Rotary shear (VR) - Twin-shaft shredder for the rough work

Rotary shear


Rotary Shear – Robust and versatile heavy-duty twin-shaft shredder

The BHS rotary shear of type VR is a low-speed, high-torque twin-shaft shredder for the shredding of large, bulky waste materials or elastic feed material. Our inert design variant of the rotary shear (VR) is mainly used in battery recycling for the safe pre-shredding of bulky battery modules or packs. In addition, the inert design variant can also be used for the safe shredding of toxic waste materials, from which a pumpable mass is produced in SMP plants for subsequent thermal utilization. It also reduces large-volume input materials as well as parts with high unit weights. The rotary shear reliably achieves superior shredding performance.

Benefits at a glance:

  • On-target shredding results
  • Inert design for safe shredding processes
  • High throughput rate
  • Easy-to-replace wear parts
  • Suitable for continuous operation

Inertizable designs for absolute process safety

When shredding and processing potentially hazardous materials such as batteries or toxic waste, it is necessary to inert  the working chamber to prevent fires, explosions, hazardous gas leaks, or chemical reactions. For process reliability in processing these problematic materials under a protective atmosphere, BHS offers the rotary shear in an appropriate, inert design. 

In the BHS process solution for the safe and economical recycling of lithium-ion batteries, the inert design is an integral part of a battery recycling plant for the safe pre-shredding of bulky battery modules or battery packs.

On-target shredding results

  • Reliable shredding to the desired granulation
  • Uniform material density

Clean and consistent cutting quality

  • Precision-made blades with narrow tolerances
  • Easy-to-replace blades
  • Long blade life thanks to special hardening method

Low operating costs

  • Wear parts can be reconditioned and reused several times
  • Inexpensive to replace set of shearing shafts

High system availability

  • Long-lasting wear parts
  • Patented bearing shell bridge system for fast and simple replacement of shearing shafts

    High throughput rates

    • High-torque drive
    • High hourly output thanks to optimized geometry of shearing tools
    • Ready for use in three-shift operation


    • Disaggregation of a large number of input materials
    • Tearing tools can reliably process even voluminous or bulky feed material due to relatively large shaft diameters
    • Optional push-in unit

    One-piece machine housing

    • Heavy duty thanks to single-piece, welded steel construction
    • No screw connections which are prone to causing malfunctions
    • Long machine life

    Torque buffering

    • Improved operational reliability
    • Prevents damage


    Optimized cutting and shredding

    Two counter-rotating shear shafts grasp and shred the input material. Each shaft is equipped with several high-precision cutting tools that function like scissors. There are gripping hooks at the tip of each tool that guarantee fast and reliable material infeed. Scrapers are placed on the outside of the shaft to prevent material from sticking. The piece size of the final product is affected depending on the cutting blade width.

    [1] Infeed hopper

    The machine is equipped with a large, central infeed hopper. In addition to standard solutions, customer-specific hoppers are also available.

    [2] Machine housing

    The machine housing is designed as a highly robust, one-piece, welded steel construction. This allows the machine to absorb extremely high forces without difficulty.

    [3] Rotor with shearing tools

    The material is shredded between two rotor shafts rotating in opposite directions towards the center. The shearing tools are specially positioned on the rotor shafts to ensure a high crushing performance.

    [4] Scrapers

    The scrapers are attached to the side walls of the machine housing and reach in between the shearing discs. They prevent material from adhering to and building up on the rotating shear discs. If discs wear out, each one can be replaced individually.

    [5] Drive

    Every shaft is powered independently. The drive consists of a spur gear and an electric motor from well-known manufacturers. In case of an overload, the drive allows the shearing disc to be retracted by changing the direction of rotation.

    [6] Torque buffering

    As a standard feature, each drive unit is protected by large torque buffers. Every buffer unit consists of four solid rubber elements mounted to a robust welded steel structure.

