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NEWS
September 2012
Refrigerator recycling in Serbia
Newsletter for customers and employees
MeWa plant
officially opened
in Niš
>>> Page 6
The topics:
Metal cleaning:
QZ now hard at work
in Portugal
>>> Page 2
Copper recycling:
Turkey swaps copper cable
for fibre optic cable
>>> Page 4
Sprung mattresses:
Steel and textile recycling
in Bad Essen
>>> Page 8

2
Metal recycling
Stripped down twice:
One QZ
with two jobs
It‘s its versatility that makes it so valuable. In Portugal,
the MeWa Querstromzerspaner QZ now also strips
From left to right: José Manuel Teixeira,
Alain Schröder and Paulo Lourenco.
down old electrical devices and
at the same time cleans the
ferrous metals that stem from
other waste flows. The result is
perfect utilisation of the plant.
The Portuguese company Transucatas
has its origins in metal recycling,
with several sites across Portugal.
With its expansion in recent years, plants
for recycling tyres and various industrial waste
products have also been added. Transucatas
also uses turn-key MeWa plants with
pre-granulation, granulation and separating
technology to produce homogeneous
substitute fuels in defined grain sizes from
mixed industrial waste.
In these plant types, a magnetic separator
removes the ferrous metals from
the material flow after pre-granulation.
However, there are often still plastic films
and textiles attached to the sharp-edged
wires and metal profiles. This significantly
impairs the intrinsic value of the metal
fraction. Further processing of the metals
is therefore recommended.
Transucatas has now implemented
a solution in Maia, near Porto, which is
trend-setting in two ways: Recently, the
company also started recycling electronic
scrap and in doing so drafted a plant plan
together with MeWa and the Portuguese
MeWa sales partner Gruman, which can
strip down electronic scrap and also separate
metals from different origins.
With the MeWa QZ 2000 HD Querstromzerspaner,
it is possible to meet all
the requirements of the European WEEE
directive regarding environmentally friendly
recycling of waste electrical and electronic
equipment and, at the same time,
guarantee highly economical utilisation
of the plant.
Chains instead of knives
This is primarily due to the recycling
principle of the patented MeWa machine.
In contrast to shredding plants, which
are operated in Portugal too by competitor
companies, the QZ Querstromzerspaner
does not rely on cutting tools. Instead,
chains, which are fitted to the floor
of a tank, accelerate the material at high
speeds. The reciprocal physical stress and
the impact against the drum wall cause
the material to break down. And it does
this in a gentle manner. Large parts break
up, but small parts exit the outlet opening
of the machine intact.
Looks like plastic waste... ...but is 70% ferrous metal.
Metal recycling
This principle is particularly beneficial
for electrical equipment. Environmentally
harmful parts, such as batteries and capacitors,
remain undamaged. At the same
time, plastic housings, transformers, aluminium
components, computer PCBs and
other components are separated. The metals
incorporated in shafts and electric motors,
for example, present no obstacle to
the Querstromzerspaner. The wear costs
are minimal compared to those of shredder
plants, and contamination due to destroyed
capacitors and batteries is not a
problem.
The plant in Maia takes full advantage
of these benefits. In addition to electrical
scrap, metal separator fractions can be dispatched
in the QZ. Plastics and textiles separate
from the metals and lie freely on the
evacuation conveyor ready for subsequent
sorting. After the Querstromzerspaner, the
material runs through various classification
and separating technologies as well as Fe/
NFe separation. A downstream sorting cabin
is used for quality assurance. At the
end, the fractions are ready for sale in maximum
purities. Depending on the material
composition, throughputs of four to six
tons per hour can be achieved.
Satisfied partners
The Transucatas partners, José Manuel
Teixeira and Carlos Teixeira, are impressed
with the investment: „With the versatility
of the MeWa QZ, we will later be able
to run the plant in three-shift operation.
After the successful test phase, we can
promise ourselves the best output results
and high profitability.“ ■
3

Copper recycling
Turkey, with its booming economy, is also in the fast lane on the data
highway. The country on the Bosphorus is modernising its data
networks and now backing fibre optic broadband. Waste disposal
companies, such as ER Metal in Gebze near Istanbul, are handling
the excavated copper cables, for this reddish metal still remains
highly sought-after.
In 2011, Turkey had the strongest economic
growth worldwide. Almost all
global companies have now taken root
in the prospering economic metropolis of
Istanbul. The city on the Bosphorus is already
the symbol of an international hub.
