In an industrial context increasingly oriented towards speed and process optimisation, the scrap metal recycling sector requires solutions that combine operational flexibility, logistical efficiency and production continuity. These are no longer mere advantages, but real conditions for remaining competitive in the long term.

The Flex Mobile hammer mill was designed precisely to meet these needs. It was the first Panizzolo machine, developed even before the stationary models: a unique solution that paved the way for our current range of metal grinding and processing equipment.

From the outset, the series was designed to combine performance and maximum flexibility. Today, years later, it continues to be a strategic solution for companies looking for a compact, reliable and ready-to-use machine in any operational context. Originally designed for the Italian market, the Flex Mobile series has been able to demonstrate its full potential over time, establishing itself on the international scene as well, thanks to a design approach focused on simplicity and process flexibility.

Logistics management and agile configuration

Designed as a turnkey, ready-to-use solution, the Flex Mobile series offers the best in convenience and speed of operation. Thanks to its configuration, transport and installation are extremely easy, even in settings with limited space. The compact design avoids oversized transport by road, simplifying logistics and reducing costs, while the special frame facilitates loading and unloading. Installation is equally simple and quick: the machines are supplied pre-assembled, mounted on roll-off boxes and, in the case of the Flex Mobile 1000, with integrated pistons that facilitate lifting and positioning, guaranteeing full plant operation in just a few steps.

Flexibility in scrap handling

What makes Flex mobile mills extremely competitive is their operational flexibility. Thanks to the patented cradle, it is possible to change processing configuration in less than twenty minutes, quickly adapting the system to the type of material to be processed or the desired size of the output product. From small transformers to electric motors, from WEEE scrap to shredded aluminium and tin cans, to mixed iron-plastic materials: the Flex Mobile series allows a wide variety of scrap to be processed, meeting the needs of companies operating in different sectors and looking for uncompromising versatility.

Energy efficiency

The Flex Mobile series includes models with powers from 90 kW to 315 kW, capable of handling between 3.5 and 15 tonnes/hour depending on the configuration. A central aspect is energy efficiency: each component is designed to maximise the ratio of energy consumption to productivity. According to an analysis based on public market data, the Flex series provides energy savings of between 22% and 62%. This has a direct impact on reducing operating costs and contributes to making the treatment process more environmentally sustainable as well.

Easy maintenance

An efficient treatment plant cannot do without agile maintenance. In this respect too, Panizzolo’s mobile mills are an optimal solution. The machine is designed to facilitate the inspection, greasing and replacement of components subject to wear. Thanks to full access to the grinding chamber, the cradle, rotor, grids, hammers and armours can be easily serviced. All operations are simple and intuitive reducing the number of operators involved and without the need for special equipment or advanced technical skills. This approach results in leaner plant management, optimising overall efficiency.

Reducing noise emissions

A further strength of the Flex Mobile series is the presence of sound-absorbing panels integrated in the external structure. These are specific, water-repellent and weather-resistant materials which guarantee a significant reduction in noise emissions during operation. This feature makes the Panizzolo mobile mill ideal for production contexts where noise management and compliance with environmental regulations are crucial. But not only that. Noise reduction helps to create a more comfortable environment for operators, reducing the risks of exposure to high noise levels, in full compliance with occupational health and safety regulations.

Quality-oriented design approach

In line with our high-quality standards, the mobile mills are built for longevity and high performance. Wear is concentrated only on easily replaceable components, such as hammers, grids and armours, made from special steels and high-grade castings. The high quality of the materials – from the framework to the welds – helps to preserve the integrity of the mill even when crushing the heaviest scrap.

Rotors and hammers respond to the same construction logic: the rotors are designed to efficiently absorb mechanical stresses, while the hammers, with free 360° rotation, guarantee optimal impact and efficient crushing, reducing the risk of breakage and ensuring continuity of performance.

These measures reflect the design philosophy that unites all our solutions, which is oriented towards a precise objective: to provide reliable systems, designed to last and capable of adding value to the investment in the long term.

The treatment of Waste Electrical and Electronic Equipment (WEEE) is one of the most pressing challenges for the recycling industry. According to the Global E-waste Monitor, more than 62 million tonnes of e-waste will be generated globally in 2022. To give an idea, the volume of WEEE produced would be enough to fill 1.55 million 40-tonne trucks, an unbroken line of vehicles that could circle the entire earth’s equator.

Another relevant figure concerns the recycling rate: only 22.2% of WEEE is treated and recovered correctly, leaving tonnes of valuable materials unused. This leads not only to a significant environmental impact, but also to an estimated economic loss of more than 62 billion USD per year, highlighting how much the potential of these materials is still underestimated.

