Innovation does not happen by chance. It is the result of a continuous journey of research, experimentation and constant dialogue with industry operators. The experience gained in plant design and operation enables us to transform this knowledge into concrete technological solutions developed to improve metal recovery processes.

Research & Development has always been a key driver of the company’s growth. Over the past two years, we have further strengthened this commitment by increasing investments and expanding the involvement of several company departments — from mechanical design to the commercial team — with the goal of evolving our solutions while keeping the needs of industry operators at the center. The latest results of this work will be presented at the next edition of IFAT Munich.

Among the innovations we will bring to the exhibition are two new grinding systems designed to translate the established quality standards of Panizzolo technology into more essential and targeted solutions. Machines that maintain the same reliability and robustness as our plants, but with configurations even more focused on specific processing requirements.

Alongside these solutions, we will also present a new line of conveyor belts developed with a modular design approach, allowing greater flexibility in plant layout configuration and optimizing the management of material flows within the process.

Completing the innovations is a next-generation separator that integrates artificial intelligence algorithms, a technology designed to bring sorting operations to a higher level of precision and automation. A further step towards increasingly intelligent processing systems capable of supporting operators in handling complex materials and improving recovery quality.

“These solutions represent a new phase in the development of Panizzolo technologies,” comments Mauro Panizzolo, owner and Sales Manager. “The recycling sector is currently undergoing a significant transformation, which also requires a different approach to technology design. For us, this means continuing to develop systems capable of supporting this evolution while maintaining strength and reliability over time.”

In the processing of scrap metal, variability is an intrinsic part of the process, and those working in the industry are well aware of this challenge: input materials are never all the same, volumes change, and ideal conditions have a limited duration. It is in this context that the true effectiveness of a mill is measured: not so much when everything is standardised, but when the process has to guarantee stability despite the many variables that come into play.

Flex hammer mills were developed from this awareness and from the direct experience that we gained in the field. The series is the result of observing plants in operation and constant feedback from customers and operators, which enabled us to offer a reliable solution for the flexible grinding of scrap metal. A technology developed to work continuously, ensuring process control, structural quality and more efficient and optimised plant operation over time.

A flexible approach to grinding

Designed for processing small and medium-sized scrap metal, the Flex series is characterised by its wide range of applications and its ability to meet the needs of different production contexts. The mills efficiently process different materials such as small electric motors, transformers, scrap from WEEE, shredded aluminium, tin and iron with plastic.

This versatility is supported by the patented interchangeable cradle, which allows Panizzolo mills to adapt quickly to grinding multiple types of scrap or changing piece size in processing. In an environment where material variability is the norm, flexibility becomes a decisive element in maintaining stable production performance.

Constant productivity under varying operating conditions

The Flex series ensures a productivity of up to 14 tonnes per hour, depending on the model and material handled. The continuous work cycle and the use of high-efficiency components allow constant processing volumes and output material quality.

Process continuity is not only a production advantage, but an element that affects the overall organisation of the plant. Working with stable parameters allows better planning of downstream activities and contributes to maximising overall output, improving profitability even with varying workloads.

Process stability

The oscillating table with eccentric, designed in-house, regulates the movement of material during loading and unloading, ensuring a uniform flow in the grinding process. This solution makes it possible to avoid accumulations or discontinuities in the passage of material, contributing to the regularity of the work cycle.

This is complemented by a system that integrates 22 to 26 vibration dampers installed between the base and the floor, capable of damping approximately 80% of the vibrations generated by processing. The benefit is not limited to operational comfort, but directly affects component life span, the structural integrity of the machinery and process continuity in the long term.

Intuitive maintenance

Ease of maintenance is one of the aspects that make a real contribution to the stability of a machine or plant. For this reason, maintenance activities have been designed for maximum practicality: they require a small number of operators and do not require special equipment or complex procedures. Operations such as periodic checks and greasing are quick and intuitive, contributing to minimising downtime and reducing operating costs. An approach that facilitates daily management and improves reliability.

