METAL CHIP

PROCESSING
SYSTEMS
excellence in engineering - since 1933

THE NATIONAL ADVANTAGE

SINCE 1933
A PIONEER AND LEADER
Founded in 1933, National pioneered metal chip processing
during World War II. The War Production Board selected
National Conveyors Company to develop processes for the
recovery and recycling of metal wastes generated from the
manufacture of aircraft, ships, tanks, munitions and other
military equipment. National engineers and designers
succeeded in this effort, establishing the basic technology of
metal chip processing as it is known today. In recognition of
this achievement, the Company was awarded several U.S.
Government citations. Since then, National has established a
worldwide reputation as a leader in this field and continues
this worthy tradition by providing economical state of the
art solutions.
OFFICES AND PLANT
NATIONAL CONVEYORS COMPANY

WORLDWIDE RECOGNITION

A REPUTATION FOR PRODUCT QUALITY

AND FOLLOW UP SERVICE

National metal chip processing systems have been

selected by leading manufacturers in North America,
Europe, Latin America and Asia, handling the following
types of metal scrap:

Nationals customers regularly commend the quality of its

systems - both in terms of performance and maintenance.
Hundreds of National systems are now providing trouble-free
performance after 20, 30, or more years of continuous
operation.

Aluminum
Mixed Metal Waste
Die Casting Scrap
Brass
Stamping Scrap
Nodular Iron

Cast Iron
Bronze
Stainless Steel
Magnesium
Carbon Steel
Titanium

After-the-sale service is a strong tradition at National. Our

local representatives and factory based engineers and
technicians carry out periodic on-site visits to review system
performance and offer useful recommendations.

SMALL OR LARGE SYSTEMS

THE NATIONAL NO COMPROMISE
APPROACH
National takes a No Compromise approach to system
design and supply. Unlike other suppliers, we do not impose
on our customers the application of various items of proprietary equipment with advice that one or two such designs can
serve a multitude of needs. National consistently adheres to
the practice of selecting the best equipment available - for
each particular application - rather than trying to fit equipment
only manufactured by National to the project. We have
developed long standing alliances with many machinery
manufacturers - an arrangement which permits us to select
and economically package the most suitable items of
equipment for each application. This tailor made approach
has important benefits for the system user in terms of
optimum, trouble-free performance.

Whether your needs call for a small, pre-engineered, stand

alone system or a custom high capacity, multi-metal, computer controlled chip processing system, National can serve your
needs with economical, leading edge technology and heavy
duty, low maintenance equipment.

excellence in engineering

since 1933

OBJECTIVES/DESIGN CONSIDERATIONS
CHIP PROCESSING OBJECTIVES
There are several economic, operational, environmental and safety related reasons
for the use of metal chip processing systems. Principal reasons or objectives include:
1. Obtain an optimum price for metal scrap - through upgrading.
2. Optimize the physical characteristics of scrap for internal reclaim (re-melt) operations.
3. Reclaim and recycle costly cutting oils.
4. Minimize in-plant waste handling costs.
5. Compliance with pollution control regulations.
6. Compliance with worker health & safety requirements.

TYPES OF METAL SCRAP

Proper system design and equipment selection depends upon having a thorough understanding of the physical characteristics
of the scrap to be handled and processed. This understanding is critical to the selection of the type of conveyors, classification
equipment and size reduction equipment. Some of the more common types of metal scrap are pictured below.

BROKEN CHIPS: Also known as shoveling

chips. This material is free flowing and has normally been crushed to a particle size of 1 - 2
(25mm-50mm). The compact nature of such
chips and extensive surface area retains
considerable coolant. Density and weight varies
with metal type.

BUSHY TURNINGS (TIGHT): This material

consists mostly of spirals, long strings and
helixes together with some smaller particles.
During its production and handling it has become
compressed in some manner. Medium bulk
density depending on metal.

BUSHY TURNINGS (LOOSE): Similar material

as found in the tight version but tends to form in
light, fluffy bundles which are more difficult to
convey and process. Low bulk density.

IRON BORINGS & CHIPS: This scrap is

generally finer in size structure - typically from
about 3/16 (4mm) to dust and may host a
considerable amount of coolant. High bulk
density.