Every discarded electronic device contains precious metals such as copper, aluminium, steel, iron and other reusable materials. Recovering them efficiently is key to reducing dependence on virgin resources, limiting environmental consequences and maximising the value of waste.

At Panizzolo, we turn this challenge into an opportunity. Our grinding, separation and refining plants process large household appliances (category R2), small household appliances and consumer electronics (category R4), recovering high-quality iron, copper, aluminium and steel granules, ensuring an efficient, sustainable and value-oriented process.

WEEE recovery, step by step

To maximise the valorisation of WEEE, we have developed a processing cycle that integrates the grinding, separation and refining phases, with an End-of-Waste approach. Specifically, the plants apply only mechanical and in-line treatments, with productivity ranging from 3 to 20 ton/h.

Grinding

A key element of the process is the grinding phase, entrusted to the Mega and Flex series hammer mills, designed to offer superior performance in terms of productivity, energy efficiency and adaptability to different types of WEEE. Thanks to their solid construction and patented components, Panizzolo mills guarantee optimal volumetric reduction, facilitating the separation of ferrous and non-ferrous components.

Separation

Subsequently, the material undergoes a sorting process, which uses advanced technology to achieve extremely precise separation of the different metal and plastic fractions. This system ensures a high level of purity of the recovered materials, increasing their quality and value.

Refining

The refining stage completes the WEEE treatment cycle and provides a very high quality output, obtaining only metal granules, classifiable as secondary raw material, which can be sold directly to foundries.

Turnkey solutions for efficient recycling

Our aim is to offer much more than just machinery: we develop complete, customisable plants designed to ensure efficient and profitable recycling. Turnkey solutions combine innovation, flexibility and user-friendliness to optimise every step of the process, improving operational efficiency and reducing running costs. Our range of plants is highly modular, allowing companies to adapt and expand their production capacities according to market dynamics, even in view of new business opportunities.

Further added value is the synergy between design, installation and assistance. From initial consultation to installation, from training to after-sales service, we offer our customers all-round support, accompanying them on a path of long-term technological and production growth.

Sogliano Ambiente: a winning partnership

The collaboration with Sogliano Ambiente, an Emilia-based company that has been involved in waste disposal and treatment for more than 25 years, is a concrete example of the Panizzolo approach. From the beginning, the company needed to find a partner that could provide a tailored solution for WEEE treatment, capable of evolving over time with new implementations. The installed system consists of two main lines. The first, dedicated to volumetric reduction, includes a hydraulic opener, designed to perform manual sorting and prepare the material for the next step. The second line focuses on the grinding and separation of metals, thanks to a Flex 1000 hammer mill flanked by two advanced separation systems, which enable the end-of-waste cycle of ferrous and non-ferrous metals.

Today, the collaboration continues to evolve. Sogliano Ambiente chose to expand its plant by integrating new Panizzolo sorting islands, with the aim of further improving the quality of recovered materials and increasing the value of the final product.

Advanced training

In an ever-changing industry, investing in training is essential to sustaining business growth. That is why, through the Panizzolo Recycling Academy, we offer our customers a programme of specialised courses that enable them to acquire all the necessary skills for optimal machinery management, from operational to organisational. Thanks to an approach based on best practices and strategies applicable to the work environment, training guarantees concrete results: from optimising the energy efficiency of plants, to improving productivity, to promoting a more flexible and proactive operational approach. At the end of the course, the skills acquired in metal treatment and recovery are recognised with an official certificate, confirming the completed training.

New strategic directions

Innovation is at the heart of our strategy and the engine that drives every project. This year, investments in Research and Development are focused on expanding the product range, with the introduction of new solutions, targeted technology upgrades and an increase in accessories to further improve plant performance. The push for innovation goes hand in hand with an international expansion strategy, increasingly oriented towards non-EU markets. With this in mind, we are strengthening our sales network and reinforcing our presence in key industrial areas, offering state-of-the-art solutions to meet the new challenges of the global market.

This strategic vision is also reflected in the choices related to participating in major industry events. While recognising the importance of Ecomondo, which over the years has represented an important opportunity for discussion and growth, our path this year leads us to take new directions, focusing our energies on international markets and strategic development projects. In this context, we will be involved in a number of key global events in 2025, including Residuos Expo Mexico, E-Waste World, BIR and Aluminium USA, to name a few. These events will allow us to strengthen our presence in non-EU markets, consolidate strategic relationships and bring our solutions into new contexts.

