The Russian 1-ton capacity circuit board recycling production line is a comprehensive PCB processing project that combines a fully automatic PCB Dismantling Machine with a high-efficiency Motherboard Crushing & Separating Line. Designed for large-scale electronic waste recyclers, this system provides stable 1-ton/h throughput while meeting Russia’s strict environmental and industrial safety standards.

1. Project Background

The Russian customer specializes in recycling waste electronic components, computer motherboards, home appliance PCBs, and communication equipment boards. Their main objectives were:

• Handle 1 ton per hour PCB processing capacity
• Reduce labor workload in manual dismantling
• Recover copper, aluminum, precious metal–bearing components, and fiberglass efficiently
• Maintain clean, safe, and dust-free operation in cold-climate conditions
• Use equipment with long service life and strong wear resistance

To meet these needs, the project integrates automatic solder removal, component recovery, continuous crushing, airflow separation, and electrostatic metal separation technologies.

2. On-Site Equipment Configuration

(1) Fully Automatic PCB Dismantling Machine

• This unit performs the pre-processing stage by removing electronic components from bare PCBs.
• High-temperature circulating heating ensures fast and uniform solder melting
• Components fall off automatically without manual prying
• Clean separation of resistors, MLCCs, IC chips, BGA, connectors, and gold-plated parts
• Safe operation with heat insulation and fume collection system

(2) Motherboard Primary Shredding Section

• Large PCBs and dismantled boards are fed into a heavy-duty industrial shredder.
• High-torque shafts handle thick computer boards easily
• Slow-speed cutting reduces dust and protects metal integrity
• Automatic feeding enhances operator safety

(3) Fine Crushing & Pulverizing System

• Processed PCB fragments are reduced to 20–40 mesh for optimal separation.
• Multi-stage crushing with wear-resistant alloy cutters
• Intelligent overload protection prevents breakdowns
• Stable output suitable for continuous 1-ton/h production

(4) Airflow Gravity Separation

• Separates lighter resin powder and fiberglass from heavier metal powders.
• High separation accuracy
• Adjustable airflow to match different board types
• Ensures stable material purity before electrostatic processing

(5) Electrostatic Metal Separator

• The core technology for final metal extraction.
• Recovers copper, aluminum, and mixed precious metal particles
• Metal purity reaches ≥ 98%
• Highly efficient in separating resin-fiber mixtures

(6) Pulse Dust Collecting System

To comply with Russian industrial dust emission requirements:

• Full-line negative pressure design
• Pulse-jet filter system keeps the workshop dust-free
• Ensures safe and clean operation even during winter low humidity

(7) PLC-Controlled Central Operation Panel

• One-button start/stop
• Real-time monitoring of current, temperature, and airflow
• Fault alarm and interlock protection

3. On-Site Operation Performance

• Since commissioning, the Russian 1-ton line has demonstrated:
• True 1,000 kg/h stable throughput
• Metal recovery rate above 98%
• Continuous 24-hour operation with low downtime
• Strong performance in cold climate due to optimized heating and insulation
• Significantly reduced labor: only 3–4 operators required per shift

4. Customer Benefits

(1) Operational Efficiency

• Automated component removal saves 60–70% labor
• High throughput increases daily processing volume

(2) Economic Value

• High yield of copper, aluminum, and gold-bearing components
• Clean recovered materials sell at higher market value
• Environmental Compliance
• Dust-free workshop
• No wastewater discharge
• Meets local regulatory standards
• Long-Term Sustainability
• Modular design allows expanding to 2-ton or 3-ton lines
• Stable spare parts supply and remote technical support