TG-Impact 500 Horizontal Impact Crusher

Impact Crushing for Secondary Metal Fragmentation

The TG-Impact 500 is a horizontal shaft impact crusher designed for secondary size reduction in metal recycling lines where primary-shredded or pre-sheared scrap needs further fragmentation before downstream separation. A high-speed rotor carrying blow bars strikes incoming material against impact plates (curtains) mounted in the crushing chamber. The impact force fractures the metal along grain boundaries and existing micro-cracks, producing a more uniform fragment than compression crushing alone. This makes the impact crusher particularly effective as a secondary stage after a jaw crusher or twin-shaft shredder, where the goal is to liberate trapped non-ferrous metals from ferrous matrices and produce consistently sized fragments for magnetic and eddy-current separation.

Key Specifications

The rotor spins at peripheral speeds that generate sufficient impact energy to fracture pre-sized metal fragments. Material fed into the chamber is accelerated by the blow bars and thrown against the first curtain, where it shatters. Fragments that are still too large bounce back into the rotor path for a second impact, or deflect to the second curtain for further reduction. The gap between rotor and curtains is adjustable—reducing the gap produces finer output; widening it increases throughput at a coarser fragment size.

How Impact Crushing Differs from Compression and Shear

The three primary crushing mechanisms in metal recycling each operate on different physical principles:

• Compression (jaw crusher): Material is squeezed between two surfaces until it fractures. Effective for hard, brittle materials. Produces fewer fines but larger fragment size variation.
• Shear (shredder): Material is cut between rotating shafts. Effective for light-gauge and mixed scrap. Output size depends on shaft gap and cutting disc spacing.
• Impact (this machine): Material is struck at high velocity and fractured by the energy transfer. Effective for brittle metals and for liberating bonded materials. Produces more uniform fragment size and more fines, which can improve downstream separation efficiency.

For metal recyclers, the impact crusher's advantage is liberation. When metal fragments are crushed by impact, brittle components (cast iron, hardened steel) shatter while ductile components (copper wire, aluminum) deform rather than fracture. This differential response helps separate mixed metal streams—brittle fragments pass through at a consistent size while ductile metals flatten and can be screened out separately.

Blow Bar Selection and Wear Management

Blow bars are the primary wear consumable. The choice of blow bar material depends on feedstock composition:

• Martensitic steel: Good all-round choice for mixed ferrous scrap. High hardness with moderate toughness. Resists impact spalling better than harder ceramics.
• Hardened alloy steel: Higher hardness for abrasive feed streams. May be more prone to chipping if tramp uncrushable metal enters the chamber.
• Composite (steel + ceramic inserts): For highly abrasive feed. Ceramic inserts provide extreme wear resistance but the bar must not be run with tramp steel that can crack the inserts.

Blow bars are reversible—use both edges before replacement. The impact curtains are also lined with wear-resistant plates that are bolted for replacement. A tramp iron release system (hydraulic or mechanical) protects the rotor and blow bars from uncrushable objects that enter the chamber.

Application Scope

The TG-Impact 500 is positioned as a secondary crusher in a multi-stage recycling line:

• Secondary reduction after primary jaw crusher output
• Fragmentation of pre-shredded scrap to uniform size for separation
• Liberation of non-ferrous metals from ferrous matrices in mixed scrap
• Processing of cast iron and brittle steel components to foundry-charge size
• Reduction of aluminum castings and engine components for remelting

The impact crusher is not designed for primary reduction of large solid castings or thick structural sections—these should be pre-processed through a jaw crusher or shear first. Feeding oversized material risks rotor damage and blow bar breakage.

Drive and Electrical Configuration

The rotor is driven by a V-belt drive from the main motor, with a flywheel to smooth peak loads. Motors are available in 50 Hz or 60 Hz configuration. The control panel includes motor amperage monitoring, automatic shutdown on sustained overload, and emergency stop circuits. VFD (variable frequency drive) is available as an option for applications requiring rotor speed adjustment to optimize fragmentation across different material types.

Compliance and Certification

The machine frame and guarding carry CE marking per the Machinery Directive. The manufacturing facility operates under ISO 9001 quality management. UL-listed control panel configuration is available for North American buyers on request. Safety interlocks on all access doors prevent opening during rotor operation.

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