Even in the ancient world, it was not only
commodities and merchants who operated
on the Silk Road, but also ideas, world
views and entire people between the Mediterranean
and Asia.
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Telecommunications networks
Today, caravans from east to west are
rare. To be able to master modern trade,
finance and data transfers, it is rather
high speed internet connections that are
most in demand. Consequently, Turkey is
one of the nations within the G20 states
to modernise its telecommunications networks
most quickly.
Istanbul bridges the gap between east and west both figuratively
and literally: Bosphorus Bridge in Istanbul at night.
Fibre optic brings
copper to light
The medium of the future is the optical
fibre. Not only does this allow for faster
data connections and higher transfer rates,
but the optical fibre is also significantly
cheaper than the previously used copper
cables. For every kilometre of new fibre
optic networks, almost the same volume
of copper cable is dug out of the earth.
One man‘s joy is another man‘s sorrow?
Is this the end of the age of copper
cable and the beginning of the fibre
MeWa-News September 2012
UC 150 and UG 1600 MSL at the cable recycling plant in Sekerpinar, Turkey.
optic era? Only for data networks. Everyday
life without copper is unthinkable. This
is a situation in which everyone stands to
win. For example, unlike fibre optic cable,
copper can conduct electricity. It has the
second highest conductivity of all metals,
ranking after silver but before gold.
PCBs and integrated circuitry, transformer
coils and electric cabling – almost all
industrial machines rely on copper. Every
mid-sized car today contains over 20 kg
of copper. With the development of electric
and hybrid cars, this share will increase
significantly. In a booming industrial
nation like Turkey, the copper from the excavated
data cables is therefore urgently
required elsewhere.
ER Metal recycles cables
Copper can often be recovered without
any loss of quality. Specialist waste
disposal businesses, like the Turkish metal
recycling firm ER Metal based in Gebze
on the Sea of Marmara, deal with the
proper disassembly of the cable. In an industrial
area in Sekerpinar, not far from the
company‘s headquarters, a new site with
storage space and a weigh bridge was recently
acquired. In a hall of 3,000 m², the
supplied cable waste is sorted and me-
MeWa-News September 2012
chanically recycled. To this end, Erdogan
Akbay, Director of the Turkish metal recycling
firm, has invested in technology from
MeWa. „The machines are extremely robust,
and allow for long-term work,“ said
the businessman, explaining his decision.
A UC 150 Rotary Shear and a UG 1600
MSL Granulator crush the cable to small
grain sizes. A magnet separates the ferrous
metals from the material flow and
Copper recycling
a subsequent sorting line separates the
different fractions from each other. The
plastics from the sheathing are thermally
recycled, and the copper, in maximum purity,
is then available for transport to the
copper works.
Thus, on the journey from the Silk Road
to the fibre optic street, copper is brought
to light – for an up-and-coming economic nation
has a high demand for raw materials. ■
From left to right: Gabor Vidak (MeWa), Dennis Schmidt (MeWa), Erdogan Akbay (ER Metal),
Ahmet Baran (MeWa), Volkan Akbay (ER Metal).
5

6
Refrigerator recycling
From left to right: Siniša Mitrovic (President of the Serbian Chamber of Commerce), Helmut Oberguggenberger (MeWa),
Ninoslav Milenkovic, Vladimir Zivaljevic, Vujadin Scekic (all three from Jugo-Impex management), Zoran Perisic (Mayor of Niš).
Serbia joins in refrigerator recycling
MeWa plant opened in Niš
The first waste-disposal plant for refrigerators and electronic scrap in Serbia
was recently officially opened in front of over 400 guests and significant media
interest. Some 800 refrigerators or 80 tons of electronic scrap will in future be
recycled each day at the site in Niš.
Not even 12 months ago, representatives
of MeWa and the Jugo-
Impex shareholder Vujadin Ščekić
met for initial talks in Niš. After this, not
only was the former production hall of the
Serbian washing machine manufacturer
EIDA completely redeveloped, but modern
offices and function rooms were also created.
By the time of the opening ceremony
at the end of September, the first refrigerator
recycling plant in Serbia had been
running in test operation for two months.
With a throughput of 20,000 refrigerators,
all parameters were optimised and the
future staff extensively trained.
Major media interest
Everything else was also perfectly
arranged for the opening ceremony: Over
400 guests from the worlds of politics, economy
and environmental associations as
well as several television cameras and radio
microphones had gathered in front of the
stage, the start button was ready, the new
plant presented itself in the spotlight and
the experts waited for the start signal at
their future workstations.