Optimisation of operational consumption

In recycling processes, energy is an increasingly important cost item and a critical parameter in the overall evaluation of a plant. Consequently, one of the central aspects in the design of the Flex series is the optimisation of the relationship between energy input and production output.

The mills are designed to ensure high performance with low energy consumption, contributing to reduced operating costs and improved processing sustainability. Specifically, according to an analysis based on publicly available market data, the Flex series offers energy savings of between 22% and 62% compared to other models with similar motors. The control software contributes to this balance by automatically monitoring and adjusting the main operational steps, limiting energy losses and keeping the process at optimum efficiency levels.

Designed for the long term

The Flex series reflects our design approach in every construction detail. Structural solidity comes from a design conceived to cope with the stresses of grinding, without compromising on durability. The high-quality steelwork and UNI EN ISO 3834-2 certified welds guarantee a reliable structure, even under the most demanding operating conditions.

This balance between design and construction allows the mill to maintain consistent performance, limiting wear, unscheduled downtime and extraordinary interventions. An approach that translates into machinery and solutions capable of sustaining the process over the long term, allowing customers to enhance the value of their investment and build stable, reliable plants ready to evolve over time.

Every year around 40 million vehicles worldwide reach the end of their life cycle. A continuous flow of materials that, if managed correctly, can be transformed from complex waste to a strategic resource for the circular economy. In Europe, where more than 6 million vehicles are dismantled every year, the Directive 2000/53/EC requires that at least 95% of each vehicle’s weight be recovered, with a minimum target of 85% for actual recycling. An ambitious goal that calls for increasingly advanced technologies and an industrial vision focused on sustainability and process efficiency.

What you can really recycle from a car

According to analyses of passenger vehicles, a modern car is composed on average of 75% metals, 15% plastics, and the remainder of glass, rubber, fluids and electronic components. Ferrous metals are efficiently separated through shredding and magnetic sorting, while the recovery of non-ferrous metals, such as copper, aluminium and brass, requires more complex refining and separation processes. However, not everything that remains after shredding can be put to immediate use. As a matter of fact, the treatment generates a light fraction called car fluff (or Automotive Shredder Residue – ASR), consisting of plastics, fibres, foams, rubber residues and small metal particles, which, due to its heterogeneous composition, is one of the main obstacles to reaching the recovery targets imposed by regulations.

In recent years, the evolution of technologies has made it possible to valorise this fraction as well, recovering additional quantities of metals and reducing the amount going to landfill. Solutions such as high-efficiency refining, densimetric and eddy-current separation, and even pyrolysis or energy recovery processes are transforming car fluff from complex waste to  a complementary resource in the recycling process.

In parallel, the increase of electronic components and composite materials in modern cars makes it increasingly important to have processing systems capable of precisely handling mixed materials, cables, motors and technical plastics, ensuring selective separation and the maximum purity of the recovered metals.

The environmental and economic value of ELV recycling

Recycling a car is not just about reducing waste, but regenerating value and resources. Every tonne of recovered steel or aluminium saves large amounts of energy and reduces CO₂ emissions compared to production from virgin raw material, thus making a tangible contribution to a more sustainable industry. In Europe, around 90% of materials from end-of-life vehicles are nowadays reused or recycled, an achievement that testifies to technological progress and the increasing focus on the circular economy. In addition to its environmental benefits, the car recycling sector generates skilled employment, stimulates the search for new solutions, and fosters the creation of supply chains for metal recovery and the production of secondary raw materials, which are increasingly key to the competitiveness of the European industry.

Industry trends and challenges

According to some estimates, the ELV recycling market was globally worth around $27.5 billion in 2023, with an expected growth of 6-7% per year until 2032. A dynamic and fast-moving sector, driven by three converging forces: technological evolution, energy transition and regulatory pressure. In this scenario, ELV recycling is no longer an end-of-supply chain activity, but an integral part of the industrial strategy of the automotive sector, now at the core of new trends and challenges that will define its future.