    [7] Hydraulic Pusher Unit

    A hydraulic pusher device is available as an option. It ensures continuous material infeed when processing low-density, light or bulky feed stock.

    Frequency Inverter

    The machine can optionally be equipped with an electronic frequency inverter. This allows the speed to be adapted to individual process conditions and prevents the generation of costly peak currents.

    Quick changing system

    Quick changing system

    Quick changing system

    The shear shafts’ quick-change system consists of a specially designed quick coupling located between the shear shaft and the gearbox and a patented bearing shell bridge. The quick coupling is screw-fastened and makes shaft changing possible without having to disassemble the drive system. The bearing shell bridge can be easily removed. Once this is done, it is then possible to remove the shear shafts by lifting them up.


    Two rotor shafts, which rotate in opposite directions towards the center and collect the input material, are enclosed in a heavy-duty housing. Each shaft is equipped with several high-precision cutting tools that function like scissors. There are gripping hooks at the tip of each tool that ensure fast and reliable material infeed. The hydraulic pressure unit can be used to assist as needed in individual cases. Scrapers are placed on the outside of the shaft to prevent material from sticking to the rotating cutting tools. The particle size of the end product greatly depends on the width of the selected cutting blade.

    Technical specifications

    Performance data
    TYPEDrive powerRotor speed (max.)Rotor diameter x lengthNumber of cutting toolsWidth of cutting tools
    VR 09122 x 55 kW18 rpm480 x 1.200 mm12 per shaft50 mm
    VR 12152 x 90 kW18 rpm530 x 1.500 mm13 per shaft58 mm
    VR 15182 x 160 kW11 rpm730 x 1.800 mm11 per shaft80 mm

    All specifications apply to the standard design. Technical data for customized designs may differ from the specified data. All technical data may change due to development. Subject to modification without notice. 

    Dimensions & weights
    TYPEABCDEFGShredding chamber length x widthWeight
    VR 09125.200 mm2.200 mm4.000 mm1.500 mm2.500 mm2.300 mm1.500 mm1.200 x 900 mm14 ton
    VR 12155.500 mm2.500 mm4.200 mm1.500 mm2.800 mm2.500 mm1.500 mm1.500 x 1.200 mm22 ton
    VR 15187.600 mm3.000 mm4.800 mm1.500 mm2.900 mm2.800 mm1.500 mm1.800 x 1.500 mm40 ton


    "Rotary Shear (VR)" product flyer
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    Tests give certainty

    Which technical solution is the right one for your recycling process? Don’t leave anything to chance. Our team of specialists will test your material at our test center and develop a solution tailored to your specific needs.

    E-Waste World | Metal Recycling | Battery Recycling - Conference & Expo 2024

    06/26/2024 - 06/27/2024 | Frankfurt am Main (Germany)

    ICBR 2024 - International Congress for Battery Recycling

    09/10/2024 - 09/12/2024 | Basel (Switzerland)

    IFAT India 2024

    10/17/2024 - 10/19/2024 | Delhi (India)

    Technical articles in the media

    Safe long-term investment: BHS-Sonthofen receives order for BASF battery recycling plant

    August 2023

    BHS-Sonthofen is supplying BASF with a complete line for the mechanical reprocessing of lithium-ion batteries into black mass. This marks the third large-scale plant for BHS, with the first one having operated successfully for over a year. As a result, customers can benefit from the combined experience and know-how of this machinery and plant manufacturer from the South German Allgäu region, providing them with increased investment security.

    recovery 04 | 2023

    Recovering valuable materials - Safely avoiding hazards during the recycling of lithium-ion batteries

    December 2020
    BHS-Sonthofen is refining their innovative process for the recycling of spent batteries. It reliably prevents fires and the release of hazardous gases, as the crusher process is kept gas-tight all the way until the dryer, which is where the electrolytes are evaporated. This process is suitable for automobile batteries as well as lithium-ion and other household batteries. The resulting products are ready to be sold.
    recovery 06 | 2020

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