And with the symbolic handover of the
keys to the new operator, E-Reciklaza, the
time had come: The representatives of all
parties involved in the completion of the
new plant pressed the red button together,
to start the trend-setting recycling project.
The Jugo-Impex Group, to which
E-Reziklaza belongs, has its origins in the
sale and distribution of refrigerators, but
for ten years now has been operating recycling
plants for copper and cable, and
also dismantling used electrical equipment
manually for some years. Now the Serbian
company has succeeded in joining the
world of mechanical recycling.
„In Serbia, a law was passed regulating
the disposal of refrigerators and
electronic devices in accordance with
the WEEE directive of the European Union,“
explained Jugo-Impex CEO, Ninoslav
Milenković. „To be able to implement this,
we have searched for the best possible
technology and have found a strong partner
in MeWa.“
Electronic scrap and refrigerators
For MeWa, the new recycling line also
represents a further milestone in plant
construction. The new building in Niš is designed
to selectively process refrigerators
or electronic scrap. The process thus follows
the MeWa recycling process, which
has been awarded several environment
prizes.
For decades, refrigerators were manufactured
with the use of chlorofluo-
MeWa-News September 2012
Combi-recycling plant for refrigerators and electronic scrap in Niš, Serbia.
rocarbons (CFCs). Significant quantities
were processed both in the refrigeration
circuit and in the insulation. If refrigerators
are not handled properly, these CFCs
are released into the atmosphere and rise
from there into the stratosphere. Decomposed
by the energy-rich radiation of the
sun, the released chlorine reacts with the
ozone and destroys it.
One effect of this reaction is the
„ozone hole“. The harmful effects of
the release of CFCs has been recognised
worldwide and has resulted in new refrigerators
being built without the use of CFCs.
In new appliances, the CFCs have largely
been replaced with combustible coolants
or with pentane as the propellant in the
insulating foam. All types are now found
in recycling.
The dismantling process
The MeWa plant technology is designed
for simultaneous processing of CFC
and pentane-foamed refrigerators. In
a first step, the glass shelves are removed
from the refrigerators, the cable and
compressors removed and the refrigerant
extracted. The carcass is then entered into
the automatic recycling process via a gastight
sluice. This prevents the escape of the
greenhouse gases from the process. In a
single-step process, the patented MeWa
QZ 2000 HD Querstromzerspaner first
breaks the refrigerator down into its individual
parts. These consist of iron, aluminium/copper,
plastic and the polyurethane
powder (PUR foam) of the insulation.
The crushed PUR foam is then filtered
and separated from the CFCs and other
solvents in a matrix degasification process.
These are routed into a cryogenic air-recycling
plant using nitrogen. There, the CFCs
and pentane gases are liquefied and provided
in pressurised containers for transport
to a chemical recycling facility.
The iron, aluminium/copper and plastic
parts are separated with mechanical
separating technology. In the end, the materials
– now free from CFC adhesions –
are available for resale in highest quality,
for example as class 1 refrigeration scrap.
Some 800 refrigerators can be processed
in this way each day. This covers
the demand for all of Serbia. If the plant in
Niš cannot be fully utilised in some phases,
it is also possible to recycle electronic scrap
there too. Instead of refrigerators, approximately
four to five tons of household appliances,
entertainment electronics, computers
or washing machines per hour can
be broken down into their individual parts
in the MeWa Querstromzerspaner and separated
into fractions by the existing separating
technology.
Refrigerator recycling
Logistics available
The required logistics have been set
up by Jugo-Impex with an in-house collection
system in Serbia and corresponding
customer contracts for the output materials.
Thus, the Balkan republic has succeeded
in entering into an economically
profitable refrigerator recycling business
working according to the latest environmental
standards.
Reason enough to celebrate Serbian-style.
After the commissioning, there
were many hours of dancing, singing
and laughing with live music and culinary
delights. ■
Constantine I, Niš
Niš is the birth city of the Roman emperor
Constantine I.
Constantine the Great, as he was also
called, achieved religious freedom in
the Roman Empire through the Edict of
Milan in 313. This also represented the
beginning of the rise of the still young
religion of Christianity to the most important
religion in the Roman Empire.
The thousand-year anniversary of this
edict will be celebrated by Niš in the coming
year with many events.