TRANSITION TO AN ELECTRIC VEHICLE FLEET
With more than 14 million electric vehicles registered in 2023, the sector faces new challenges related to the management of complex components such as high-voltage batteries, permanent magnets and critical materials such as lithium, cobalt and rare earths. These elements require targeted processes of securing, treatment and selective recovery, capable of combining sustainability and profitability.

AUTOMATION AND DIGITALISATION
The heart of innovation is increasingly moving towards smart process management in new-generation systems, advanced sensor technology, machine vision and real-time data analysis enable optimisation at every stage of treatment. The data-driven logic improves the quality of recovered metals and reduces error margins, paving the way for a more precise, efficient and measurable recycling model.

TOWARDS A ZERO WASTE LOGIC
The concept of zero waste is gradually replacing the linear view of recycling with a more circular concept, in which each vehicle component is recovered. This integrated approach requires increasingly close collaboration between system manufacturers, recycling operators and industries using secondary raw materials.

COPPER AND ALUMINIUM AT THE CORE OF THE TRANSITION
At the same time, global demand is growing for recycled aluminium and copper, central materials for electric mobility and sustainable industrial production. Europe, in particular, is aiming to become more autonomous in finding these resources, favouring investments and innovations that can make ELV recycling a strategic cornerstone of the circular industry.

Panizzolo solutions for the treatment of vehicle materials

In light of these dynamics, Panizzolo solutions offer a tangible contribution to the treatment and recovery of materials from end-of-life vehicles, combining high production performance, reduced management costs and ease of use.

The technologies embedded in our systems enable the acceleration of the metal recovery stages, guaranteeing flexibility in processing and the high quality of ferrous and non-ferrous metal output. The final recovery of ASR is completed through the refining end-of-waste, cycle process, fully compliant with environmental regulations and geared towards maximum economic yield, with an output suitable for direct sale to smelters. The treatment lines offer a productivity ranging from 7 to 35 tonnes/hour and can handle different types of materials, including end-of-life vehicles, car packs, car engines and ASR. Thanks to a modular design and established know-how, each system can be adapted to the operational needs of the customer, with a view to maximising recovery and investment. An approach that combines innovation, efficiency and sustainability, turning what was once waste into a valuable industrial resource.

Energy efficiency has become one of the key benchmarks in the assessment of plant performance. Not only because it does have a direct bearing on operating costs, but also because it reflects a company’s ability to adapt, innovate and compete. However, it is no longer just an environmental issue, but a core issue to ensure the economic sustainability of businesses. This is particularly true for the metal treatment and recycling industry, where energy consumption has a direct impact on profitability and competitiveness.

Today, businesses are required to tackle two parallel pressures. On the one hand, the energy cost, subject to strong fluctuations, significantly impacts operating margins. On the other hand, European and international environmental regulations are pushing for a tangible ecological transition, based on traceable processes, reduced emissions, and optimized consumption. Against this backdrop, energy efficiency is the most effective response to both challenges.

Energy-intensive plants vs. optimised plants

In the metal recycling sector, the difference between an energy-intensive plant and an optimised one does not only concern power consumption, but the entire production logic. Older systems tend to require consistently high power, regardless of the type of material being processed. This leads not only to significant energy waste, but also to greater wear and tear on mechanical components, rough control of operating parameters, and generally lower productivity.

On the contrary, a system designed according to efficiency criteria can adjust the absorbed power to the actual load, ensuring process stability and energy consumption proportionate to yield. The adoption of high efficiency motors, intelligent inverters, modular configurations and monitoring systems makes it possible for you to take action on the progress of the system in real time by optimizing each phase and reducing both operating costs and environmental impact.

In a direct comparison, the difference between the two models is reflected in numbers: with the same number of tons treated, an optimised plant can generate significant energy savings, increase hourly productivity and ensure more consistent, exploitable output. Choosing modern technologies does not just mean upgrading a machine but rethinking the production cycle with a view to greater overall efficiency.