In the coming months, we will unveil more details about new technologies and upcoming projects, confirming our commitment to forward-looking solutions.

The choice of a recycling system is a strategic decision that can determine the success of a company. It is a significant investment, which must ensure efficiency, productivity and sustainability in the long run. Therefore, the process can be complex and cannot be left to chance: precise evaluations of technical, logistical and economic aspects are required.

At Panizzolo Recycling Systems we are familiar with this complexity. Since 1946, our experience gained first as tradesmen and then as system designers has allowed us to get to know the dynamics of the industry and experience first-hand the challenges that companies face on a daily basis. A key moment in our journey was the development of the Piove di Sacco system in the 1980s and 1990s. Equipped with 250 kW hammer mills, this system was a real revolution for us: thanks to low energy consumption and high productivity, we were one of the first in Italy to prove that high performance and optimised consumption can coexist.

Since then, our pragmatic and innovative approach has evolved without pause, leading us in the 2000s to the marketing of complete scrap processing systems internationally. Today, our offer is comprehensive, with flexible solutions capable of adapting to an ever-changing industry. It is this know-how, gained in the field, that has taught us which four factors are essential to consider when choosing a recycling system.

1. Logistics: organising space to maximise efficiency

The logistics aspect is often underestimated in system design, yet it is one of the main factors influencing productivity, safety and operating costs. Well-organised logistics ensure a smooth and uninterrupted workflow, avoiding dead spots and minimising downtime. Each system must be thought of as a dynamic organism, in which the available space must not simply be filled, but strategically enhanced.

At Panizzolo, we always start from the customer’s operational reality: we analyse the initial storage, material handling routes, loading and unloading points, and the areas dedicated to the different processing stages. Our standard systems are not rigid, but designed to be adaptable. Together with the customer, we study the best solutions to optimise every available square metre, without imposing predefined configurations. In this way, space is utilised optimally, increasing overall productivity.

2. Energy consumption: a double challenge

Energy efficiency has become a crucial challenge for recycling companies, especially in Europe, where rising energy costs and increasingly stringent regulations impose high standards in terms of sustainability. In this context, remaining competitive means finding the right balance between output quality and consumption optimisation, minimising inefficiencies and reducing operating costs.

Panizzolo systems perfectly meet this need, thanks to innovative technologies that balance power, quality and consumption. Our hammer mills, for example, are equipped with smart control systems to monitor consumption, avoiding drops or overloads. From an energy-saving perspective, our solutions are designed to reduce waste and optimise performance. The star among them is the Mega Series, capable of achieving a productivity of 35 ton/h and energy savings of 57% to 76% compared to other models with similar motorisation.

While, in Europe, efficiency is a necessity imposed by the market, in other parts of the world the cost of energy is generally lower. In these contexts, the priority is not so much to reduce consumption as to ensure a quality of output that meets export standards. Thanks to the flexibility of our systems, we are able to meet both requirements: reducing consumption where necessary and ensuring consistent quality for the marketing of processed materials.

3. Quality: a long-term investment

The quality of a recycling system is not limited to the mechanical components, but is directly reflected in the performance and quality of the final output. Opting for low-cost solutions may seem advantageous at first, but it carries significant risks: frequent breakdowns, more costly maintenance work and a quality of treated material that does not meet the standards required by the market. The way we see it, quality is not a cost, but rather a strategic investment for the future. That is why we design our systems in-house, taking care of every detail and integrating advanced technologies from international brands recognised as the best in the industry for quality and reliability.

It is also crucial to devote the right resources to each step of the treatment cycle. Grinding, for example, which is often undervalued in favour of separation systems, plays a crucial role in preparing the material for the subsequent steps. Precise and uniform volumetric reduction simplifies the work of separation systems, improving efficiency and contributing to a quality-compliant end product. With this in mind, Panizzolo hammer mills guarantee optimum size, ensuring maximum synergy between grinding and separation.

4. Flexibility: the key to the future of the sector

The recycling sector is characterised by constant evolution: new regulations, complex waste and changing market dynamics require companies to be ready to change fast. Therefore, the choice of a recycling system, also given its scale, cannot be limited to meeting current needs, but must be designed to support the company’s future growth. A system that meets production needs perfectly today could be obsolete in a few years if not designed with a long-term vision.

With this in mind, we develop modular and scalable systems that evolve with the customer’s business. Our interchangeable cradle, for example, allows adaptation to different types of scrap metal, while our broad portfolio of solutions and consultative approach guarantee constant support, even years later. With the possibility to integrate new modules and upgrades according to market needs, the system becomes a strategic lever to compete, innovate and grow over time.