Komptech machines – turning waste into new raw materials

The Komptech Terminator can be used as a robust, slow-running crusher for almost all types of solid waste. The hydraulic roller drive with load-dependent speed control utilises the highest crushing forces.

Our world's resources are finite. But we are still wasting far too many of them and producing mountains of waste. What if we could use this waste, which seems worthless to most, as a global resource and create new opportunities?
This vision guides the work of the Austrian company Komptech GmbH. It supports its customers in extracting new raw materials from waste through extensive recycling; these materials can then be returned to production. For example, waste wood can be fed into the production of new wood materials or used as an energy source for heat and electricity production. Organic waste, on the other hand, can be converted into stable, plant-friendly humus substances through composting. For organic waste with a higher moisture content, fermentation is an economically and environmentally suitable treatment method. Clean energy is produced from the degraded organic matter and the fermentation residue becomes compost and liquid fertiliser.

With more than 4,000 customers in over 80 countries and an export rate of almost 95%, Komptech is a leader in waste processing technology. The environmental specialist's range of services includes all essential process steps for the treatment of solid waste and woody biomass. The company also has a worldwide service network, its own digital tools and extensive expertise in the implementation of site-specific reprocessing concepts.

Komptech's technology focuses on the following steps in waste treatment: crushing, screening, separation and sorting. Komptech recycling systems are designed and dimensioned according to customer requirements. This creates efficient solutions for handling complex tasks. Half of Komptech's machines are already available as e-mobile or hybrid versions. With comparable throughput, the Crambo e-mobile, for example, can save up to 70 percent of energy costs. In addition, the concept allows the use of renewable energy instead of fossil fuels and thus contributes directly to CO₂ reduction.

Komptech not only produces new machines and systems that process materials in such a way that the majority of them can be prepared for reuse. At Komptech, the machines themselves are also subject to the principle of sustainability. Thanks to a proven maintenance concept, the robust machines achieve a long service life. But it doesn't end there: Komptech also retrofits used machines and components, such as gearboxes, extends their lifespans and thereby contributes to the conservation of resources.

Examples to follow – Komptech extends the lifespan of machines

Komptech machines are consistently maintained. A service is due every 500 operating hours. This is mainly carried out by Komptech employees or by the company's partners.

OELCHECK all-inclusive analysis kits are always counted on, especially in European countries. The analysis kit and its accompanying sample note are perfectly designed to meet Komptech's requirements. Whether for hydraulic, gears or engine oil, fuel, coolant or lubricating grease – the kit is universally versatile.

Detecting impending damage early

Besides the oil condition, the focus of the investigations is on the condition of the individual machine components and signs that indicate impending damage.

Proactively used, the OELCHECK laboratory reports reveal any changes and Komptech can take countermeasures in good time.
Maintenance work is planned in a targeted manner and unforeseen breakdowns are prevented.
If a lubricated component is damaged, this is usually revealed early on by the analyses. As a rule, the affected component can be reprocessed and its useful life thus extended.
With regular careful maintenance, the machines can fully utilise their robustness and reliability and achieve impressive service lives. A Terminator 5000S direct, for example, recently achieved a record service life of 70,000 operating hours.
Oil changes still take place at fixed maintenance intervals of 500 operating hours, but there is a trend towards condition-dependent oil changes in the future. This makes OELCHECK analyses absolutely indispensable.

The best new machines become the best used machines

A used Komptech machine is far from scrap metal! Here, too, Komptech focuses on sustainability and gets many used machines back into shape as part of the "Certified used" programme.

Buyers of used machines can rely on the quality and reliability of their Komptech machine, just like when buying a new one. The company processes used machines according to a defined process. Every step in this process – from initial inspection to reprocessing and final inspection – is subject to strict specifications.

After the initial inspection, the machine is disassembled. The components are then examined in detail. Above all, the individual gears, the engine and the hydraulics are examined meticulously. The final quality control is carried out at the end. OELCHECK all-inclusive analyses play an important role in this process. The "new" used machine must pass the entire process successfully, and the OELCHECK analyses must prove that the gears, engine and hydraulics are in perfect condition.

How a machine is reprocessed

The machine is checked according to the manufacturer's checklist (route card). All components are carefully inspected.
The engine is tested according to the CAT checklist by Zeppelin.
Oil analyses are conducted over the entire period – for rental machines.
Pressures in the hydraulic system are measured.
The rotor is balanced (Axtor/Topturn machines).
A test run is performed with material (Axtor).

-> Final acceptance takes place according to new machine standards.

Only when there is no doubt about the quality of a used machine does Komptech grant a warranty for the renewed machine and label it with the "Komptech certified used" quality seal.

The operators of the new used machines:

Maintain machines younger than six years and with less than 6,000 operating hours.
Know that inspection, reprocessing and quality control were performed according to Komptech standards.
Also benefit from a warranty of six months or 500 operating hours.

The Komptech Crambo is one of the best machines for shredding all types of wood and green cuttings. Two slow-running rollers with cutting tools minimise the fine content as well as noise and dust emissions and provide resistance to contaminants.

For further information: www.komptech.com