DIE CASTING SCRAP: Risers, sprues and the

like, removed following the casting process.
Particle size varies and may include larger pieces
of reject or broken castings. Bulk density
depends upon metal type.

STAMPING SCRAP: Generated by perforating

and trimming operations. Generally free flowing.
Typical particle size range is 1 (25mm) to 8
(200mm) in the major dimension. Thinner gauges
are more difficult to handle. High bulk density.

A SYSTEM FOR ANY NEED

National chip systems process cast iron and aluminum chips at large engine plant.

Chip processing and load out system at transmission components plant. National-Arboga crusher and chip wringer in background.
Motorized swivel chutes distribute chips to roll off containers.

National chip processing systems installed at a major U.S. automotive components plant.

National Stand Alone chip processing system processes steel turnings.

Dry chips are pneumatically conveyed to containers.

CHIP COLLECTION & CONVEYING

MECHANICAL CONVEYING
Several different types of mechanical conveyors are used to convey metal chips and turnings. Each has its own unique
benefits where properly applied. The physical characteristics of the material to be handled must be carefully studied to
insure the correct selection of conveyor. A wrong choice, based on inexperience or overemphasis on initial cost, can lead
to undesirable consequences. National provides the following types of mechanical conveyors.

DRAG FLIGHT CONVEYOR

Used for conveying broken, crushed or finely sized chips only.
Suitable for both horizontal and inclined runs. Do not use
where stringy (bushy) turnings are present as these will cause
jamming of the drag chains. The usual configuration is a rectangular trough fitted with a single strand or two parallel strands
of drive chain to which vertical drag flights are attached providing the conveying mechanism.

HINGED STEEL BELT (APRON) CONVEYOR

A multi-purpose metal scrap conveyor useful for a combination
of horizontal and elevating runs. It is used as an elevating
conveyor for wet or dry coarse chips or bushy scrap. Nationals
belt includes special tight formed hinge loops and arc welded
side wings to preclude common wear and jamming problems
encountered with conventional steel belt designs.

SCREW (HELICOID) CONVEYOR/FEEDER

Screw conveyors may be properly applied for short horizontal
or inclined runs. Also frequently used as controlled rate feeders
fitted to the bottom of storage bins or surge hoppers. Nationals
design usefully features constant thickness, abrasion
resistant flights continuously welded to an oversized, heavy
wall pipe shaft.

PUSH-BAR CONVEYOR
A reciprocating stroke (push-pull) plow mechanism moves
material in the desired direction. Especially effective for
handling bushy, stringy bundles and mixtures of bushy and fine
chips together with large volumes of coolant. Normally installed
at or below floor level. Coolant removal can be aided by use of
wedge wire screen panels at selected points, draining into
a sub trough.
8

CHIP CONVEYING - PARTS SEPARATION

PNEUMATIC CONVEYING
National Conveyors is the leading designer and supplier
of metal chip pneumatic conveying systems. Pneumatic
transport has the following advantages over mechanical
conveying: (1) Lower capital cost, (2) much lower
installation cost and (3) lower system maintenance cost.

Two design options are offered by National:

Dilute phase pneumatic conveying
Dense phase pneumatic conveying
Dilute phase pressurized air systems can be used for
conveying chips at medium pipeline velocities for
distances of 2,000 feet (610m) or longer. Dense phase
pressurized air systems are used for low velocity
conveying of wet or dry chips.

Photograph above shows a National double gate air lock type chip
feeder used for regulating chip feed to dilute phase conveying system.
Photograph at left shows a dense phase pneumatic transporter used for
feeding metal chips into the conveying pipeline. Chips are delivered to the
top of the transporter where oversize material is scalped and removed
through the inclined chute.

PARTS/SOLIDS SEPARATION
Properly designed chip processing systems must include
provision for separation of parts and unwanted tramp
oversize material which may unavoidably be mixed with
metal scrap. Such items can cause damage to downstream equipment.