Towards the end of his life, Constantine
resided in the city of Constantinople,
which was named after him
(today Istanbul).
7

Cosy rolls with cores
as hard as steel
MeWa‘s pioneering solution for production
waste of sprung mattresses
In the production of sprung mattresses,
huge amounts of waste from edge cutoffs
occur as production waste. Nobody
has really dared to handle this unwieldy
and heavy material to date. But now
Kastrup Recycling in Bad Essen has taken up
the challenge. Together with MeWa, a truly pioneering solution
has been developed.
On the 40,000 m² large company
premises in the industrial area of
Bad Essen Wehrendorf, Kastrup
Recycling collects and sorts various secondary
raw materials. The modern site and
the location with good transport connections
with direct links to motorways, the
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Textile recycling
Mittelland Canal and the rail network allows
the company to further differentiate
its range of services and expand its services
with the new MeWa plant.
One of these new services is piling up
on the company premises in the form of
huge rolls of sprung mattresses. The textile/wire
bundles looks like foam cushions
at first glance. But the rolls of up to
1.70 metres are literally full of substance.
The waste from the production of sprung
mattresses consists of 93% iron. The cosy
steel mesh weighs up to 250 kg.
Mittelland Canal at Bad Essen Wehrendorf.
Spring core challenge
Their weight and size means these
soft bundles of steel present a real
challenge. After all, the high share of iron
alone is a knock-out criterion for most
shredders. Not only that, but this particular
iron is spring steel with a hardness of
54 HRC, thus forming a constant, almost
insurmountable resistance to shredding.
„This is a material flow that nobody actually
wants,“ admits MeWa Sales Manager
Jürgen Müller-Webers.
Not so at Kastrup Recycling in North-
Rhine Westfalia. The company, which is
based in Bielefeld, has been collecting
waste materials for over 100 years, recycling
them and then recirculating them.
Director Volker Kretzschmar was thus impulsively
interested in the high levels of
recyclable material in textile waste. The
search for the right technology to recycle
the bulky load led the waste disposal
manager to Gechingen.
Pre-granulation in the UC 150
And when it‘s a case of mastering pi-
oneering tasks, the designers at MeWa
continuously provide extremely innovative
solutions. The positive trials in the Gechingen
test stand were followed immediately
by the detailed plans. Recently, a
MeWa UC 150 Rotary Shear with intensified
drive output started providing the necessary
power in Bad Essen. The rolls are
fed into the hopper completely and, with
the help of the compactor, shredded into
strips in a single operation.
Via an intermediate bunker, the
shredded wires and fabric scraps are
fed into a MeWa UG 1007 Granulator.
The post-granulator, with
reinforced rotor, crushes the
material to a grain size of less
than 30 millimetres.
A subsequent separating
station then provides separate
fractions. The fluff and material
is blown out with an air separating
unit, and a magnet lifts off
the spring steel. This is supplied to the
steel-producing industry. The textiles, on
Textile recycling
Pre-granulation in the UC 150... ...and post-granulation in the UG 1007.
the other hand, are marketed as substitute
fuel.
Director Volker Kretzschmar is extremely
happy with the solution, as the
MeWa machine technology and the existing
infrastructure in Bad Essen have allowed
the recycling company Kastrup to
lay the foundations for further handling
of scrap. ■
9

10
Bio-QZ
Packaged food
is washed
In 2010, the Danpower
Group from Potsdam
took over the biogas
plant in Bad Köstritz.
And they modernised it
from top to bottom.
With a new recycling
and feeding line, the
plant can now be
operated economically
again.
The Danpower GmbH, based in
Potsdam, is an investor of bioenergy
projects with high experience.
The company operates 27 biogas plants
throughout Germany.
The new owner of the biogas plant
Bad Köstritz set up first a sustainable concept
for efficient operation of the plant.
For planning and implementation of the
High packaging share in the organic waste.
The Bio-QZ 1200 used for recycling organic waste.
task, Danpower obtained the help of two
strong partners in Silberland GmbH and
MeWa.
Investments were made in the infeeding
line, for example, so that the range
of materials used could be expanded significantly.
The input materials are mainly
organic waste from households and restaurants
as well as packaged food from
supermarkets from the entire area of Gera.