The numbers of efficiency

Metal recycling is, in itself, a virtuous choice from an environmental point of view. However, it is energy efficiency that establishes its real impact. Some data help to understand the scope of this opportunity. When it comes to aluminium, for instance, recycling makes it possible to save up to 95% of energy compared to primary production. Producing one ton of aluminium from bauxite requires over 51,700 kWh, whereas just 2,300 kWh are required through recycling.

Even for steel, advantages are significant. The estimated energy savings compared to production from iron ore vary between 60% and 74%. On an environmental level, recycling one ton of steel prevents us from mining over one ton of iron ore, thus curbing air pollution by up to 86%, water pollution by 76%, and saving water by as much as 40% with respect to primary production.

Efficiency in economic terms

In addition to the obvious environmental benefits, energy efficiency is a pivotal element for the economic sustainability of businesses. Energy consumption is one of the main cost items in the daily management of a plant. As already highlighted, an obsolete machine consumes more, requires more maintenance and produces less efficiently, thereby adversely impacting overall margins.

Investing in efficient systems means reducing operating costs, increasing productivity per kilowatt hour consumed and improving return on investment. Furthermore, energy efficiency grants access to tenders and public funding, which are increasingly allocated to the benefit of ecological transition projects. In a scenario where ESG criteria become a discriminating element in purchasing decisions and supplier selection, efficiency also becomes a competitive advantage in business and reputation terms.

Technology, strategy and positioning

Choosing efficient technologies, therefore, is no longer just a technical or environmental issue – it is also a strategic decision. Companies that embrace modern solutions, capable of combining high performance and low energy impact, develop a strong positioning strategy in the most advanced markets. In international B2B relationships in particular, energy efficiency is key to being perceived as reliable, sustainable and innovation-oriented suppliers.

Cutting down on consumption means being more resilient against energy price increases and more flexible in production cycle management. Not only that. Also responding to the expectations of customers who are increasingly sensitive to the issue of sustainability and looking for partners who can support environmental and safety goals as well as reduce the carbon footprint.

Panizzolo’s approach to energy efficiency

Truly achieving energy efficiency requires an integrated approach. It is not enough to take action on single process stages, but it is necessary to reappraise the entire plant based on technologies, materials treated and production targets.

It is along these lines that Panizzolo’s solutions fit in: a complete range of scrap grinding, sorting and refining plants, designed to maximize performance while minimizing consumption. Highly efficient components, intelligent software and real-time control systems enable to optimize every treatment stage, thereby ensuring operational continuity even with mixed or complex materials. Modular configurations also allow the system to be sized according to actual requirements without oversizing and waste. To complete the offer, a customised technical consultancy service supports the customer in the production cycle design and optimization, with a view to combining energy efficiency, environmental sustainability and economic return.

This approach enables us to transform efficiency into a tangible value by making each plant not only more efficient, but also more competitive, resilient and capable of generating long-term value.

In a recycling sector increasingly characterized by complex flows and growing material volumes, it is essential to adopt solutions that guarantee reliable performance and operational continuity from the early stages of processing. It is precisely from this need that Kraken was developed, the series of industrial pre-shredders Panizzolo dedicated to the volumetric reduction of the most challenging scrap. The series debuts with the PSH 2300 model and will soon be expanded with other versions created for different production capacities and plant engineering requirements.

In this interview, Mauro Panizzolo, Owner and Sales Manager, gives us a closer look at the new project, exploring its strengths, challenges, and strategic objectives. But before getting into the heart of the article, here’s a short video in which Mattia Molena, Marketing Manager, introduces the Kraken series, illustrating its main advantages and application context.

Kraken represents an important innovation in your range. What are the design premises of this new series?

The Kraken series was born from a double need: on the one hand to complete our offer with a dedicated pre-shredding solution that can be integrated with Mega hammer mills and matched to their performance; on the other hand, we want to meet the increasing demand from our customers: robust technology that ensures effective volume reduction and consistent flow to the next stages of the line. With the introduction of the new series, we expand our capacity to follow the entire process, from pre-shredding to refining. It is a solution that further strengthens the value of our approach: offering not only machinery, but an integrated technological system, built on concrete challenges and needs.