VIBRATING GRIZZLY OR SCREEN

Vibrating grizzlies and vibrating screens are used to sort
solids by size. The vibrating grizzly is a coarse material
screening device having a number of parallel bar
elements spaced for the desired size of separation.
Vibrating screens are normally used for feeds from which
larger objects have already been removed and a more
accurate final product sizing is desired. The selection of
screen decking is a critical consideration and is dependent
largely on the physical configuration of the feed material.
9

PARTS SEPARATION
NATIONAL PARTS SEPARATOR
AIR EXHAUST
FEED
REJECT
SLOT

AIR INTAKE

FEEDER
PAN

BLOWER
TURNINGS

REJECTS

PARTS SEPARATOR

When parts of other solids must be scalped from bushy

metal turnings, the National parts separator shown here
may be usefully applied. Chips and turnings together with
occasional parts, bar ends or other larger items are
delivered by conveyor to the feeder pan which is
mechanically oscillated with a sideways action. This
condition causes long narrow items to orient themselves
so as to easily report through the reject slot. Pressurized

air flow passing upwards through the reject slot has

sufficient buoyant force to carry metal chips and turnings
over the slot opening. Heavier parts and tramp metal
items are not supported by the induced air flow and pass
downward into a collecting hopper from which they
discharge into a container. Air flow is vented from the top
of the discharge hood and can be recirculated when
required.

CRUSHING AND SHREDDING

Size reduction of metal scraps by crushing or shredding
is commonly performed when material larger than about
1-1/2 (38mm) is being generated (such as machine turnings). Size reduction is beneficial in these ways:

10

crushed scrap commands a higher market price

reduces stringy, bushy scrap to a smaller size,

making handling easier

enhances recovery of cutting oils and coolants

during the chip wringing (centrifuging) process

produces a product with higher bulk density

(greater weight per unit volume) minimizing
handling, transport and storage costs

Moreover, crushing is often an essential process step

when pneumatic conveying, bin storage, briquetting or
thermal drying is employed.
Three types of crushers and shredders are commonly
used in chip processing systems:

vertical shaft (crusher) shredder

horizontal shaft two roll shredder
horizontal shaft, ring type crusher
(Hammermill)

National offers all three. They are briefly described on the

following page.

CRUSHING & SHREDDING

NATIONAL
VERTICAL SHAFT
CRUSHER/SHREDDER
A highly efficient machine for
coarse or fine particle size
reduction. Metal turnings are
drawn downward by the rotating feeder arm. Side wall cutters break up bundles. Final
reduction occurs in the lower
throat zone which is fitted with
rotating and fixed cutting
tools. Automatic parts (solids)
rejection is an important
feature (see Bulletin 1200A).

NATIONAL HORIZONTAL
SHAFT TWIN ROLL
SHREDDER
Useful as a bundle breaker
and for coarse to medium size
reduction, counter rotating
shafts (rolls) are fitted with
toothed cutting rings. Turnings
fed at confluence of rolls are
drawn inward where shredding occurs. Shredder can be
hydraulically or mechanically
driven.

ROLLING RING TYPE

CRUSHER
An excellent machine for
medium and fine crushing of
metal turnings. Hammer rings
held by rotating arms smash
(crush) incoming turnings
against a manganese steel
breaker plate and grate bars
located in the bottom of the
crushing chamber. Product
size is controlled by grate
bar opening. Crusher has provision for rejecting oversize
solids.

LARGE SOLIDS ARE REJECTED BY

ROTATING CRUSHER RINGS,
CAUSING THIS MATERIAL TO REPORT
TO OVERSIZE BYPASS CHUTE

TRAMP METAL

FEED
CONVEYOR
PROTECTIVE
HOUSING

TRAMP
OVERSIZE

MANGANESE
STEEL LINERS

ROTOR
SHAFT

MANGANESE
STEEL
GRATE BARS

SECONDARY TRAMP
METAL DISCHARGE

CRUSHED CHIP DISCHARGE

11

CHIP WRINGING (CENTRIFUGING)

The chip wringer (centrifuge) is the heart of any chip processing system. This is where the principal goal of extracting
residual cutting fluids is accomplished. National offers both horizontal and vertical bowl centrifuge designs. These are
described below.
HORIZONTAL BOWL SELF-CLEANING CENTRIFUGE
The National Horizontal Bowl Self Cleaning Centrifuge has become the preferred device for chip wringing at major metal
working plants in the U.S.A. and internationally. Both fixed bowl and adjustable bowl models are offered. Design features
and user benefits include:
HIGH EFFICIENCY LIQUID/SOLIDS SEPARATION
Up to 550 gravities of centrifugal force and uniform feed
distribution assure optimum dewatering performance.
CONTROLLED LIQUID SEPARATION PERFORMANCE
The bowl may be positioned so as to provide a selected
drainage screen exposure which results in the desired
product dryness.

