50% Increase in Throughput

Cycle Systems, the region’s undisputed leader in recycling activities, set a tremendous example for reusing scrapped equipment. A few years ago Cycle Systems began the process of transforming a decommissioned locomotive engine into a power plant for a shredder at its Lynchburg facility. This transformation would provide them with many benefits including reduced energy costs, opportunity to use “green” fuels, and, most important for a recycling organization, the demonstration that many of our “throw away” products can provide useful service beyond their original purpose.

Shortly after starting up its new automotive shredder (built with recycled materials) Cycle Systems hired Sunapsys to review the control and information systems. The original scope of this project was to develop a documentation set that would simplify electrical system troubleshooting efforts. The shredder is a huge piece of equipment, as it can turn an entire car into an unrecognizable pile of shredded metal in under a minute. Downtime is expensive and Cycle Systems wanted to develop systems that would significantly reduce downtime.

Working with Cycle Systems personnel, Sunapsys engineers realized during the documentation process, that there were opportunities for system improvement. These opportunities were fairly simple to implement but required close collaboration between Cycle Systems and Sunapsys to identify. One such opportunity for system improvement included adding sensors to monitor shaft speeds and fuel levels; making key operating information available on the HMI; and automatically recording data required for DEQ reporting.

Like most industrial operations, Cycle Systems desired increased shedder throughput. Some throughput was gained, in the form of reduced downtime, with the system documentation and system information additions provided by Sunapsys, but Cycle Systems felt there were more significant gains to be realized.

Cycle Systems utilized Sunapsys’ control expertise to study critical process variables and note their effect on throughput. Most of the shredder’s operation procedures were developed intuitively. This shredder is not an off-the-shelf product complete with manufacturer’s rep and owners manual. It is an ingenious, massive scale recycling effort utilizing salvaged components collected over the years by Cycle Systems. Through a comprehensive study of the critical process variable, Sunapsys engineered a better way to operate the shredder and employed control system modifications to allow this improved operation method.

Cycle Systems’ partnership with Sunapsys has resulted in increases nearing 50% of throughput on their automotive shredder at their scrap processing plant in Lynchburg, Virginia. Adjustments to the system are ongoing as continuous improvement is cornerstone to Cycle Systems’ company goals.