In scrap metal processing, the real difference today lies not only in performance, but in the ability to design flexible systems, ready to evolve over time. Variable volumes, heterogeneous materials and ever-changing markets require a new approach: the system can no longer be a static solution, but must be capable of adapting and generating value in the long term.

This is the context in which we developed the new project for Metfer S.r.l., a historic Italian company specializing in the management, transport, and trade of scrap metal.

In the following video, Mattia Molena, Marketing Manager, and Francesco Ruggiero, Head of Automation Design, take a closer look at the design choices and technologies that characterise the new plant.

A collaboration that evolves over time

Founded in 1992 by Michele Montrone, continuing the business started by his father in 1973, Metfer is now part of a group with several operational sites in Friuli-Venezia Giulia and a consolidated presence in Italy and abroad. The company specializes in the processing of mixed metals and electric motors, a sector that requires robust, versatile and highly controllable systems.

Our collaboration does not begin today: Metfer already had a plant equipped with a Flex 1000 Mobile hammer mill, which made a concrete contribution to the expansion of the business. As production requirements evolved, the need to take a further step forward arose naturally. Hence the decision to choose us again as a partner to develop a system upgrade oriented towards higher performance and a long-term vision.

Not just productivity: the importance of monitoring

The new system stemmed from two very specific needs: to increase productivity and introduce a structured yield monitoring system capable of providing continuous and objective data on system performance. In the processing of mixed metals and electric motors, profitability depends not only on the volumes processed, but on the ability to extract value from each batch. Without precise control of yields and process parameters, the return on investment remains partly theoretical and difficult to measure. As Diego Montrone, co-owner of Metfer, points out:

“Growth today is linked to understanding and controlling the process: only in this way is it possible to understand where value is generated and how we can make processing more efficient.”

Having a clear view of performance means being able to identify inefficiencies, guide operational choices, and work towards continuous improvement. In this sense, process control becomes crucial to transforming the investment into measurable and sustainable value over time, supporting decisions based on concrete data.

The key role of grinding

The heart of the line is the Mega hammer mill, chosen for its high performance and the strategic role that grinding plays within the treatment cycle. Often underestimated, this phase is the crucial moment where the quality of the entire process is decided. Effective grinding is, in fact, essential to ensuring proper scrap preparation, improving not only the overall efficiency of the system, but also the quality of the output material and the stability of the process over time. The system also includes a selection and separation area, designed to maximize the mill’s performance and already prepared for future technological upgrades.

Prisma: for advanced process management

With the Metfer project, the real qualitative leap concerns not only performance, but the very way the treatment is managed. A distinctive feature of the new system is the integration of Prisma, the software we developed internally to offer structured and centralized process control. The system builds on our direct experience in plant management and is now applied on an industrial scale. Prisma collects and integrates information from machinery, electrical panels, scales, and control systems into a single interface. All data is recorded and logged, allowing operators to analyse performance over time, identify inefficiencies and intervene more precisely in the event of anomalies.

Advanced batch management lies at the heart of the system. For each process, operational parameters, yields and energy consumption are recorded, directly linking technical performance and economic results. Data is no longer just a figure, but becomes a practical tool for controlling quality, efficiency and profitability. As highlighted by Francesco Ruggiero, Head of Automation Design at Panizzolo:

“Technical data thus becomes a concrete tool for controlling production, quality, and profitability, allowing for the precise measurement of process efficiency and return on investment. Prisma does not just describe what happens, it helps the company guide improvement interventions and objectively evaluate the economic sustainability of various processes.”

In this way, the process is no longer based solely on experience, but on objective and continuously updated information, which supports operational and strategic decisions. At the same time, complete traceability of processes improves energy efficiency, reduces waste, and opens up new opportunities, such as the structured management of third-party activities.

Systems designed to evolve

The Metfer project demonstrates how today’s system design must go beyond responding to an immediate need. Each system is required to operate in a constantly changing landscape, where materials, volumes, and demands are ever-evolving. For this reason, supporting the customer means providing not only technology, but also experience and tools capable of supporting informed decisions throughout the system’s life cycle.
As Mauro Panizzolo, owner and Sales Manager, points out:

“Designing a system means thinking about how it will evolve, not just how it needs to function today. Our goal is to support customers on their growth path, building solutions that maintain value over time.”

This vision translates into systems designed to adapt to new production objectives, progressively integrating additional features, while maintaining efficiency and reliability. An investment-protecting approach reduces the risk of obsolescence and allows the company to grow without disrupting its infrastructure.
Thanks to this approach, Metfer now has a solid, high-performance solution ready to meet the challenges of a complex market. A project that reflects our philosophy: to develop systems capable of evolving and generating lasting value.