Panizzolo Mega Series Hammer Mills

The Panizzolo MEGA Series comprises high-capacity stationary hammer mills developed specifically for demanding scrap metal grinding and recovery applications.

Available as the MEGA 725 and MEGA 735, the range provides processing capacities of up to 25 and 35 tonnes per hour respectively, making it suitable for larger scrap processors requiring substantial throughput combined with effective liberation of ferrous and non-ferrous metals.

Rather than simply reducing scrap in size, MEGA hammer mills are designed to liberate metals from complex material streams and create material suitable for efficient downstream separation. They can be supplied as an individual processing machine or integrated with magnetic, eddy current, air, screening, sensor and refining technologies to form a complete metal recovery facility.

Panizzolo’s engineering philosophy focuses specifically on scrap grinding, balancing processing costs against the value of recovered outputs while prioritising structural strength, processing flexibility and straightforward inspection and maintenance.

Heavy-Duty Processing for Complex Scrap

The MEGA Series is designed to process heavier and higher-volume scrap streams, including:

• Mixed ferrous and non-ferrous scrap
• End-of-life vehicles (ELVs)
• Car engines
• Electric motors up to 40 kg
• WEEE and WEEE-derived material
• Mixed aluminium casings
• Aluminium sheet and profiles
• Aluminium cans
• Incineration slag
• Metal fractions recovered from municipal solid waste

Panizzolo’s application records demonstrate the MEGA 725 processing materials including car engines, electric motors, ELVs, aluminium profiles, mixed metals, aluminium scrap and municipal solid waste, while the MEGA 735 has been applied to aluminium recycling, aluminium casings, MSW-derived cans and car engines.

This processing flexibility makes the MEGA range particularly relevant to scrap metal recyclers handling multiple incoming streams rather than operating around a single consistent feedstock.

Panizzolo MEGA Series Range

*Maximum productivity figures supplied by Panizzolo. Actual throughput will depend on incoming material, feed preparation, configuration and treatment requirements.

MEGA 725

The MEGA 725 combines a 355 kW electric drive with processing capacity up to 25 t/h. Its 5,200 kg rotor carries 24 heavy-duty 52 kg hammers and is designed for substantial scrap processing applications.

MEGA 735

The larger MEGA 735 increases processing capacity to up to 35 t/h, powered by a 450 kW electric motor. The machine incorporates an 8,800 kg rotor carrying 32 × 52 kg hammers, providing the additional processing capability required for large-scale scrap recovery operations.

Designed Specifically for Scrap Grinding

Panizzolo developed the MEGA Series around the demands of metal processing rather than general-purpose material reduction.

The design considers the stresses associated with heavy scrap, material movement through the mill, wear, maintenance requirements and the relationship between energy consumption, throughput and the commercial value of recovered material.

Heavy-Duty Rotor

The MEGA rotor is internally engineered by Panizzolo to facilitate material intake and the grinding of heavier scrap.

Its construction incorporates special bearing supports, a special cast double pulley and a dedicated mill attachment system designed to absorb the stresses generated during processing.

Purpose-Designed Cast Hammers

MEGA hammers use a special casting developed in collaboration with the University of Padua and specialist Italian foundries.

The hammers provide 360-degree free rotation and are engineered to balance impact force, hardness, wear resistance and crushing performance.

Panizzolo reports a 13,000-hour lifecycle for its cast hammers during mixed iron scrap treatment. This is application-specific test data rather than a universal service-life guarantee.

Patented Interchangeable Cradle

Processing flexibility is supported by Panizzolo’s patented interchangeable cradle, a key component within the grinding process.

The cradle, armour and interchangeable grids can be configured according to the incoming scrap and required treatment cycle. The cradle system allows operations and configuration changes to be completed in less than 20 minutes.

This provides an important advantage for recyclers handling changing scrap streams, allowing the mill configuration to be adapted without lengthy changeovers.

Controlled Material Feed

The MEGA Series incorporates a loading conveyor developed in-house by Panizzolo for continuous operation under demanding processing conditions.

