In March 2023, Alfa Recycling, one of the largest scrap processing facilities in Bavaria, Germany, took a significant step toward modernizing its operations. By integrating the Blue Devil pre-shredder from Italian manufacturer Zato into its shredding line, the company achieved a remarkable increase in productivity—boosting its throughput by 30 to 40 percent and significantly reducing energy consumption and downtime.
Located in Munich’s Aubing-Lochhausen-Langwied district, Alfa Recycling operates on more than 100,000 square meters and has direct rail access. It forms part of the ALFA Group, a regional consortium of recycling and waste management companies in Bavaria and Austria, employing around 1,000 people. Although
connected to the broader TSR Group under Remondis, Alfa retains operational independence, positioning itself as a prominent mid-sized player in the recycling industry.
The collaboration with Zato emerged through a longstanding professional relationship between Alfa Recycling’s managing director, Karl-David Schlehenkamp, and Andreas Schwenter, managing director of Veneto Schwenter GmbH and official representative of Zato in the region. The two had previously co-founded a waste management company and had shared experience using Zato machinery, laying the groundwork for trust in the brand’s reliability and performance.
Schlehenkamp was seeking a solution to increase throughput without extending production hours.
Having assessed various pre-shredders on the market, he ultimately chose Zato’s Blue Devil due to its proven performance, safety features, and maintenance efficiency. The decision was informed by Alfa’s experience with a used Zato machine, which had already demonstrated the durability and efficiency the
company needed.
Installed as the first step in Alfa’s shredding line, the Blue Devil serves to pre-shred light mixed scrap—such as materials collected from local recycling centers—before passing it along to the main shredder. The machine features twin-shaft rotary shears powered by four hydraulic motors and four planetary gears, capable of operating with either diesel or electric power. Its slow shaft rotation generates high torque, enabling the precise and effective breakdown of tough materials with minimal dust and noise.
One of the standout features of the Blue Devil is its integration of advanced control technology. The system uses a programmable logic controller (PLC) to adjust shaft speed dynamically in response to material resistance, monitor performance metrics, and manage alarms or overload shutdowns. Additionally, the machine is remotely monitored by Zato technicians in Italy using Industry 4.0 technologies, including augmented reality and artificial intelligence. The user interface, a high-resolution 10-inch touchscreen, allows for real-time data uploads to Zato’s service portal.
The installation required no specialized foundation, reducing costs and accelerating deployment. Once operational, the pre-shredder enabled Alfa to increase throughput to approximately 25 tonnes of scrap per hour, totaling around 250 tonnes per day.
The main product—ferrous shredded scrap—is then delivered to steel mills after undergoing further separation and sorting.
Operational efficiency was not the only benefit. The Blue Devil also enhanced workplace safety. Traditional shredders face high risks from gas canisters, fuel tanks, or oversized scrap, which can cause explosions or equipment damage. The pre-shredder filters out such hazards, drastically reducing the risk of incidents. According to Schlehenkamp, the system is designed to reverse automatically if it encounters a piece that is too heavy, allowing it to be safely removed before any damage occurs.
Energy efficiency also improved. While the total electricity usage did not drastically drop, the pre-shredder minimized peak power demands by delivering pre-shredded material to the main shredder. This reduction in power spikes resulted in lower energy costs overall—a crucial factor given the volatility of energy prices.
Alfa Recycling opted for a full-service package through Veneto Schwenter, with routine inspections scheduled every four to six weeks. As the machine is still under warranty, these inspections are currently focused on preventive maintenance and performance tracking. Thanks to its reliability, remote monitoring, and
minimal maintenance needs, the Blue Devil quickly became an integral part of Alfa’s operations.
For Schlehenkamp, the investment has clearly paid off. With higher throughput, improved safety, and reduced costs, the Blue Devil has delivered on its promise. As he concludes, “If you know what the machine can do and what it‘s made for, it’s a real pleasure to work with. The Zato Blue Devil works exceptionally well.”
