Large Containers, Small Footprint: IBC Container Recycling at Dansk Emballage in Denmark
The Danish company Dansk Emballage, Vamdrup, specializes in the collection and reprocessing of Intermediate Bulk Containers (IBC). The containers are sorted, washed, and recycled on-site. A significant role in this process is played by a W5.18 single-shaft shredder
Dansk Emballage has over 30 years of experience in trading new and reconditioned industrial packaging such as IBCs, drums, canisters and pallets. The company collects, cleans, repairs and recycles this packaging in an ISO 9001 and ISO 14001 certified process. If reprocessing is not possible, the IBC containers are sent for material recycling. The same concept also applies to plastic drums and canisters. The containers come from companies in the chemical and food industries throughout Scandinavia.
Heart of the Recycling Line: The WEIMA W5.18
The WEIMA W5.18 single-shaft shredder is ideal for shredding large volumes of plastics. It features a V-rotor with a diameter of 500 mm and a rotor length of 1,800 mm. The Siemens PLC control system with an intuitive touch panel makes the shredder easy to operate. A generously sized inspection hatch ensures convenient access for maintenance work. The owners are also impressed with the material feed:
“The swing ram transports the IBC containers very quickly and thoroughly to the rotor. These are partly 16-kilogram IBCs, and within a short time, shredded plastic pieces measuring 60 mm come out. We are very satisfied with the result,” says Martin Schack Staffeldt.
Innovative Additions for Maximum Results
The shredding process at Dansk Emballage is optimally tailored to plastic applications. Before shredding, all grids, pallets, and valves are removed from the cans, drums, or IBCs, leaving only pure plastic.
Thanks to an integrated and automated water injection system in the shredder’s cutting chamber, the containers are pre-washed during shredding. This cleans the containers of coarse residues and significantly reduces the risk of fire.
Dansk Emballage has also opted for additional rotor wear protection. This ensures the rotor is well-protected against foreign objects and abrasive materials. A camera installed inside the shredder allows for continuous monitoring of the process.
The pre-shredded material is then transported to a granulator for further size reduction. This is followed by a friction washer. The combination of granulator and friction washer enables effective shredding and cleaning of plastic waste. The granulator ensures further reduction of material size, while the friction washer removes contaminants to provide clean granules for further processing. These two processes are crucial for the quality of the recyclate and the efficiency of the entire recycling process.
Circular Economy: Turning Old into Valuable
Dansk Emballage uses 35% of the recycled material to produce new IBCs – a closed-loop system that is highly appreciated by customers.
The decision to choose WEIMA was made after a thorough evaluation of various suppliers. "We looked at many different potential suppliers for the shredder and ultimately chose WEIMA. And we are very satisfied with it," says Martin Schack Staffeldt.
The comprehensive service and support from the local WEIMA representative in Denmark have significantly facilitated the implementation and operation of the shredder.