How technology is reshaping metal recycling

For decades, metal recycling was characterized by brute strength — massive machines turning scrap into raw material for reuse by the steel industry. But today, the industry is being reshaped by a quieter force: data, sensors and digital intelligence. 

Peter Thomas, head of technology at Lindemann Metal Recycling, has seen this transformation first-hand. "I've been in metal recycling for over 10 years," he says. "Over that time, the trends have been to make machines more maintenance-friendly, to connect them through digitalisation — and to give customers greater control of how the machines are operated." 

The last two years, he says, have marked a turning point. Digitisation and condition monitoring have taken ‘a great leap forward, with customers demanding far more visibility into how their machines perform. "They want to know what condition the machine is in, what the downtime and production has been — even whether vibrations might suggest a component failure is likely," Thomas explains. "That kind of intelligence is becoming a standard expectation." 

Lifespan to lifecycle 

Traditionally, premium metal recycling machines were built to last 20 or even 30 years. That benchmark, Thomas says, is shifting fast. "Now, customers are looking for high quality machines with a lifespan of around a decade," he notes.

It's not just about shorter lifespans, it's about smarter design. Maintenance that once required hours of manual work can now be handled through electric controls, reducing downtime, and boosting productivity. "If you can cut downtime, you gain more production time," Thomas says. "And with today's control systems — such as SDA and VFD — you can get up to 25 percent more production from the same amount of energy. That's a game changer." 

Both technologies are recent Lindemann's innovations. The Shredder Drive Assistant (SDA) ensures the machine works as hard as it can without overloading, while Variable Frequency Drive (VFD) technology reduces energy costs and makes the machine flexible enough to adapt to different materials — from dense scrap to light aluminium. Together, they make shredders both more productive and more efficient.

Data purity

The process of recycling metal may seem straightforward — shred, sort, and melt — but the science behind it is evolving rapidly. The steel industry now demands tighter tolerances for what enters its furnaces, pushing recyclers to deliver cleaner, more precisely graded material.

"There's a growing need to know more about the output — the chemical mix of what's coming out of the shredder," Thomas explains. "We're using technologies like laser-induced plasma spectroscopy, where material is partially melted and the vapor analysed. That lets you determine exactly what's in each stockpile — X percent iron, Y percent copper, and so on."

This level of insight is what will allow recyclers to guarantee specific quality levels in the metals they deliver. "The most important thing is to know exactly what's coming out," he adds. "Technology lies at the heart of giving customers this knowledge."

Out of harm's way

One of the most visible technological shifts is how machines are operated. Until now, shredder operators worked in cabins positioned above the shredder — close enough to see the scrap being fed in. "The need for this reducing," Thomas says. "Now it's increasingly camera-controlled operation. Operators sit in control rooms some distance from the shredder, surrounded by screens and safely away from the shredder."

It's a simple change, but one with major safety implications. "If there's an explosion (from an errant gas bottle, for example), you're far safer in a control room than next to the shredder," Thomas notes. "Automation doesn't remove the need for human oversight, but it makes that oversight safer and more efficient." 

Data-driven relationships

Lindemann's technological evolution isn't only about smarter machines — it's about closer partnerships with customers. "The days of building a machine, selling it, and then forgetting each other are over," Thomas says. "We need to work together constantly." 

Through remote telematics tools like MyLindemann, operators can continuously monitor their machines and receive early warnings of potential breakdowns or parts replacement needs. "The next generation of customers are digital natives," he says. "They demand real time information and connectivity from anywhere in the world." 

Metal recycling not only needs to produce cleaner scrap, it has to do it in a cleaner way. To meet tightening environmental regulations, modern sorting, and dedusting technologies can be easily retrofitted to older models. "It's an investment worth making, and not just for the environmental benefits. If a shredder producing 160 tons an hour (at an average scrap value of €250 a ton) is shut down due to a regulatory failure, the financial losses quickly mount up," Thomas notes. "So, the whole industry has to become more sustainable." 

Looking ahead: robots, sensors and smart design

Asked what comes next, Thomas doesn't hesitate: robotics. "We'll see robots in the sorting area of scrapyards, separating specific materials before they even reach the shredder," he says. "There will also be more sensors and measuring devices to gauge the quality and condition of the output." 

He also predicts lighter machines and faster maintenance, thanks to smarter, modular designs. "Grids and rotors - and even blades are very heavy — they need cranes to lift. We need to accelerate that process with new technologies and design improvements by making it safer and easier in parallel." 

Lindemann is expanding into emerging markets, such as India and South America, adapting its machines to smaller capacities, while maintaining the brand's premium quality. "There's pressure to make machines both better and more economical," Thomas admits. "But that doesn't mean cutting corners. It means cleverer design." 

Ultimately, technology is transforming metal recycling from a heavy industrial process into a data-driven discipline. "Recycling is already a vital part of the circular economy," Thomas reflects. "And as the world transitions to lower-carbon solutions, its importance will only grow. The smarter our machines become, the stronger our role in that future."