SELF-CLEANING, HORIZONTAL BOWL DESIGN

When the centrifuge is coasting to the stopped
condition, the residual chip load tumbles from the
machine leaving it in a clean condition for the next start
up (see photograph below).
EASY INSPECTION & MAINTENANCE
All internal wetted parts can be inspected in 5 minutes.
Simply open the hinged front door. The motor and drive
components are externally mounted.

HOW IT WORKS
Wet chips enter the centrifuge through the feed inlet hopper (1) and delivery chute (2) from which they are uniformly
distributed across the surface of the rotating bowl (3), aided by feed distribution vanes. Newly arrived wet chips move
outward over the rotating bowl surface, discharging onto a rotating, cylindrical wedge wire drainage screen element (4).
New chips move onto the screen surface displacing previously arrived chips. Separation of liquid occurs as chips pass
over the drainage screen. Dewatered chips fall through the solids discharge chute (5) from which they are normally
collected by a conveyor. Liquid which has passed through the drainage screen element (4) flows through the liquid
discharge chute (6) for collection.

View shows self cleaning action

when centrifuge is coasting to
the stopped position.

National Model HD82VS Horizontal Bowl Centrifuge

OPTIONAL PATENTED FEATURE

AVAILABLE WITH VARI-SCREEN T.M. MODEL
Usefully, by simple external adjustment, the bowl (3)
may be moved laterally back and forth over the
drainage screen surface (4) thereby establishing the
best choice of screen exposure for optimum liquid
removal and the achievement of desired product dryness. Positioning of the bowl is easily accomplished
by rotation of the external adjustment mechanism (7).

Bowl positioned for minimum

drainage screen exposure

12

U.S. PATENTS
5,788,861
5,855,800
FOREIGN PATENTS PENDING
Ask for Bulletin No. 900-2

Bowl positioned for maximum

drainage screen exposure

CHIP WRINGING
VERTICAL BOWL, PNEUMATIC DISCHARGE TYPE CENTRIFUGE
HOW IT WORKS (See Below)
Chips and cutting fluids (coolants) are fed into a conical inlet hopper (1) reporting to the bottom of the rotating bowl (2).
The bowl is mounted on a heavy-duty shaft and bearing assembly (3), driven by a non-slip timing belt and sheave
arrangement (4) and easily accessible foot-mounted motor (5). Chips and fluids arriving within the bowl are immediately
subjected to a high centrifugal force. This centrifugal force causes both chips and fluids to be thrown against the bowl surface.
The arrival of additional (new) chip feed causes chips already present on the bowl to be displaced in an upward direction along
the bowl surface. As chips and fluid arrive at the upper periphery of the bowl, they pass across a stainless steel wedge wire
screen (6) through which cutting fluids are centrifugally expelled into a discharge chamber (7) from which this fluid flow is
directed to a coolant collecting sump (not shown) for subsequent treatment or disposal. Dried chips pass across the screen
into the chip discharge housing (8) from which they are pneumatically expelled by the airflow generated by fan blades (9) into
discharge piping (10). The airflow generated by the wringer is normally adequate for conveying chips for a distance of up to
about 100ft. (30m). Typically, the pneumatic discharge pipe delivers dried chips to a roll-off container, truck or interim storage bin.

BATCH TYPE CHIP WRINGER

National Model TI-30 pneumatic discharge centrifuge installed

at a major aircraft manufacturer.

The National-Rousselet Timesaver chip wringer centrifuge is an efficient and economical device for manual, batch
processing of metal chips and turnings. An excellent choice for smaller machining operations. Three high capacity (labor
saving) models are offered having basket volumes of 10 cu. ft. (290 I.), 16 cu. ft. (460 I.) and 32 cu. ft. (900 I.) Rugged 3 point
suspension. Controlled acceleration and smooth braking. There is no other comparable batch type centrifuge.

