Optimal process residual fractions from Automotive Shredder Residue (ASR)

Optimum recycling of any material

Residual shredder fractions consist of a mixture of recyclable materials. To recover them, the input material must first be shredded. Shredder light fractions (SLF) and shredder heavy fractions (SHF) are generated in phase one. These will have very different compositions based on the input material. Both require compatible process technology in order to extract the valuable materials they contain. As one of the pioneers in residual shredder fraction and material processing, BHS-Sonthofen offers optimal solutions for both fractions.

Benefits at a glance:

  • Excellent selectivity
  • High throughput rates
  • Inexpensive to operate; low energy/wear and tear costs
  • Tried and trusted technology
  • Fully automatic operation possible
  • Many references available
  • European market leader in the processing of fine fractions

Having the right technical system is critical for handling both heavy and light materials

When it comes to processing SHF and, more specifically, SLF, recycling plant operators are required to comply with increasingly strict legal regulations. This applies in particular to how shredder residues contaminated with hazardous substances need to be handled. Against this backdrop, it is all the more important to separate 100% of all recyclable raw materials, not least because this also increases the profitability of recycling. BHS experts will recommend the right system and optimum configuration for any shredding application. Whether you are talking about a single machine or the technical design of an entire plant, the solutions we develop for individual applications are tested at our in-house test center.

Shredder light fraction (SLF)

Shredder light fraction (SLF)

Suction is applied in the large shredder’s working chamber to separate the SLF from the SFF. It is not possible to immediately sort the SLF without further mechanical processing due to affinity (the metal particles adhere to other components).

The rotor shredder (type RS) is used to separate composites comprised of multiple materials, some of which are highly entangled. The residual fraction can then be further separated into mineral and organic components. The rotor impact mill (type RPMV) is particularly well suited for the processing of grain sizes of up to approx. 25 mm. It shapes the metallic components into pellets. This makes it possible to readily separate metal fractions from the remaining material in the next step. Components larger than 25 mm in size are processed in the universal shredder (NGU)

Shredder heavy fraction (SHF)

Shredder heavy fraction (SHF)

Shredder heavy fraction (SHF) contains a number of valuable raw materials (metals). The largest share is comprised of aluminum at up to 30%, followed by heavy metals (such as copper, lead, zinc and stainless steel) at up to 20%. The rest is made up of rubber, plastics and mineral components.

In the case of smaller screen fractions of under 25 mm, the metal yield can be increased using BHS technology. The rotor impact mill (type RPMV) cleans and pelletizes the metals. In addition, mineral components are pulverized, which acts to break down the adhesion limits. As a result, the metal fractions can be more effectively recovered during the subsequent separation process.

Efficiently processing shredder fractions


Efficiently processing shredder fractions

The BHS rotor impact mill is a high-performance crusher with a vertical shaft that addresses the needs of the recycling industry. The mill’s unique impeller rotor works together with a toothed anvil ring to subject the inserted material to severe mechanical stress. Material compounds are crushed and separated selectively, entangled materials are isolated, and brittle-hard materials are crushed very finely. At the same time, metals are shaped into balls and cleaned. Watch the video to find out how to optimally prepare shredder fractions for separation by disaggregating composite material and pelletizing metals with the RPMX rotor impact mill.

Machine portfolio

Rotorshredder (RS)

The Rotorshredder (RS) can do it all! Optimally shreds, separates and disaggregates valuable and residual metaliferous waste materials.

Rotor impact mill (RPMV & RPMX)

Ball shaper operating based on unique crushing principle

Universal Shredder (NGU)

Continuous high-performance crusher for all cutting-related applications

Brochure of the "Recycling Technology" business unit
"Fine treatment for optimal metal recovery" application 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.

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Success stories

Recycling company in the UK relies on plant technology from BHS to process ASR fractions, electronic scrap and meatballs

May 2020
A British company commissioned a recycling plant that was planned and implemented by BHS. The plant is designed to handle a variety of materials such as automotive shredder residue (ASR) fractions, electronic scrap and so-called “meatballs” (electric motors and motor armatures). The process developed together with the company is based on a profitability analysis and ensures marketable end products.

Less wear for economically efficient processing of ASR

March 2019
Since March 2019, a BHS-Sonthofen rotor impact mill (type RPMX) has been in operation at Jansen Shredder Recycling BV in Moerdijk, the Netherlands, for the fine processing of automotive shredder residues (ASR). Thanks to years of experience in the processing of metal-bearing waste materials, the experts from Sonthofen found the optimal solution for processing abrasive materials. Wear costs at Jansen have significantly decreased since.

Plant for recycling automotive shredder residues (ASR) in Finland.

July 2017
Kajaanin Romu Oy operates one of Finland’s most cutting-edge plants for recycling scrap in the town of Kajaani, located approximately 500 km northeast of Helsinki. The company commissioned a BHS-Sonthofen plant for processing automotive shredder residue (ASR) fine fractions of particle sizes between 0 and 30 mm. It separates the feed material abundant with valuable metals into ‘light’ and ‘heavy’ fractions in a single pass. This allows the plant operators to economically produce fractions that can be sold profitably. Moreover, the plant significantly reduces the cost of material disposal at landfills.

Don’t let valuables end up at the dump!

January 2016
A metric ton can contain up to 20 grams of gold and up to 200 to 300 grams of silver, as well as platinum and other precious and non-ferrous metals. Heavy non-ferrous fractions of material left over after shredding and processing large automotive, electrical or electronic scrap components still hold a lot of value. Previously, the recyclable materials were deposited in landfills. Based on our unique process, BHS-Sonthofen processing plants can recover these metals.

Customized recovery | Recovery of metallic fines from ASR

February 2023

The recovery of metallic fines from ASR requires a customized approach. Auto shredder residue (ASR), fines from shredded electrical and electronic equipment and waste incinerator bottom ash all have one thing in common: They contain valuable metals that are worth recovering. Therefore, processing these fine materials is of high importance.

recycling today scrap recycling | Winter 2023 | Supplement to recycling today

Recuperación de metales valiosos: alto rendimiento para un procesamiento fino mejorado

August 2022

BHS optimiza la calidad de su molino de impacto de rotor con un nuevo diseno de martillo. AMBISORT Circular ofrece siempre procesos novedosos y de alto valor añadido para el sector del reciclaje. Un destacado ejemplo es la recuperación de valiosos concentrados de metales a partir de varios composites y desechos industriales, que sin duda es todo un desafío técnico.

RETEMA 07/08-2022

BHS fine treatment process recovers valuable metals from residual materials

July 2022

There is currently no way around the issue of resource saving but how can valuable materials can be recycled in the best possible way? Metals in particular are considered important scarce raw materials whose recovery is essential for the sustainable use of resources. BHS-Sonthofen offers an effective solution for metalliferous residues with a size of up to 25 mm.

recovery 04-2022

Recycling company in United Kingdom processes ASR fractions and electronic scrap using the BHS Rotorshredder

February 2022

British recycling specialists Recycling Lives commissioned a recycling plant that was planned and implemented by BHS-Sonthofen. The plant is designed to handle a variety of materials such as automotive shredder residue (ASR), electric and electronic scrap (WEEE), as well as so-called "meatballs" (electric motors and motor armatures). The process developed together with the company is based on a profitablity analysis and ensures marketable end products.


June 2020
recycling today June 22, 2020

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