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This copper wire recycling production line adopts dry crushing and air separation technology, which is widely applicable to process waste electric wires, household cables, automobile wiring harnesses, industrial mixed wires and various scrap cables. The equipment can completely separate copper granules and plastic insulation materials through crushing, screening, vibration sorting and wind separation. The processed high-purity copper granules can be directly supplied to smelters for secondary refining, and the separated plastic materials can be recycled and resold, bringing dual economic benefits.
The whole production line features high automation, low energy consumption, stable operation and low failure rate. Equipped with a professional dust removal system, it achieves zero sewage discharge and low dust emission, fully complying with local environmental inspection standards. It is perfectly suitable for small, medium and large waste recycling factories, effectively improving waste recycling efficiency and cutting manual labor costs.
Raw Materials: Miscellaneous wires (square-section wires, motorcycle wires, etc.), household square-section wires, automotive wires, cables, and other miscellaneous wires.
Customer Background：
Munich, Germany | Large-scale industrial waste recycler. Mainly processes automotive wiring harnesses, industrial cables and mixed scrap wires, with a daily processing capacity of over 5 tons.
Customer Requirements：
Hourly capacity ≥ 500kg/h for stable and continuous production.
Copper granule purity ≥ 99.9%, eligible for direct supply to smelters.
Processing materials: iron-containing automotive wiring harnesses, thin communication wires and thick industrial cables.
Compliant with EU CE certification and environmental dust emission standards.
High level of automation to reduce labor costs.
Problems & Challenges：
The old equipment had poor sorting accuracy. Copper granules were mixed with aluminum and plastic, with purity only 96%, resulting in a loss of over 200 euros per ton.
Serious copper powder loss in fine wires (0.5–1mm), with the recovery rate lower than 85%.
Severe dust pollution and poor workshop conditions, leading to multiple warnings from environmental authorities.
The machine was prone to blockage and blade wear, causing 8–10 hours of downtime and maintenance every week.
Solutions：
Recommended complete production line: Model 600 dry-type copper granulator + electrostatic separator.
Equipped with Cr12MoV high-wear-resistant alloy blades to prevent blockage and extend service life by 50%.
Three-stage separation: Crushing → gravity air separation → high-voltage electrostatic separation, to accurately separate copper, plastic and iron.
Fitted with a pulse bag dust removal system; dust emission ＜10mg/m³, fully compliant with EU standards.
Optimized wind speed and electrostatic parameters for fine wires to reduce copper powder loss.
Adopts integral PLC intelligent control with one-key start, automatic alarm and remote monitoring.
Project Results：
Stable hourly output of 500–600kg/h, fully meeting production capacity demands.
Copper granule purity stably reaches 99.9%+, available for direct high-price sales to smelters.
The metal recovery rate increased to 99%, greatly reducing fine copper loss.
Dust emission meets EU standards, passing environmental assessment with no environmental fines.
Labor demand reduced by 60%, saving about 3,000 Euros in labor costs monthly.
Equipment failure rate decreased by 80%, with monthly downtime less than 2 hours.
Customer Testimonial：
"The equipment runs stably with high copper purity and eco-friendly performance. It has greatly improved our profits and solved environmental problems. Highly professional service!"
