How real-time data is reshaping shredder performance

In scrap recycling, every ton counts. Visibility into operations can mean the difference between improved efficiency and lost productivity. That's the premise behind WENDTOS, a new software platform from WENDT that is designed to help scrapyard operators monitor performance, wear part life, and downtime in real time from any web-enabled device. 

WENDTOS, short for WENDT Optimization System, launched earlier this year after a multi-year development and beta testing phase. Built from the ground up to meet the specific needs of metal shredding operations, the platform is already being rolled out on all new WENDT auto shredders, with broader availability for non-WENDT machines and downstream systems in the pipeline.

Bringing a lagging industry up to speed with WENDT's control system

Digital transformation may have swept through other sectors, but the scrap recycling industry has been slow to follow. When asked why WENDT has chosen to launch its optimization platform now, Justin Kibler, business development manager at WENDT, offers a candid response that reflects urgency and opportunity for the rollout. "Yesterday was the best time," says Kibler. "Today is the second-best time."

While industries such as logistics, manufacturing, and energy have forged ahead with tech innovation, many players in scrap recycling have been slower to modernize their data infrastructure. Operators have typically relied on local computers, programmable logic controllers (PLCs), or even custom Excel spreadsheets to cobble together insights from disconnected machine signals. For Kibler and his team, that fragmented approach was no longer tenable.

"Our customers struggle to understand the data behind the systems they're running," he explains. "What are their throughputs? Something as simple as how much material they're actually running can be difficult to ascertain."

WENDTOS is WENDT's answer to that challenge: a platform that enables operators to track, analyze, and act on shredder performance data in real time. With key performance data, production data, and maintenance data transmitted via an independent cellular signal from an onsite RSS module to WENDT's servers in Buffalo, New York, the platform provides remote access to auto shredder metrics with any web-enabled device. Users can monitor multiple auto shredders across different locations from a single interface.

Core features and functionality of the WENDTOS insights for shredders

At its core, WENDTOS provides a series of interconnected dashboards that translate raw sensor data into actionable insight. Among the most frequently used tools are:

Smart Performance tracks throughput (tons/hour), motor load, thermal capacity, and other key auto shredder KPIs in real time.

Operational Outline is a calendar-based module to schedule run times, material types, and downtime events.

Smart Maintenance tracks the life cycle of internal wear parts based on tonnage processed, issuing proactive replacement alerts.

Downtime Reporting logs and categorizes all forms of downtime, from scheduled maintenance to unshreddable events, and provides clear insight into efficiency gaps.

Smart Hydraulics monitors oil particulate levels, fluid temperatures, filter life, and tank levels to support predictive maintenance and prevent equipment damage.

Smart Water tracks water injection flow rates to ensure proper dust suppression and system performance during operation.

Production Reports are automated daily, weekly, and monthly summaries delivered via email and available in-platform for easy-to-access performance reviews.

Building the right tool for shredders

From the start, WENDTOS was designed to do more than just capture data. The goal was to create a flexible, customer- centric system that adapts to the unique needs of different facilities.

Kibler is clear: "Data reporting programs are a dime a dozen. What sets WENDTOS apart is the configurability guided by our industry expertise. We're working with every customer to make sure they're seeing data in the way that's most useful to them."

This means frequent feedback loops, hands-on training, and one-on-one collaboration throughout the onboarding process. WENDT's team often holds weekly or bi-weekly sessions with facility managers and operators to walk through data, refine reports, and explain new features. For operators less familiar with digital tools, the learning curve is addressed through step-by-step coaching.

"If we just gave them a login and walked away, they'd probably never use it," says Kibler. "We make sure they get the most out of it."

Integration and scalability 

While WENDTOS comes pre-installed on all new WENDT auto shredders, the platform is also designed to be adaptable for use on older equipment and third-party systems. For older WENDT equipment, simple upgrades like adding belt scales and vibration sensors can bring machines online with minimal disruption. For non-WENDT systems, integration is handled with completely bespoke solutions.

"Every competitor system is set up differently, so there is a potential hurdle when integrating into a system that isn't designed and built by WENDT," says Kibler. "But we've built the framework. It's all about understanding what's [already] there and how to talk to it."

The future road map for WENDTOS includes expanding beyond the shredder operator to cover non-ferrous systems. Kibler explains that this next phase could involve developing new dashboards tailored to equipment used for recovering materials like aluminum, copper, and stainless steel. WENDT also plans to integrate technology from existing partners, like TOMRA, to support this evolution.

Security by design 

With rising concerns around data privacy and cybersecurity in industrial operations, WENDT took deliberate steps to decouple WENDTOS from a facility's internal network. Instead of transmitting data via local internet, WENDTOS uses a secure cellular signal through the RSS module, creating a physical barrier between customer systems and WENDT servers. The data only ever flows out of the system with nothing getting sent back to the facility's site.

"Even if our servers were compromised, there's no way to access the customer's shredder system," says Kibler. "All we're doing with the connection is reading data. By design, we don't even have the ability to make changes to the local system or shut things down."

The value of visibility 

When asked about return on investment, Kibler is candid. WENDTOS isn't a silver bullet — it's a tool that empowers operators to make better decisions.

"The ROI depends on what you do with the information," he says. "We can show you which feedstock runs better, which operator is more efficient, or where there's a spike in temperature. But it's up to the management team to act on that."

Even with early adopters still in the data collection phase, the platform is already delivering insight. Facilities are identifying cost-saving trends, scheduling smarter maintenance, and minimizing downtime.

What's next for the WENDT Corporation? 

WENDTOS is still evolving with new features rolling out regularly. Plans include enhanced detection capabilities for radiation and moisture, expanded integration with partner equipment, and predictive analytics based on weather conditions and historical performance.

For scrap recyclers unsure about making the leap to digital, Kibler's advice is simple: "Try it. Let us show you what it can do. Once you've experienced this level of data capture, you'll wonder how you ever operated without it."

In a market defined by thin margins and operational efficiency, smarter shredding technology starts with better information. WENDTOS is designed to support that transition.