What materials can the Kraken series handle?

The pre-shredder was developed for the processing of high-impact scrap metal. Its robust structure, the 630-kW motor and a total weight of 95 tons allow to manage a wide range of materials: vehicles and car bales also complete with engine and mechanical parts, aluminium profiles, mixed ferrous scrap and bulky material. It is designed for those who work in high-capacity plants, where there is no room for machine downtime.

One of the most interesting aspects are the gear shafts. What differentiates them?

Behind the performance of the Kraken series is very in-depth interior design work, starting right from the gear shafts. We studied a specific geometry and configuration to obtain precise and controlled tearing, capable of reducing the material in a single pass. This ensures a regular flow towards the mill, maximizing the energy efficiency and minimizing mechanical stress on downstream machines.

Now let’s talk about maintenance and durability. How did you address these aspects?

Durability and the simplicity of intervention. These were two key points in the design, in line with our construction philosophy. The pre-shredder is equipped with a shaft quick release system, which allows the replacement of components subject to wear in reduced times. The bearing supports are also designed to protect mechanical parts from dust and contaminants, ensuring continuity even in harsh environments.
Added to all this is a compact and functional configuration: the electrical panel and hydraulic power unit are placed in dedicated containers, a choice that simplifies transport, installation and start-up, with maximum logistical flexibility also for existing systems.

And in terms of security, how does the Kraken pre-shredder perform?

We developed the new series with particular attention to safety in real-world contexts of use. The pre-shredder is capable of processing potentially critical components, such as cylinders or tanks, opening them and removing any residual gas or flammable liquids. This is a fundamental function, especially when dealing with mixed scrap where the content of the input is not always predictable. In this way you reduce the risk of explosions, failures or damage to downstream machinery, helping to make the entire plant safer and more stable.

Construction quality has always been an essential aspect of the Panizzolo approach. How does this translate to the Kraken project?

In this case too we have rigorously applied our Quality Policy: certified metalwork, reinforced welding and selected components from internationally recognized Italian and Northern European suppliers.
A concrete example are the planetary gearboxes, a top-of-the-range solution chosen for their ability to withstand extreme loads and work continuously even in critical operating conditions. This approach, oriented towards maximum quality, translates into a reliable solution, durable and high-performance, with optimised operating costs and a return on investment that consolidates in the long term.

Control software plays an important role in managing manufacturing processes. How was it designed?

The Kraken series control system is intelligent and flexible. Operators can choose from preset recipes or create custom configurations depending on the material. This makes it possible to optimize consumption, reduce mechanical stress and better manage the production cycle, even in the most dynamic contexts.

The Kraken pre-shredder is part of a major project in the United Arab Emirates. What is this project about?

The new solution is one of the key elements of the system we are building for Emirates Global Aluminum (EGA), one of the world’s leading producers of aluminium. We are talking about a large-scale project: it will be the largest plant of its kind in the United Arab Emirates, with a processing capacity of up to 170,000 tons of scrap per year. It is a strategic stage in the roadmap of decarbonization by EGA, designed to produce high-quality, low-emission secondary aluminium. For us it is much more than a simple supply: it is a technological collaboration at the highest level which consolidates our role as strategic partner for the development of plants that meet global environmental challenges.

In a world racing towards ever more ambitious sustainability goals, aluminium recycling has become a strategic asset for the future of the industry, thanks to its properties of lightness, strength and, above all, infinite recyclability.

One of the most significant benefits concerns energy savings: according to the International Aluminium Institute, recycling aluminium saves up to 95% of energy compared to production from virgin raw material. It is also estimated that the recycling of post-consumer scrap avoids the production of about 20 million tonnes of primary aluminium each year, contributing to the reduction of about 300 million tonnes of CO₂.