Model SC 100 KC Chip Wringer

Ask for Bulletin No. 0299-R

13

CHIP LOAD OUT

The final phase of any chip processing system - chip load
out - must be designed to accommodate both the present
and potential future needs of each installation. Normally.
processed chips are loaded directly into containers, trucks
or rail cars. In some cases, chips may be conveyed to
storage silos or bins from which they are loaded into trucks
or rail cars. Conventional chip load out systems employ
both mechanical and pneumatic conveying methods
together with various types of fixed or moveable chutes,

slide gates, or the like. When the chip load out station is
located a considerable distance from the chip processing
system, pneumatic conveying is a preferred transfer
method.

Mechanical conveyor discharges to swivel chute providing a

means for loading two roll off containers.

National pneumatic discharge type centrifuge can convey chips

for a distance of about 100 ft. (31m)

National offers its exclusive Vari-Slot overhead load out

conveyor system. Acknowledged as the most advanced,
state of the art method for uniformly distributing chips into
containers or trucks, it is described on the following page.

Above: National supplied long distance pneumatic

conveying system carries processed chips approximately 2,000 ft. (610m) to interim storage silos.
At Left: A screw type feeder is used to evacuate the
bin in the foreground. A live bottom vibrating actuator is fitted to the other bin.

14

VARI-SLOT TM TRUCK LOADING CONVEYOR

THE MOST EFFICIENT AND ECONOMICAL METHOD FOR TRUCK OR RAIL CAR LOADING
The National Vari-Slot T.M. load out conveyor is a unique
design of overhead drag type conveyor used for uniform
distribution of bulk materials into trucks, rail cars, containers
or bunkers.
The discharge station of the conveyor is comprised of one or
more sections, each fitted with an articulating bottom plate
which may be controllably positioned to provide the desired
material discharge pattern.

THE APPARATUS AND METHOD OF THE

NATIONAL VARI-SLOT CONVEYOR IS
PATENTED. U.S. PATENT NO. 6,109,425.
FOREIGN PATENTS PENDING.

Individual articulating bottom plates may be positioned for

zero discharge, maximum discharge or a selected intermediate rate of discharge.
The choice of which conveyor bottom plates are left in a
closed position and which plates are positioned to permit
material discharge depends on the desired distribution
pattern and the length of the trailer or container to be loaded.
Generally speaking, the vari-slot conveyor is used for
loading trailers, rail cars or containers ranging in length
between 20 ft. and 60 ft. (6m to 18m).

CONVEYOR DISCHARGE SECTION

FEED STATION
TRAILERS OR CONTAINERS
OF VARYING LENGTHS CAN
BE QUICKLY AND EASILY
ACCOMMODATED

Multiple National Vari-Slot loading conveyors are used for metal

chip loading at an automotive parts manufacturing plant.

Vari-Slot

T.M.

conveyor in operation

EXCEPTIONALLY UNIFORM
LOAD DISTRIBUTION
MINIMUM HEAD ROOM, NO
CHUTES OR GATES ARE
REQUIRED

Ask for Bulletin No. 900-01

excellence in engineering

since 1933

15

DEWATERING SYSTEMS FOR GRINDING SWARF

AND DISPOSABLE FILTER MEDIA
REDUCE THE COST OF METAL
SLUDGE DISPOSAL WITH A
NATIONAL-SEBRIGHT HIGH
DENSITY EXTRUDER
The National-Sebright High Density
Extruder is a highly efficient machine for
dewatering metal grinding sludge (swarf)
and saturated disposable filter media.

Sludge (swarf) volume

reduced by 50% or more

can

be

The dry, cake-like discharge product

will generally be suitable for disposal
in a local landfill, with considerable
savings over other specialized disposal arrangements.

Achieve compliance with Federal and

State regulations governing the
handling of wet waste.

Several machine sizes are available.

Pilot testing of your swarf can be

arranged.

Ask for Bulletin No. 1101 for complete

details.

National-Sebright High Density Extruder installed

at automotive components manufacturing plant.

The photographs at the right show cast

iron grinding sludge (swarf) before and
after processing in a High Density
Extruder.
CONVERT THIS.....................................................TO THIS

ENGINEERS & MANUFACTURERS

Since 1933

33 Nicholson Road, East Granby, CT 06026 Tel. (860) 653-0374 Fax (860) 653-2965
Bulletin No. 0902

www.nationalconveyors.com