Briquetting Metal Swarf: Turning Production Waste into Valuable Raw Material

Machining metal generates large quantities of swarf, grinding sludge, and fine production residues. Loose metal swarf requires a lot of storage space, is difficult to transport, and often still contains cutting fluids or other liquids.

With a powerful briquetting press, these production residues can be compressed under high pressure into compact briquettes. This not only reduces the material volume. Storage, transport, liquid recovery, and further metallurgical processing can also be significantly improved as a result.

The briquetting presses of the Arno®Brik series from ATM Recyclingsystems were developed for processing a wide variety of metal swarf and special materials. The machine program ranges from compact systems for smaller material volumes to powerful systems for continuous industrial operation.

What Is a Briquetting Press?

A briquetting press is a hydraulic machine that compresses loose swarf, sludge, dust, or comparable production residues under high pressure. In the process, the material is shaped in a pressing tool into a solid, dimensionally stable briquette.

Unlike a baling press, a briquetting press does not compact large-format sheet metal or bulky scrap parts. Briquetting presses are designed primarily for fine-grained materials generated during turning, milling, drilling, grinding, or sawing.

Suitable materials include, for example:

• Steel swarf
• Cast iron swarf
• Stainless steel swarf
• Aluminum swarf
• Magnesium swarf
• Copper and brass swarf
• Bronze and titanium swarf
• Grinding sludge

Depending on the version, Arno®Brik presses can process both dry metal swarf and moist or poorly flowing materials. Different feeding options allow adaptation to the flow characteristics of the respective input material.

Why Should Metal Swarf Be Briquetted?

Metal swarf is not worthless waste. Collected by grade and properly processed, it represents a valuable secondary raw material. However, its loose form often makes economical return to the material cycle difficult.

Briquetting improves the conditions for storage, logistics, and recycling.

Significant Reduction in Material Volume

Loose metal swarf has many voids and therefore a correspondingly low bulk density. As a result, it quickly fills containers, silos, and transport vehicles used for further processing or collection by the metal recycler.

Recovering Cutting Fluids

Metal swarf and grinding sludge often contain cutting fluids, cutting oils, or water. If these liquids are not separated from the metal, they increase transport weight and make further recycling more difficult.

During briquetting, the liquids contained in the material are pressed out and collected in a recovery system. After appropriate treatment, cutting fluids can, under certain conditions, be returned to the production process.

ATM states that briquetting suitable grinding sludge can press out more than 90 percent of the oil and water it contains. The actual result, however, depends heavily on material composition, moisture content, and process parameters.

This can result in several potential benefits for companies:

• lower demand for new cutting fluids
• less liquid in the material to be transported
• reduced disposal and treatment costs
• cleaner work and storage areas
• better conditions for metallurgical recycling

Better Transport and Storage Properties

Briquettes are more compact and dimensionally stable than loose swarf. They are easier to collect, dose, store, and transport.

Unlike fine or long swarf, compacted briquettes do not spread uncontrollably in containers or on conveyor systems. This can also reduce the risk of material losses during transport.

The uniform shape also facilitates automated further processing. Briquettes can be transported via conveyor technology, chutes, or other material handling systems to subsequent process steps in a targeted way.

Advantages When Melting

Loose metal swarf can oxidize quickly due to its large surface area. In addition, lightweight swarf can partly float on the surface of the melt when melted, instead of sinking in immediately.

Highly compacted briquettes, on the other hand, have better transport and melting properties. ATM points out that, compared to loose swarf, compacted briquettes can be melted down more easily and safely. According to ATM, studies conducted together with the Montanuniversität Leoben also showed throughput advantages when melting aluminum briquettes.

The actual improvement depends, among other things, on the following factors:

• material type and alloy
• purity of the swarf
• briquette density
• residual moisture
• type of melting furnace
• charging and process control

The system should therefore always be matched to the input material and the subsequent recycling process.

More Safety with Critical Materials

Due to their material properties, titanium and magnesium swarf can place particular demands on storage and processing. Fine swarf has a large surface area and can pose an increased fire risk.

Controlled compaction reduces the surface area of the loose material and simplifies handling. ATM therefore offers specially tailored briquetting solutions for materials such as magnesium, titanium, aluminum dross, and various special alloys.

For such applications, precise material analysis, suitable safety measures, and an individually configured system are especially important.

The Arno®Brik Series at a Glance

ATM Recyclingsystems offers the Arno®Brik series in several performance classes. This allows both smaller metalworking businesses and large industrial production sites to select a system suited to their material volume.

The machine program includes:

• Arno®Brik 5
• Arno®Brik 7
• Arno®Brik 10
• Arno®Brik 12
• Arno®Brik 15
• Arno®Brik 18
• Arno®Brik 22

Depending on the model, the possible briquette diameters range from roughly 50 to 240 millimeters. According to the technical product data, maximum throughput for steel and cast iron ranges from less than 0.3 tonnes per hour on the smallest model up to around 12 tonnes per hour on the Arno®Brik 22. Achievable performance depends on the material, bulk density, swarf shape, moisture content, and other process conditions.

