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AFR Systems

RDF Production (Shredding Line)

PH1’s RDF production and waste processing systems are designed to convert diverse waste streams – including industrial waste, mixed municipal solid waste (MSW), paper and pulp waste, textile waste, and agricultural biomassu – into consistent, high-calorific refuse-derived fuel (RDF).

 

Our high-capacity, modular RDF processing lines integrate shredding, screening, separation, and conditioning to deliver uniform particle size, clean fuel fractions, and reliable calorific value. Engineered for high uptime and continuous operation, PH1’s RDF systems are ideally suited for cement plant co-processing and waste-to-energy (WTE) applications.

Benefits of the PH1 Integrated Shredding Line

  • Handles a Wide Range of Waste Materials

Capable of processing industrial, municipal, paper & pulp, textile, and agricultural biomass, ensuring consistent shredding for RDF, SRF, and recycling applications.

  • Fully Integrated & Seamless Operation

PH1 manages complete system integration, combining shredders, screens, separators, and conveyors into a single automated line – eliminating the need to approach multiple equipment suppliers.

  • Reduced Operational Costs & Maintenance
Heavy-duty design, low-wear components, and self-cleaning features minimize downtime, OPEX, and maintenance efforts.
  • ATEX-Compliant & Advanced Fire Safety Protection
Designed in line with stringent ATEX safety standards, the system incorporates explosion prevention, spark detection, fire suppression, and safety interlocks — ensuring safe handling of combustible and volatile waste streams.
  • Optimized Resource Use & Sustainability

Enhances RDF/SRF quality, increases waste-to-energy conversion efficiency, and reduces reliance on virgin fuel, supporting plant sustainability goals.

  • High Throughput & Efficiency
Designed for primary and secondary shredding, screening, and separation, delivering consistent particle size and clean fractions to maximize fuel quality and downstream processing.
  • Modular & Customizable
Whether greenfield installations or retrofits, the line adapts to plant layout, waste type, and capacity requirements, ensuring maximum operational flexibility.
  • Dust-Controlled & Safe Operation
Integrated dedusting, fire control, and enclosed material handling systems ensure clean, dust-free, and safer working conditions.
  • Proven Track Record
Successfully installed in 30+ cement and WTE plants worldwide, delivering reliable performance and measurable ROI.

Primary Shredders Industrial Waste & Bulk Reduction

Primary shredders (pre-shredders) form the first stage of industrial waste processing, designed to handle large, bulky, and difficult materials. Engineered for high-torque, heavy-duty operation, they ensure efficient size reduction and reliable feed preparation for downstream sorting, RDF production, and waste-to-energy processes.

Key Features

  • Handles bulky and mixed waste streams including industrial waste, commercial refuse, MSW, C&D debris, plastics, textiles, and bulky paper/cardboard.
  • High-torque, slow-speed shredding for reliable reduction of tough and irregular materials with low risk of jams.
  • Robust mechanical design built for continuous duty cycles, heavy loads and abrasive materials.
  • Available in variable configurations (e.g., hook and rasper type) to suit waste composition and input needs.
  • Hydraulic and electric drive options to match plant power strategies and control requirements.

Waste Types

  • Mixed Municipal Solid Waste (MSW)
  • Industrial & commercial waste
  • Bulky and oversized items
  • Construction & demolition waste
  • Textiles, cardboard, paper bales
  • Plastics and composite materials

Capacity

Up to 125tph

Size

Down to 100mm

Secondary Shredders: Precision Size Reduction & RDF/SRF Quality

Secondary shredders, also known as fine shredders, operate after primary shredding and material separation to deliver controlled, uniform particle sizes for RDF, SRF, recycling, and waste-to-energy applications. They refine pre-shredded material into consistent fuel fractions, improving calorific value, handling efficiency, and downstream process stability.

Key Features

  • Designed for precision size reduction and homogenisation, producing a clean, consistent feed for fuel or recycling processes.
  • High rotor speed and refined cutting geometry tailor output sizes for specific end-use requirements.
  • Built for durability under continuous operation with replaceable wear parts and adaptable screens.
  • Available with hydraulic or electric power options and multiple shaft types for flexibility.

