CHILE / CABLE LINE UPGRADE

Copper Wire Shredder Upgrade in Chile

How Jonathan expanded an existing BS-F1000 copper wire shredder with a BS-A1300 main crusher as incoming cable volumes grew. The project focused on solving plug-wire processing, copper loss and capacity without rebuilding the factory.

Equipment: BS-F1000 copper wire shredder + BS-A1300 heavy-duty main crusher

Project location: Chile

100 kg/h

Starting capacity

55 → 110 kW

Main crusher power

1.5–2 t/h

Customer-reported upgraded capacity

Chile

Project location

The Challenge Was Throughput, Not a New Factory

Jonathan’s mid-sized recycling factory in Chile processed communication cables, auto wire harnesses, square wires and plug wires under 30 mm. The existing single-phase machine was limited to 100 kg/h, could not handle plug cables and left valuable copper mixed with plastic.

Incoming scrap volumes were growing faster than the original line.
Plug wires required a more capable heavy-duty process.
The goal was higher separation performance without expanding the factory footprint.

Step 1 — The Right Setup for Higher Throughput

Jonathan found BSGH through Alibaba in early 2022. After reviewing his cable materials and daily processing requirements, our engineering team recommended the BS-F1000 with a pre-shredder for processing plug cables.

Der Vorzerkleinerer breaks the cables into smaller pieces before they enter the main crusher. This reduces the workload on the main crusher, increases the system’s processing capacity and helps protect the crusher’s blades.

Jonathan placed his first order in July 2022. Following delivery to Chile and a short start-up adjustment period, the system operated steadily at approximately 1 ton per hour.

After the first installation, Jonathan said the machine ran steadily and handled plug wires with less manual work. His team could process the cables faster, so less material piled up in the warehouse. When more scrap cable started coming in, he returned to BSGH to increase the capacity of the same line.

Customer Video: BS-F1000 Running in Chile

Customer-shared machine videos after the first BS-F1000 installation, before the 110 kW crusher upgrade.

Step 2 — Upgrade the Crusher to Increase Capacity

After almost a year of successful operation, the BS-F1000 copper wire shredder had become an important part of Jonathan’s recycling business. As incoming material volumes increased, he wanted more capacity without expanding the factory or replacing the complete line.

BSGH Granulator therefore developed a customized upgrade by integrating the heavy-duty main crusher from the BS-A1300 into the existing BS-F1000 system. Crusher power increased from 55 kW to 110 kW, allowing the line to handle larger volumes and more challenging materials while occupying virtually the same footprint.

The upgrade offered a practical and cost-effective path to higher productivity, so Jonathan moved forward with a second order.

Results After the 110 kW Crusher Upgrade

Following the 110 kW crusher upgrade, Jonathan shared the following results from his existing BS-F1000 line.

“The 110 kW crusher has exceeded our expectations. Our processing capacity has increased to nearly 1.5–2 tons per hour, and the upgrade integrated seamlessly with our existing system.”

“Instead of investing in a new production line, we achieved a substantial increase in output with a much more cost-effective solution. We are very pleased with the results and look forward to working with BSGH again.”

— Jonathan, Chile

A Two-Stage Upgrade, Not a Complete Replacement

Jonathan’s project developed in two stages: first, a BS-F1000 system to handle plug cables; later, a 110 kW crusher upgrade as incoming volumes increased. The second investment built on the existing line rather than replacing it entirely.