New performance data from Eriez shows scrap recyclers can achieve precise copper control without sacrificing throughput. Full-scale installations of the Shred1 Ballistic Separator consistently deliver copper levels below 0.15% while processing more than 127 tonnes (140 tons) per hour.

Copper contamination has traditionally forced recyclers to choose between costly melt chemistry corrections and rejecting marginal feedstock. A newly published report suggests the Shred1 removes that trade-off, providing a purely mechanical solution that supports both high productivity and tighter chemical control.

According to the data, the system delivers verified performance across four key measures: high throughput, with scalable operation well above 90 tonnes (100 tons) per hour and many confirmed US installations exceeding 140 tons per hour per Shred1; low copper levels, with consistent production of premium #1 shred containing 0.13–0.16% copper; improved melt efficiency, with melt yields increasing from a typical 88% to as high as 94%; and rapid payback, with operational improvements that can deliver return on investment within months.

At a major US scrap processing facility, the Shred1 consistently produced premium shred with copper levels as low as 0.13%. This enables the operator to blend higher-copper input material while still meeting melt specifications, ensuring output ships as premium-grade product rather than being downgraded or diverted.

Comparable results were achieved at a European recycling facility through a 76-heat melt trial. Low-copper shred produced by the Shred1 averaged 0.145%, with melt chemistry closely aligning with theoretical predictions. This consistency reduced reliance on dilution scrap and supported more precise furnace optimisation.

Beyond copper control, the report also highlights measurable improvements in overall melt performance. Material previously delivered an approximate 88% yield, which increased to 94% following installation of the Shred1 alongside polishing magnet technology, improving furnace efficiency and accelerating economic returns.

Installed downstream of primary scrap drum magnets, the Shred1 separates material using magnetic forces and high-speed ballistic trajectories. Unlike air, optical or X-ray-based systems, this mechanical process sorts by mass and density, delivering stable separation performance with minimal operator intervention and no loss of throughput.

During operation, liberated shred is conveyed at high speed towards the head pulley. Low-copper material, more strongly influenced by the magnetic field, follows the pulley arc and is discharged behind a splitter, while higher-copper material continues forward for additional polishing.

“Scrap processors are under increasing pressure to meet tighter melt chemistry requirements without slowing production,” said Mike Shattuck, Business Development Manager – Recycling at Eriez. “These results show that copper control is no longer theoretical. The Shred1 delivers repeatable, measured performance at industrial scale and integrates seamlessly into existing shred lines.”