Arno®Brik 5 and 7: Compact Solutions for Smaller Material Volumes

The Arno®Brik 5 and Arno®Brik 7 are suitable for businesses with manageable swarf volumes or limited floor space.

The compact design allows integration into existing production areas. Different pressing tools and feeding options allow adaptation to the respective material.

Typical areas of application include:

• turning shops
• milling operations
• toolmaking
• smaller foundries
• metalworking production businesses
• processing of high-value special alloys
• decentralized swarf processing directly at the point of production

A weighing system allows the material quantity per press cycle to be defined. This makes it possible to produce briquettes of controlled length and consistent quality.

Arno®Brik 10 and 12: For Industrial Use

The Arno®Brik 10 and Arno®Brik 12 are designed for larger material volumes and demanding industrial applications.

According to ATM, starting with the Arno®Brik 10, a special fill-valve technology is used on the press cylinder. This can reduce the drive power required for the pressing process. The PZT pump-switching technology also regulates the required oil volume for the individual cylinders and minimizes pressure losses within the hydraulic system.

These machines are suitable, for example, for:

• larger machining operations
• automotive suppliers
• aluminum and metal foundries
• industrial recycling plants
• centralized swarf collection systems
• automated production lines

Arno®Brik 15 to 22: High Throughput Capacities

For very large volumes of swarf, ATM offers the Arno®Brik 15, 18, and 22 models. These systems feature high pressing forces, larger pressing tools, and correspondingly high throughput capacities.

According to product data, the Arno®Brik 22 achieves a main cylinder force of 12,500 kilonewtons. Depending on the material, throughput of up to twelve tonnes of steel or cast iron swarf per hour is possible. For brass and copper, up to ten tonnes per hour are stated.

Systems like these are typically used where large quantities of metal swarf are generated continuously and briquetting needs to be fully integrated into the material flow.

Robust Construction for Continuous Operation

Briquetting presses must withstand high pressing forces and millions of press cycles over many years. A stable construction and durable pressing tools are therefore essential.

Depending on the model, Arno®Brik systems feature two- or three-column technology. The massive, welded construction is designed for continuous industrial operation.

A movable tool frame compensates for relative movements during the compaction phase. This is intended to reduce wear in the press box. Different tool diameters and materials also allow the briquette quality and service life to be adapted to the specific material.

Automation and Integration into Production Lines

A briquetting press can be operated as a standalone machine or integrated into a fully automated processing system.

Depending on the application, additional components can be used:

• swarf crushers
• conveyor systems
• swarf silos
• screening systems
• sorting technology
• dosing systems
• weighing systems
• liquid collection and filtration systems
• sludge conveyors
• briquette discharge systems

In addition to briquetting presses, ATM also offers solutions for crushing, screening, sorting, and conveying metal swarf. This allows the entire process, from material feed to the finished briquette, to be coordinated end to end.

The machines can be operated manually or automatically. Process sequences are visualized via a graphical control panel. Integration into automated production lines, as well as remote maintenance and system adjustments, is also provided for.

Which Briquetting Press Is Right for You?

Selecting a suitable briquetting press should not be based solely on hourly throughput. What matters is the interplay of material, process, and desired outcome.

The following questions should be answered before sizing a system:

What Material Is Being Processed?

Steel swarf behaves differently from aluminum, magnesium, or brass swarf. Grinding sludge and powdery materials also require their own feeding and pressing concepts.

What Is the Condition of the Swarf?

Short, dry swarf has different flow properties than long drilling swarf, swarf nests, or moist grinding sludge. In some cases, shredding or pre-treatment is therefore required.

How Much Material Is Generated?

In addition to average throughput, production peaks and future capacity expansions should also be taken into account.

What Liquids Are Present?

The type and quantity of cutting fluids affect pressability, liquid recovery, and the equipment required.

How Will the Briquettes Be Processed Further?

Briquette diameter, density, and residual moisture should be matched to storage, transport, and the subsequent melting process.

Material Tests Provide Planning Certainty

Since metal swarf and grinding sludge vary considerably depending on the production process, sizing based solely on general material descriptions is often not sufficient.

At the ATM Test & Competence Center, customer materials can be examined under practical conditions. Among other things, this includes testing the suitable machine, possible pre- or post-treatment, achievable throughput, briquette quality, and the amount of liquid that can be recovered.

A material test helps size the future system realistically and better assess the economic and technical results even before the investment is made.

Conclusion: Getting More Value from Metal Swarf with Briquetting Presses

Briquetting turns loose production residues into compact, more easily recyclable secondary raw materials. Companies reduce the storage space required, simplify their logistics, and create better conditions for transport and melting.

For moist swarf and grinding sludge, valuable cutting fluids can also be recovered. This reduces resource consumption and can lower disposal and operating costs.

With the Arno®Brik series, ATM Recyclingsystems offers briquetting presses for a wide range of materials and performance classes – from compact standalone machines to fully automated processing systems for continuous industrial operation.

Would you like to briquette metal swarf, grinding sludge, or special materials economically?

ATM Recyclingsystems supports you with material testing, machine selection, and the design of an individually tailored overall solution.