The conveyor is designed to handle a wide range of scrap and incorporates metal slats to help prevent material spilling from the conveyor, wear-resistant sections for durability and automatic adjustment through Panizzolo’s control software.

Internally designed eccentric mechanisms on the loading and unloading sections also help balance material movement and distribution, providing controlled inlet and outlet flows through the processing system.

Electric Operation and Energy Efficiency

Both MEGA models use fixed electric drives, with 355 kW on the MEGA 725 and 450 kW on the MEGA 735.

The range has been designed around the relationship between energy consumption and production capacity, with the objective of maximising hourly processing productivity while controlling the energy cost associated with each tonne processed.

For high-throughput fixed recycling operations, electric operation also removes the reliance on diesel-powered mill drives, making ongoing energy and operating costs an important consideration when comparing processing technologies.

Reduced Environmental Vibration

Given the size and processing forces involved, vibration management forms an important part of the MEGA design.

The MEGA 725 incorporates 40 anti-vibration components, while the MEGA 735 incorporates 56. These components dampen approximately 80% of the vibration generated by mill operation, reducing vibration transferred into the surrounding structure and environment.

Engineered for Maintenance

For large processing equipment, uptime is influenced not only by component durability but by how efficiently inspection and maintenance can be completed.

Panizzolo provides several systems specifically designed to simplify maintenance on the MEGA Series, including:

Hydraulic cradle release system
Four high-strength hydraulic devices assist with unlocking and extracting the cradle where it has remained installed for an extended period.

Rotor shaft extraction system
A hydraulic system assists with rotor pin extraction, helping speed up hammer maintenance and replacement.

Maintenance jib crane
A reinforced articulated crane provides up to 500 kg lifting capacity to assist with handling hammers and maintenance equipment.

Mobile maintenance cart
A dedicated cart supports routine electrical and mechanical maintenance activities.

For equipment processing potentially hundreds of tonnes of scrap per operating day, maintenance access and reduced downtime become major lifecycle considerations.

Available Soundproofing

Dedicated soundproofing is available for stationary MEGA hammer mills.

The system incorporates self-supporting galvanised steel panels containing hydrophobic sound-insulating material, mineral wool and additional acoustic layers.

For Australian fixed-site installations, this provides another consideration when engineering the overall facility layout and managing the environmental impacts associated with high-capacity scrap processing.

From Hammer Milling to Metal Recovery

The MEGA hammer mill can form the central liberation stage within a much broader Panizzolo processing system.

Depending on the material and desired commodity outputs, a processing plant can incorporate:

• Pre-shredding and volumetric reduction
• Magnetic separation
• Eddy current separation
• Zig-zag air separation
• Dynamic separation
• Screening
• X-ray sorting
• Metal sensors
• Pre-refining mills
• Refining mills
• Densimetric tables
• Optical separation

This means a processor can invest in an individual MEGA hammer mill or integrate it into a larger metal recovery plant, with Panizzolo’s modular equipment allowing processing stages to be introduced or upgraded as requirements evolve.

Why Choose a Panizzolo MEGA Hammer Mill?

The MEGA Series is suited to high-throughput scrap metal processors that need more than simple size reduction.

With capacities reaching 25 t/h with the MEGA 725 and 35 t/h with the MEGA 735, the range combines heavy-duty scrap grinding with electric operation, adaptable mill configuration and integration with downstream metal separation and refining technologies.

The ability to process materials ranging from mixed metals and aluminium through to electric motors, engines and ELVs also allows operators to develop a processing system around multiple commercial scrap streams rather than being limited to a single feed material.

Panizzolo MEGA hammer mills can be supplied as standalone equipment, integrated into an existing operation, or incorporated into a complete engineered metal recovery facility, supported by local engineering, commissioning and after-sales service.

Process More. Recover More.

Selecting the right hammer mill requires consideration of the incoming scrap, required throughput, feed preparation, downstream separation and the quality of the final recovered commodities.

Talk to Waste Initiatives about your material streams, processing volumes and recovery objectives to determine the right Panizzolo MEGA hammer mill and metal recovery configuration for your operation.