Maintaining Performance

A nonfunctioning shredding plant amounts to more than a minor inconvenience for a secure destruction company, bringing operations to a halt. The proper preventive maintenance can help companies avoid the downtime associated with major repairs or catastrophic failures.

When it comes to preventive maintenance, establishing and maintaining a routine can ensure that a company performs the necessary tasks. And having a shredding equipment supplier spend some time instructing a company’s employees on the particulars of maintenance also can help to ensure that these tasks are performed correctly.

“All shredding system maintenance can be handled by in-house personnel with minimal training,” says Michael Wilhoit, vice president of operations, Vecoplan LLC, Archdale, N.C.
 

THE BASICS

Jeff Robas, director of technical service for Allegheny Shredders, Delmont, Pa., outlines the essentials of preventive shredding system maintenance. “First, employees need to be properly trained in how to perform preventive maintenance on the shredding system,” he says. “Second, establish a systematic routine of preventive maintenance for all components. Third, document and verify that all maintenance is properly performed as indicated by the manufacturer. Lastly,” he adds, “identify any potential problems that have been discovered and determine what corrective action should be taken in resolving these problems.”

Amos Manufacturing, Alpena, Mich., provides service for Ameri-Shred equipment. The company’s Randy Beaudoin also stresses the importance of training personnel, adding that supervisors should be trained on proper maintenance as well.

Beaudoin says establishing accountability for preventive maintenance is necessary. “Someone needs to be in charge and oversee the program,” he says. “So many times I hear, ‘I thought someone else was greasing the machine.’”

A destruction firm should consult its shredder manufacturer or the operators’ manual for preventive maintenance recommendations, as they are likely to vary by shredder type and manufacturer. “The manufacturer’s recommendations for each machine are specific and varied,” says Wilhoit. “It is the responsibility of the owner/operator to become proficient in the individual characteristics of their own machine.” However, he says the basic steps of preventive maintenance include maintaining cutter and counter knife sharpness, fluid levels, tolerances and torque on cutters, counter knives, bolts and screens and belt tension.

When an operation has consistent lapses in preventive maintenance, serious damage could result. “Lack of preventive maintenance is usually the major cause of catastrophic failures,” Robas says. “Besides the obvious cost of replacement of worn out or damaged components, the loss of ‘shred time’ is usually the most costly.”
 

CLEANLINESS AND LUBRICATION

Lubrication is a critical component of preventive maintenance. This involves using the correct lubricant in the correct amount and on the correct schedule, Beaudoin says.

Insufficient greasing of sprockets and drive chains is among the three most frequent issues Robas says he has seen in destruction operations. “When I was conducting on-site inspections a few years ago, this one issue was common with many facilities,” he says. “In some cases the drive chains were bone dry, and the sprocket’s teeth were worn down to points. It was just a matter of time, a few weeks, maybe a couple of months, before an entire shredding system would come to a stop because of such a simple procedure being neglected.”

In addition to sprockets and drive chains, spur/drive gears and the drive coupler also should be lubricated according to the schedule provided by the shredder manufacturer.

Robas also says cleaning and oiling of the cutting assembly is an important part of preventive maintenance. “One of the main reasons for low capacity in a shredder is the cutting assembly is packed full of material,” he says. “This not only decreases capacity but hinders proper lubrication of the cutters.”

Maintaining proper tensioning of drive belts also contributes to proper shredder functioning. Robas says the drive belts will squeal when the shredder jams, indicating they are loose. “Typically, you’ll hear them, smell burning rubber and notice the capacity of your shredder isn’t like it used to be,” he adds.

Vecoplan’s Wilhoit says the most common service calls to his company have to do with dull cutting tools. The preventive maintenance tasks he says he sees operators overlooking most often involve cleaning the hydraulic components and cooling unit filters.

Amos commonly responds to requests for personnel training and education on shredding equipment, Beaudoin says. “This results from personnel changes, change of ownership and equipment relocation,” he says.

“We would recommend that professional service be used if existing personnel is untrained, new or change of ownership has taken place. Training by a factory technician would be highly recommended anytime new personnel is introduced to our equipment,” Beaudoin says.

When it comes to obtaining necessary replacement parts, Jim Wagner, production manager for Allegheny Shredders, says the company can ship basic replacement parts to customers within 24 hours. Spare parts packages also are available, which allow destruction companies to keep common wear parts in inventory at their facilities.

WHEN TO SEEK SERVICE

While, according to sources, most destruction companies opt to perform preventive maintenance in house rather than use the services of the manufacturer, dealer or outside service company, some issues may be best left to the manufacturer or its representative. For instance, Beaudoin recommends contacting the manufacturer or its authorized representative for an ongoing maintenance issue that has not been adequately resolved through phone support.

A destruction firm should consult its shredder manufacturer or the operators’ manual for preventive maintenance recommendations, as they are likely to vary by shredder type and manufacturer. 

“Ideally, a customer should contact the manufacturer or authorized dealer for professional service when they have new employees to train,” Robas says, “or if there’s been major damage to the equipment (such as broken cutters, damaged drive shafts, damaged or missing safety guards or covers, etc.).”

Wilhoit suggests enlisting professional help from the manufacturer for electrical component replacement or rotor/gear drive replacement.

Robert Wagner, director of marketing for Allegheny Shredders, says many of the large destruction firms opt to have service technicians from Allegheny come in yearly to train personnel on proper equipment operation and maintenance as well as to inspect the equipment to determine any deficiencies in their preventive maintenance.

Regardless of the approach a destruction company adopts, preventive maintenance is critical to optimal shredding system functioning.