The aluminium recycling industry increasingly depends on X-Ray sorting, LIBS, and evolving AI-driven technologies, while expectations regarding output quality, process safety, and energy efficiency continue to rise.
For Capiau, one of the leading aluminium recyclers in Lokeren, Belgium, these changes called for a decisive upgrade of their existing shredding and sorting system.
Faced with the challenge of processing 2,000 tonnes of aluminium scrap every month, including mixed aluminium, profiles, castings and grades such as Zorba, the company needed a solution that was more productive, more durable and better aligned with current market demands.
A tailored answer to a clear operational need
Capiau turned to Zato to reconfigure their line with two key machines: the Blue Devil pre-shredder and the Blue Shark hammer mill. Together, these systems addressed both upstream and downstream needs—boosting safety, increasing throughput, and delivering a cleaner, higher-quality scrap ready for sorting.
“Energy-wise, the new system is much more efficient,”explains Gio from Capiau.
“In the past, we often had to shred material three or four times. Now, the pre-shredder consumes very little power and the hammer mill needs only one run per batch. This saves energy, but also time and space.”
Fewer risks, cleaner flows, better results
The Blue Devil pre-shredder plays a crucial role in ensuring safety and process consistency. By removing unshreddable and nearly abolishing the chance of explosions, it protects the entire line and prepares aluminium scrap for efficient downstream processing. Its performance has also translated into a more stable and higher-capacity flow, with fewer slowdowns.
The Blue Shark hammer mill, on the other hand, is built to withstand intensive daily use while guaranteeing uniform output and excellent separation quality. It ensures that each tonne of aluminium is processed thoroughly, free of residuals and contaminants.
Technology is important. But continuous support makes the difference
One of the elements that stood out for Capiau was the collaborative approach during the design and implementation phase.
“They’re very proactive in finding the right approach,”Gio notes. “They don’t just deliver one-size-fits-all machines, but a complete solution, tailored to the customer’s needs. And that’s what you want as a recycler.”
Even after the installation, Zato’s support remained consistent.
“They don’t leave you on your own,”adds Gio. “That continuous presence is something you can count on.”
