Page 53 from: April 2014

53April 2014

these targets larger components such as electri-

cal wires, hard disks and control boards while

the second focuses on less sizeable components

such as batteries, small engines and condensers.

In the final, completely automatic stage of the

process, remaining material is reduced to uni-

form pieces of around 30 mm and subsequent-

ly separated into three main categories – ferrous,

non-ferrous and plastics. These plants range in

capacity from one tonne per hour for the ES1012

to 3 tonnes for the ES2530.

With capacities of up to 100 units per hour, the

firm’s refrigerator processing plants encompass

removal of the engine and subsequent separation

of the oil and gas contained in the refrigeration

circuit, followed by a grinding and size-reduction

stage yielding uniform pieces of up to 30 mm.

Magnets separate the ferrous and non-ferrous

metals while the rest of the material is ground

down to 5 mm, with plastic and remaining non-

ferrous metals recovered via technology using

the different specific weights of the materials. A

suction system effects the complete recovery of

CFCs released during the grinding of the poly-

urethane foam. Finally, a compactor pelletises the

polyurethane and thus renders it harmless.

‘Staggering development’
Forrec was established in 2007 by four associates

with some 20 years’ experience of recycling. It

operated initially from a 2000-sq-metre facility

at Resana in Italy’s industrial heartland in the

north east of the country; however, ‘the stagger-

ing development of the business’ forced a move

just over two years ago to a 5000-sq-metre hub

at nearby Santa Giustina in Colle.

Asked to explain the company’s strong growth

during a difficult period for most businesses,

feedback from its customers suggests three main

factors behind the popularity of its product

range, according to Forrec. These are: reliabil-

ity; high levels of performance; and the com-

pany’s emphasis on customer service, delivered

not only by its sales department but also by its

technical, after-sales and financial teams.

Indeed, the company can often provide after-

sales service on its competitors’ machines too.

Business ‘internationalisation’
Italy itself tops the league table of Forrec’s mar-

kets, accounting for around 40% of its total

sales, but the company has also invested sig-

nificant resources in the ‘internationalisation’

of the business, including representation at

leading trade fairs around the world; for exam-

ple, it has participated in recent times at shows

in the USA, Canada, Brazil, Russia, Turkey, Aus-

tria, France and Poland. ‘We have developed a

great network which allows us to enter new

markets and to consolidate old ones,’ notes Zoc-

carato. ‘Eastern Europe is becoming one of our

best markets, together with France and its

“overseas territories”, North America and Asia.’

The company’s global scope is exemplified by

the recent installation of a recycling system for

WEEE and refrigerators on the French island

of Réunion in the Indian Ocean, and by the

recent supply of a tyre recycling plant to Minsk

in Belarus (see box).

According to Zoccarato, the company’s success

has not been based solely on a major marketing

push; sales have been founded to an even great-

er extent on the comments of satisfied custom-

ers. ‘They are our best form of advertising,’ he

insists.

Zoccarato declares the company to be ‘really

ambitious’ and ‘ready to face any new challenge’.

At present, it is working on a single-shaft grind-

er specifically for refuse-derived fuel as well as

a four-shaft shredder for paper industry scrap.

And its R&D department is also studying and

testing solutions for the processing of LCD

monitors, air-conditioning units, photovoltaic

installations and batteries.

Multi-plant success in
Belarus
Forrec is celebrating the successful completion of
tests and subsequent entry into full operation of
a tyre treatment plant at the Minsk Regional Tech-
nopark, an area conceived by the government of
Belarus as a recycling centre of excellence.
Capable of processing 5 tons of tyres per hour, the
Forrec system consists of a TBH 2000 double-shaft
shredder, two MR 2000 single-shaft grinders and a
couple of FMS 2000 granulators. Efficient removal
of steel cord and textiles means the final granular
product is 99% pure, according to Forrec. The rubber
granules can be varied in size between less than 1
mm and 4 mm, depending on the subsequent appli-
cation. In Minsk, the customer aims to use the output
for, among other uses, the production of asphalt.
‘The plant employs 15 operators, who have fol-
lowed the complete technical/professional training
that Forrec always includes in each project,’ notes
the Italian company’s ceo Marco Zoccarato.
Completed within the specified time despite often
unfavourable weather conditions, ‘this can be
defined as one of our most important projects’, he
says. ‘It is the biggest installation we have planned
and manufactured, and it has been a great show-
case for Forrec to enter the Eastern European
market. This project was the first step in a great
co-operation with the customer who has gone on
to order two more big installations for processing
WEEE and refrigerators.’
Some 25 trucks have transported the equipment
for these WEEE and refrigerator lines from the
Forrec factory in Italy to the Minsk Regional Tech-
nopark. Assembly and testing are scheduled to
start shortly on a plant that, on an hourly basis,
will be capable of processing 3 tons of WEEE and
40 refrigerators.

Going from strength to strength

Medical waste recycling plant.

Twenty-five trucks leave for Belarus carrying Forrec
refrigerator and WEEE recycling plants.

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