The high packaging and foreign material
share in the substrates, however, makes
extensive processing necessary. To help
with this, the experienced MeWa employee
Harry Geppert planned a trend-setting
plant solution. The supplied organic waste
is first fed into the MeWa Bio-QZ 1200 via
a feed hopper. Extensive tests were performed
on the waste, so that the machine
settings are now optimized for the different
input materials. Up to 15.000 tons
of biowaste per year can be processed by
the plant.
The MeWa Bio-QZ as the core machine
of the infeeding process homogenizes
and then routes it into a washing
screw. The mineral content breaks off and
is discharged. The remaining oversize material
is routed through a magnetic separator,
where it is separated into a sale-
able iron fraction which consists mainly
of tin cans, and an equally recyclable plastic
fraction. The substrate is routed into
the fermenter.
From left to right: Christian Podritzke
(Danpower), Frank Griebenow (Danpower),
Harry Geppert (MeWa Site Freiberg).
The investment pays of: In the meantime,
the biogas plant Bad Köstritz has
reached its electrical output capacity of
four megawatts. ■
Black beer
Bad Köstritz is home to one of the oldest
breweries in Germany. It was first mentioned
as early as 1543. Köstritzer black
beer has made the small town in Thuringia
famous beyond Germany‘s borders.
Even Johann Wolfgang von Goethe
praised the good taste of the beer.
MeWa-News September 2012
Umut Serdar Yalcin (Director of RDF Kontamine).
Hobas-Trinkwassertanks.
Capacity: Zerkleinerte 1,000 GFK-Rohre. tons of oil filters per year.
MeWa-News September 2012
The once small town of Kocaeli to the
east of Istanbul has developed into
a leading industrial region in recent
years. Spatially, the town has long since
grown together with the Bosphorus metropolis
of Istanbul.
The necessary supplies of
raw materials are provided
by the many
recycling businesses
which
have in the
meantime
been set up
i n this area. One
of these young, modern
companies is RDF Kontamine, which
specialises in the production of substitute
fuels and has established itself as a partner
of the cement industry.
To this end, company director Umut
Serdar Yalcin commissioned a MeWa recycling
line for packaging waste two years
ago. Depending on demand,
the plant has since
been supplying homogeneous
substitute fuels in
grain sizes of 30 to 50 millimetres.
This première has now
been followed by another:
Entirely in red, Turkey‘s first
recycling plant for passenger
car oil filters shines
out. A MeWa UC 60 Rotary
Shear and a MeWa UG
600 Granulator crush the
used oil filters into small
Oil filter recycling
Oil filters for the
cement industry
Red like the famous Turkish flag, a quite
special recycling plant shines bright in the
industrial region of Kocaeli to the east of
Istanbul. The company RDF Kontamine, part
of the Anatoli Pars Group, has commissioned
the first mechanical recycling plant in Turkey
for used oil filters.
grain sizes at the Kocaeli site. In a centrifuge,
the components are freed from the
adhesive oil. These components are predominantly
ferrous metal, textiles and paper.
The oil is collected in a tank and is available
as fuel. The remaining material is dry
after the centrifuge and can therefore be
separated into a ferrous and non-ferrous
fraction with the help of a magnet.
The textiles and paper are also in demand
as fuel with a high calorific value.
The metal, on the other hand, is sold off
to steel smelting businesses. Around 1,000
tons of oil filters can be recycled per year
in the small but excellent recycling plant.
And with the red paintwork, the plant
is also a visual symbol of Turkey: At RDF
Kontamine, the national colour represents
resource-efficient conduct and a sustainable
energy supply. ■
From left to right: Fatih Aydemir (RDF
Kontamine), Éva Takács (MeWa Györ) and
Dilek Kiliç (RDF Kontamine).
11

Imprint
MeWa-News
MeWa Recycling Maschinen
und Anlagenbau GmbH
Gültlinger Straße 3, 75391 Gechingen
Editor: Harald Pandl
Tel. 0049 (0)7056 925-0
E-mail: info@mewa-recycling.com
Internet: www.mewa-recycling.com
Design: MeWa in collaboration with
Creativ-Werbung M. Dostal, Tiefenbronn
Printing: Druckhaus Weber, Althengstett
Photo credits: MeWa, M. Dostal,
Jugo-Impex, Wikipedia, Köstritzer
Schwarzbierbrauerei GmbH
Cover photo: E-Reciklaza Refrigerator
Recycling
12
MeWa around the world
...to the southernmost
point of Steiermark,
Austria...
From Gechingen
to the wide world...
...and to
Mongolia...
...to Woudrichem,
Holland...
MeWa-News September 2012