It is no coincidence that aluminium is considered one of the strategic materials to achieve the targets set by the European Green Deal, as well as the decarbonisation goals of the world’s major economies. The focus is increasingly shifting towards secondary metals, key resources to fuel production processes while minimising emissions.

Recycling as an economic lever

Aluminium recycling is not only a virtuous choice from an environmental point of view, but represents a concrete opportunity for growth and competitiveness for companies. Using quality secondary raw materials means significantly lowering energy and operating costs compared to the extraction and processing of bauxite. Furthermore, by reducing dependence on virgin raw materials, companies become less exposed to global price fluctuations and geopolitical risks. The result is more sustainable, resilient and cost-effective production, in line with the expectations of an increasingly ESG-conscious market.

Efficient technologies for the future of recycling

In this scenario, the main challenge is to increase investments in the technological innovation of recycling processes. It is with this in mind that we design our plants, developing tailor-made solutions that maximise the recovery of secondary raw materials, optimise costs and increase process profitability. Every day we speak with different production companies, each with specific needs and complexities to deal with. This direct experience guides our design approach, turning customers’ operational challenges into strengths that make each system efficient, flexible and result-oriented.

PROCESSING FLEXIBILITY
Our plants are designed to handle a wide range of aluminium scrap, from window and door profiles from demolition work to car casings, and even aluminium packs and mixed casings. The integration of patented components, such as the interchangeable cradle, allows our solutions to easily adapt to different markets, companies and application contexts.

MODULAR AND SCALABLE SOLUTIONS
Thanks to a customised approach, our systems can meet the needs of companies of all sizes, all of which share a quest for quality, performance and profitability. Each plant is designed to be modular and grow with the company, following the evolution of production needs. A real advantage for optimising initial costs and planning future investments with greater flexibility.

HIGH PRODUCTIVITY
A key element of Panizzolo’s aluminium plants are the Mega and Flex series hammer mills, designed to offer superior performance in terms of productivity and efficiency. The Mega series, for example, can process up to 2.2 times the amount of material compared to the market standard, ensuring operational continuity and resistance to even the most demanding workloads.

OUTPUT QUALITY
Our systems integrate grinding, separation and refining technologies to achieve total recovery of secondary raw materials, with high purity output suitable for direct remelting and reintroduction into the economic cycle. This translates into higher value per tonne and the ability to satisfy even the most demanding segments of the metal industry.

Panizzolo and EGA, a partnership for the largest aluminium recycling plant in the Emirates

The drive towards more sustainable production processes is redefining the aluminium industry’s strategies and more and more companies are investing in advanced equipment to create value in a sustainable way. It is in this scenario that the collaboration with Emirates Global Aluminium (EGA) fits in.

EGA, one of the world’s largest aluminium producers, has started construction of the largest aluminium recycling plant in the United Arab Emirates, with a planned production capacity of 170,000 tonnes per year. An initiative that represents a fundamental step in the group’s decarbonisation strategy and a clear signal of transition towards a circular economy.

Our technology is at the heart of this strategic project: from processing solutions to the definition of flow logic, integration between machines and the overall organisation of the production cycle. The result will help ensure an efficient recycling process capable of producing high-quality, low-carbon aluminium, marketed by EGA under the RevivAL brand.

Underlining the importance of the project were the words of Abdulnasser Bin Kalban, CEO of EGA:

“Recycling is a major growth opportunity for our industry and for EGA. With the construction of this plant, we have taken decisive steps to develop a global recycling business. The facility will allow us to expand our low-emission metal portfolio for local and international customers, representing a new milestone for the ‘Make it in the Emirates’ programme.”

EGA’s vision aligns perfectly with our mission and future perspective: to offer solutions that innovate recovery processes, making them more efficient and profitable. In this way, we support companies on their path to sustainable growth, helping to generate lasting value.
In the coming months we will be going into more detail on this project, which confirms our commitment to designing solutions geared towards the ecological transition.

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.