Waste Types

  • Pre-shredded industrial waste
  • Municipal solid waste (MSW) fractions
  • Paper, cardboard, and pulp residues
  • Textile and fibre-rich wastes
  • Biomass, plastics, and mixed sorted feed streams

Capacity

Up to 28tph

Size

Down to 15-50 mm

Screening

Flip-Flop Combi Screen: High-Efficiency Screening for Difficult Waste Streams

The Flip-Flop Combi Screen is engineered for reliable classification of difficult, sticky, wet, and heterogeneous materials commonly encountered in MSW, industrial waste, RDF, and biomass processing lines. By combining two screening technologies into a single machine, it delivers high separation efficiency while reducing plant complexity and footprint.

Key Features

  • Classifies challenging waste streams with separation cuts ranging from 0.2 mm to 120 mm, covering fine to coarse fractions.
  • Advanced vibrating flip-flop technology ensures near blockage-free operation on both upper and lower decks, even with moist or adhesive materials.
  • 3D screening elements on the lower deck ensure accurate grain sizing, preventing the passage of long pieces and unwanted contaminants.
  • Dual-deck, combined system integrates two screening stages into one compact machine.

Benefits

  • Reliable screening performance for wet, sticky, and high-contamination waste where conventional screens struggle.
  • Improved RDF and SRF quality through precise fraction separation and reduced oversize carry-over.
  • Significant savings in conveying equipment, steel structures, installation space, and overall CAPEX.
  • Higher uptime and reduced maintenance due to self-cleaning screening action.

Dynamic Screen: Precision Sizing for Mixed and Single-Stream Waste

The Dynamic Screen is a versatile and energy-efficient sizing solution designed for high-throughput waste processing applications. It delivers accurate and consistent material separation across a wide range of waste streams, making it ideal for RDF production, recycling, and waste-to-energy systems.

Key Features

  • Proven sizing solution for single-stream waste, MSW, C&D waste, wood, compost, green waste, plastics, glass, tires, and industrial residues.
  • Precisely engineered screen openings ensure accurate and repeatable material sizing.
  • Custom-designed infeed section tailored to match upstream feeding conveyors for smooth material flow.
  • Designed for low energy consumption while maintaining high screening efficiency.

Benefits

  • Consistent, high-quality output fractions for downstream shredding, separation, or RDF conditioning.
  • Flexible application across multiple waste types, reducing the need for dedicated screening equipment.
  • Lower operating costs due to energy-efficient design and optimized material flow.
  • Easy integration into new or existing waste processing and bulk material handling lines.

Separating

Air-Based Separators / Windshifters: Efficient Light & Heavy Fraction Separation

Air-based separators, commonly known as windshifters, are used in RDF and waste processing lines to effectively separate light combustible fractions from heavy inert materials. Designed for high-capacity operation and abrasive waste streams, these systems play a critical role in improving fuel quality and protecting downstream equipment.

Key Features

  • Engineered to process abrasive and heavy materials such as glass, stones, inert fractions, and metal scrap without performance degradation.
  • Capable of handling material sizes up to 600 mm, allowing direct integration after primary or secondary shredding.
  • High-throughput design with capacities of up to 200 m³/hour, suitable for large-scale RDF and MSW processing plants.
  • Advanced 3-in-1 separation technology enabling simultaneous separation of light, medium, and heavy fractions at high capacities.
  • Enclosed system design with negative pressure technology ensures dust-free and environmentally compliant operation.

Benefits

  • Significant improvement in RDF and SRF quality by removing inert and non-combustible contaminants.
  • Reduced wear and damage to downstream shredders, conveyors, and fuel handling systems.
  • Low maintenance design with minimal wear parts, resulting in reduced downtime and lower operating costs.
  • Cleaner plant environment and improved worker safety due to controlled dust extraction and containment.
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