Wali Shredder
From End-of-Life Vehicle Recycling to the Rebirth of Defective Aluminum Castings
With China’s vehicle ownership continuing to rise, the dismantling and recycling of end-of-life vehicles has become a critical link in the circular economy.
An end-of-life car weighs approximately 1.5 tons, with metals accounting for over 75% of its weight. Aluminum components, in particular, are seeing an increasing share in new energy vehicles due to their lightweight properties. Specifically, this includes 65% steel and 10% aluminum.
Research indicates that recycling 1 ton of scrap steel can reduce CO₂ emissions by 1.5 tons, offering significant environmental benefits. If not handled properly, these discarded vehicles not only cause serious environmental pollution but also lead to a massive loss of valuable metal resources.
How to achieve efficient and environmentally friendly dismantling, shredding, and metal recovery from end-of-life vehicles is becoming the core challenge for industry advancement.
End-of-Life Vehicle Dismantling and Shredding Process
1. Dismantle parts for reuse or remanufacturing (e.g., wheels, bumpers, windshields, seats, door panels, transmissions, engines).
2. Remove batteries and airbags; collect lubricants, gasoline, coolant, and brake fluid.
3. Shred the vehicle body.
4. Separate ferrous metals using a magnetic separator.
5. Separate non-ferrous metals using an eddy current separator.
6. Process Auto Shredder Residue (ASR) into Refuse-Derived Fuel (RDF).
End-of-life vehicles feature complex structures and diverse materials.
Traditional manual dismantling and primary shredding methods are not only inefficient but also pose safety risks and environmental hazards.
Wali’s End-of-Life Vehicle Shredding and Recycling System is equipped with advanced sorting technology and intelligent control systems, enabling efficient shredding and precise sorting of whole vehicles or large assemblies.
This system is designed for shredding and recycling scrapped vehicles and scrap metal, facilitating remelting and reuse in the circular economy.
It is primarily used for processing scrap steel materials such as steel scrap, end-of-life cars, thin-walled containers, non-ferrous metals, and discarded household appliances.
The process begins with a specialized dual-shaft shredder, followed by a hammer crusher for further size reduction and material compaction.
This step also cleans contaminants adhering to metal surfaces and separates different metals from each other, preparing them for subsequent sorting.
Ferrous and non-ferrous metals are then separated by a magnetic separator and an eddy current separator, respectively.
The entire system is controlled by a PLC with real-time dynamic monitoring.
It features low energy consumption per unit, high throughput, cost-effectiveness, low maintenance costs, excellent processing results, and low requirements for input power capacity.
A Dual Revolution in Space and Efficiency
When approached by a renowned automotive manufacturer with an urgent need for recycling defective aluminum castings, Wali’s technical team did not simply apply an existing solution. Instead, they conducted an in-depth on-site investigation of the production line and launched a precise technical campaign centered on the core goal of “minimizing footprint and maximizing economic benefits.”
The manufacturer’s core challenge was extremely limited production space.
Traditional multi-stage shredding lines were not only large and space-consuming with lengthy processes but also incurred high overall operational costs.
Wali’s team rose to the challenge. Where no ready-made solution existed, they created one. The technical team designed the industry’s first “One-Stop Integrated Shredding Solution for Aluminum Castings,” built around a large dual-shaft shredder.
The success of this project went beyond meeting a single requirement. It validated an important industry premise: in a context of increasingly scarce land resources and continuously rising production costs, “intensification” and “high-value recovery” are not a trade-off but can be achieved together through systematic engineering.
What Wali delivered was not just a set of equipment, but a replicable and scalable value-creation model. It proved that through precise process re-engineering and the integration of intelligenttechnology, the manufacturing industry can achieve higher resource efficiency, lower overall costs, and better environmental performance within a smaller footprint.
To Be Continued @ Wali
For years, Wali has consistently adhered to a people-centered core philosophy, immersing ourselves in customer sites and grounding our work in industry realities. In every customer interaction and every project, we strive to genuinely understand needs, confront challenges, and solve problems. We believe true value creation begins with deep empathy for our clients’ difficulties and is achieved through continuous breakthroughs in technical pathways.
Simultaneously, Wali has always kept a close eye on market trends and the technological frontier. Faced with era-defining challenges such as the ‘Dual Carbon’ goals, the circular economy, and smart manufacturing, we proactively drive technological innovation and system upgrades—evolving from single machines to integrated lines, and from mere shredding functions to full value-chain services for resource recovery. It is this dual synergy of being ‘customer-centric and technology-driven’ that has kept Wali at the forefront in a competitive market and delivered tangible benefits and sustainable competitive advantages to our customers.
Moving forward, Wali will continue to advance side-by-side with our clients, innovating based on needs, growing through innovation, and jointly writing a new chapter for resource recovery and green manufacturing within the broad blueprint of the circular economy.”
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