Lower costs. Cleaner jobsites. Happier neighbors. Safer workers. That last goal is the one Terry White, owner of B.e.t.-er Mix Inc., says he strives for most. But a process B.e.t.-er Mix previously followed continuously caused White concern because workers were putting themselves at risk trying to un-jam chunks of concrete.
“For years we’d been using a densifier on a track hoe with a set of jaws to bust up concrete block into manageable pieces for our crusher, but it was frequently getting jammed and we’d have to use pry bars to get the pieces out,” says White, who’s based in Hudson, Fla. “This would happen up to four times a day in a 12-hour work period, and each time these jams put us down for at least an hour while we worked to remove the chunks from the blades, which posed a potential injury risk.”
Keeping employees safe is a top priority for White, and it’s the reason why he explored alternative systems and equipment that could do the job more safely. White, who demoed a Badger Shredding b2060-T system last year, was impressed with the equipment’s counter-rotating shafts that could easily and safely handle large pieces with its tooth system within the blades.
“When I saw it could take big 3-ft. sections the size of a coffee table and break it down to 10 in. or into sand particles, we purchased one,” White says. “While no one had been injured unjamming our old equipment, the Badger shredder has made our problems go away and eliminated any worry.”
Before purchasing, B.e.t.-er Mix demoed several other shredding systems to crush concrete block for aggregate. He says he likes the b2060-T because it’s quieter, less dusty and more cost-effective than other equipment he tried.
In addition, White says that with considerably less downtime and reduced maintenance costs, the b2060-T has helped to increase B.e.t.-er Mix’s volume by at least 25 percent. The shredder also eliminates the secondary densification process it used in the past.
Also, the slower rpm of the blades can produce more rock and less sand, which, in Florida, is harder to come by and more expensive, according to White.
Environmental stewardship is important to B.e.t-er Mix, as well. According to White, neighboring communities have noticed significantly less dust and noise – other benefits of the machine’s lower rpm – in the area. Residents at a nearby mobile home park less than a mile west of B.e.t.-er Mix say the difference is highly noticeable, White says.
“[Neighbors] were pleased with the result, telling me it’s noticeably quieter and the air quality is better,” he says.
Innovation in the teeth
According to Badger Shredding, it redesigned its replaceable wear teeth to help its customers save money. The new blades are mounted on the counter-rotating shafts, the company says, and each blade has a tooth system that can be individually replaced.
“The heart of the Badger line of slow-speed, high-torque shredding machines is in its unique design of the shredding chamber,” says Gerry Lamer, Badger Shredding president. “Our blade replacement tips last more than 500 hours and can be replaced individually as needed rather than replacing the entire assembly.”
The shredding system goes beyond concrete use, processing carpet, rubber and more. The b2060-T can shred biomass material to assist companies producing energy from products such as food waste and green waste, Lamer says.
One component that can be attractive to concrete processing producers is the fact that even steel rebar rods, a valuable scrap metal, can be separated, salvaged and recycled.
“Our unique slow-speed shredding system allows rebar to be run through without worry that the steel will harm the equipment,” says Bob Lamer, vice president and general manager of Badger Shredding. “With our unique process, there is almost zero chance of damaging our machine from rebar.”
According to the company, the combination of a low speed and a high torque helps to shred the concrete and shears the metal rods, which are magnetically separated for recycling.
Badger’s machines are available in stationary, semi-stationary and mobile configurations, with systems ranging between 200 and 700 hp.
Amy Spreeman has more than 20 years of experience in public relations, brand marketing and trade journals. She can be reached at amy@spreemancommunications.com.