutting beams

The re-cutting beams are components designed for applications involving high mechanical stress and are also manufactured from S355J2+N structural steel.

In particular, the right choice of materials, precise cutting, and reliable manufacturing quality are crucial for the production of these components.

Challenge: Wear-Resistant Components for Recycling Machines

Recycling machines are subjected to high levels of abrasion and impact during daily operation. Components that come into direct contact with the material being processed must be designed to be sufficiently durable.

There is a demand for materials used in wear parts for recycling machines that combine high wear resistance with sufficient toughness and good machinability. Among others, wear-resistant materials such as Creusabro® 8000 are used, which are suitable for demanding applications in recycling technology.

However, the choice of material alone is not the only decisive factor. The cutting, machining, and welding processes must also be suited to the specific application. By combining material expertise with manufacturing know-how, UnionStahl can support its customers right from the component fabrication stage.

Customer Benefits: More Manufacturing from a Single Source

With the expansion of this partnership, customers receive multiple services from a single

source

. Instead of having to coordinate individual process steps with different suppliers, material supply and manufacturing are aligned with one another.

This results in the following benefits, among others:

• Reduction of Supplier Interfaces
• Coordinated manufacturing processes
• Greater supply reliability
• Uniform quality requirements
• Reduced burden on in-house production planning
• Long-lasting components thanks to coordinated material and manufacturing solutions
• Potential to reduce maintenance and downtime

For the customer, this means: less coordination effort and an end-to-end process chain—from the supply of wear parts for recycling machines to ready-to-install assemblies.

Conclusion: From Supplier to Manufacturing Partner

This real-world example demonstrates the added value that a continuously growing partnership can create. What began as the supply of Creusabro® wear plates and fired parts has evolved into a comprehensive manufacturing partnership that includes machining, welding services, and ready-to-install assemblies.

The materials are selected based on their respective functions and the stresses they will endure: Creusabro® 8000 for components subject to particularly high wear, such as tool discs, and S355J2+N for other structural components and assemblies.

UnionStahl combines material expertise with manufacturing technology, thereby supporting customers even with demanding applications beyond the mere supply of materials.

From the right wear plate to the ready-to-install component: Together with the customer, we develop solutions tailored to the requirements of modern recycling machines.