UNTHA Secondary Shredder Maximizes Throughput and Uptime
With the new SR3000XC, KORN Recycling GmbH has modernized its alternative fuel processing operation, focusing on maximum uptime, consistent throughput, and high-quality fuel production. Integrated into the existing processing line in just a few days, the new UNTHA secondary shredder has been reliably producing up to 15 short tons/hour of premium main burner fuel with a particle size of less than 1 inch for the cement industry.
Leading Waste Management Company Invests in Advanced Technology
Based in Albstadt, Germany, KORN Recycling GmbH is one of the country's leading waste management companies. With approximately 220 employees, eight locations, 66 collection vehicles, and around 5,000 containers, the company operates one of Germany's most advanced sorting and alternative fuel processing facilities.
Each year, KORN Recycling processes approximately 110,000 tons of waste, converting it into around 66,000 tons of alternative fuels, including high-calorific fluff fuel for the cement industry.
Fast Replacement of a Critical System Component
As part of a modernization project involving one of its three secondary shredding lines, KORN Recycling selected the new SR3000XC. Installation into the existing system was straightforward and completed over a single weekend. By Monday morning, the facility had already resumed full multi-shift production.
Powered by the beltless UNTHA Power Drive with 2 x 335 hp, the shredder processes pre-sorted commercial and industrial waste down to a particle size of less than 1 inch, achieving throughput rates of up to 15 tons per hour. Operating six days a week in multiple shifts, the machine delivers the high performance and reliability required for demanding continuous operation.
Slide-Gate-Free Design Meets Intelligent Material Flow
At the heart of the new secondary shredder is the XC cutting system, featuring a 39-inch rotor diameter and an approximately 10-foot cutting width. The large rotor continuously pulls material into the cutting chamber, eliminating the need for a hydraulic feed ram.
With fewer moving parts, the machine reduces potential failure points while lowering maintenance requirements.
The newly developed SR FlowGuide optimizes material flow through the cutting chamber, minimizes material recirculation, and shortens residence time inside the shredder. This allows available drive power to be used more efficiently while maintaining a smooth, continuous material flow. The result is consistently high output quality, greater process stability, and increased throughput.
The cutting system includes six rows of knives with a total of 84 strip knives. The knives feature a four-sided design, allowing each cutting edge to be used four times before replacement, significantly reducing wear part costs and downtime.
Combined with a large screen area and a rotor speed of approximately 250 rpm, the SR3000XC delivers high throughput while minimizing wear.
The direct drive system also replaces conventional belt-driven technology. Routine maintenance tasks such as belt tensioning, adjustments, and belt replacement are eliminated entirely. This reduces maintenance, increases machine availability, and lowers operating costs throughout the shredder's service life.
A maintenance-free safety clutch provides reliable protection for both the cutting system and drive components in the event of contaminants or foreign objects.
"As an operator of an alternative fuel processing facility, you need a stable process with high throughput, smooth operation, consistent product quality, and economical operating costs. UNTHA has achieved exactly that with the SR3000XC," says Alexander Korn, Managing Partner of KORN Recycling GmbH.
Developed Together with Alternative Fuel Processors
During development of the new SR series, UNTHA worked closely with experienced alternative fuel processors. A dedicated workshop was held to identify the most important requirements for the next generation of secondary shredders.
Key priorities included a slide-gate-free machine design, a low-maintenance direct drive, and bolt-on wear plates for the knife holders. The goal was to create a machine with as few wear-prone and maintenance-intensive components as possible.
"With the new SR series, we systematically simplified complex processes. The result is a robust, high-performance shredder that delivers maximum uptime with minimal maintenance," explains Christian Lanner, Head of Research at UNTHA shredding technology.
Designed for Reliability and Easy Maintenance
Because secondary shredding is a critical step in the entire processing chain, the SR3000XC was engineered with a strong focus on operational reliability and serviceability.
Its robust design and easy access to key components reduce service times while minimizing unplanned downtime.
"The throughput is excellent, and the quality of the alternative fuel consistently meets our customers' high standards. Our customers in the cement industry confirm that we deliver dependable, uniform quality without variation. We're extremely satisfied with the SR3000XC," adds Alexander Korn.
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Images Available for Download (Free for editorial use. Photo credit: UNTHA shredding technology GmbH) Untha Medienpool
Image 1: SR3000XC in operation at KORN Recycling
Image 2: Incoming material at KORN Recycling
Image 3: Final processed material—homogeneous output with no oversized particles
