At IFAT 2026, the company will present the PKR, a pre-shredder that reinterprets a central design principle of many slow-speed machines. Instead of using a conventional reduction gearbox, the machine operates with a powerful direct drive. The highly efficient torque motor generates the required torque directly within the motor, thereby reducing wear, maintenance requirements and energy losses.
Direct Drive Replaces Conventional Gear Technology
In conventional pre-shredders, the reduction gearbox is one of the most heavily stressed mechanical components. Particularly during sudden load changes, such as those caused by contaminants or unshreddable materials in the input stream, high dynamic loads occur. In addition to process forces, the rotating masses must also be absorbed abruptly. These load peaks often lead to increased wear and can result in high maintenance costs over time.
With the PKR, ALLRECO therefore adopts a different approach. The newly developed direct drive generates the required torque directly in the motor. The multi-pole torque motor achieves nominal speeds of around 30 revolutions per minute at full torque and operates entirely without an intermediate gearbox.
Fewer Components, Reduced Wear
Eliminating the reduction gearbox significantly reduces the number of mechanical components in the drive train. Transmission elements and typical wear points are no longer required. At the same time, friction losses – such as those occurring in gear teeth and bearings – are avoided. This improves the overall efficiency of the system, while the installed drive power can be reduced.
The concept also offers design advantages. Fewer moving parts and a more compact design result in a clearer machine structure. Maintenance work becomes easier, and overall operation is more robust. Load peaks are no longer transmitted mechanically, but are absorbed contactlessly within the motor itself.
Focus on Cost-Effectiveness and Plant Availability
In addition to technical robustness, economic efficiency played a central role in the development of the PKR. Eliminating the gearbox significantly reduces maintenance requirements. Tasks such as oil changes, seal replacements and regular gearbox inspections are completely eliminated. At the same time, the risk of unplanned downtime – often caused by gearbox failures in slow-speed shredders – is reduced.
Furthermore, the improved efficiency of the direct drive helps to lower energy consumption. Overall, the concept contributes to reducing total operating costs while increasing plant availability.
Designed for Demanding Material Streams
The PKR has been specifically developed for pre-shredding applications in waste and recyclable material processing. This includes applications with highly variable material compositions, high levels of contaminants and a high torque demand at low speeds.
Typical applications include household and commercial waste, bulky waste, mixed construction waste, as well as the processing of refuse-derived fuels (RDF), lightweight packaging and plastic fractions. In these material streams in particular, the direct drive demonstrates its advantages by handling load peaks with exceptional robustness.
Flexible Integration into Existing Plant Concepts
The PKR is designed for flexible integration into a wide range of plant concepts. It can be used both as a standalone pre-shredding stage and as part of multi-stage processing systems. It is also suitable as a replacement solution for existing machines with geared drives.
Thanks to its compact design and reduced mechanical complexity, the machine offers greater flexibility in plant layout and maintenance accessibility. This makes it suitable for both new installations and modernisation projects.
