A copper cable recycling line with crushing, gravity separation and electrostatic separation recovers copper from used cables at a purity of about 99%, through a dry process with no wastewater. Cables enter whole or pre-shredded, are crushed into small granules, and the separators split the copper from the PVC or rubber by the difference in weight and electrical conductivity, in a continuous automated flow.
A compact, modular copper cable recycling line is the solution for operators with medium to large volumes who want two sellable products, copper granules and PVC granules, from a single PLC-controlled system. Each stage is sized to work with the others, and the PLC system coordinates the feeding and separation speeds for a balanced flow. See the full range of recycling equipment and how it integrates into the flow.
Key Advantages for Copper Cable Recycling
• Copper granules ≥99%, gravity and electrostatic separation produce clean granules, accepted directly by smelters.
• Dry process, no wastewater, no sedimentation basins, simpler permitting than wet processes.
• Continuous PLC flow, automatic feeding, re-feeding of partially separated material and an alarm on anomalies.
• Two sellable products, copper granules and PVC/rubber granules, each with its own market and customer.
• Integrated dust filtration, capture of fine dust along the entire path, a clean working environment.
• Modular, stages are chosen and sized according to capacity and cable type.
• Small footprint, compact system compared to high-capacity lines, easy to install in medium-sized halls.
• Medium to high capacity, suitable for operators processing from a few hundred kg up to several tons per hour.
Technical Specifications, Copper Cable Recycling Line
| Parameter | Value |
|---|---|
| Process type | Dry: crushing + gravity separation + electrostatic separation |
| Feedstock | Used copper cables and wires |
| Crushing | Knife crusher for reduction to granules |
| Primary separation | Gravity / air separator |
| Secondary separation | High-voltage electrostatic separator |
| Recovered products | Copper granules (≥99%) and PVC/rubber granules |
| Control | PLC, continuous feeding, automatic re-feeding |
| Components | CE-marked where applicable |
| Capacity | Configurable per project |
Applications and Industries for Recovering Copper from Used Cables
A copper cable recycling line serves non-ferrous metal recyclers, recycling service firms and investors who collect used cables from industry, construction and demolitions. Used copper cables are one of the most valuable sources of secondary copper, with a much higher metal content than other mixed metal fractions. A dedicated line turns this abundant source into clean granules at market price.
The management of cable waste containing copper falls under European requirements for waste electrical equipment; a copper cable recycling line delivered in Europe is designed in accordance with the requirements of Directive 2012/19/EU on WEEE. For integration into a complete flow, see also the complete industry solutions.
Copper granules at ≥99% purity go directly into smelters or to refining, at better prices than unprocessed mixed cable. The PVC or rubber granules produced at the same time have their own market in regranulation and technical articles, so a copper cable recycling line generates two revenue streams simultaneously from a single feedstock source.
The modular design means you can choose the capacity that matches your volume: from a compact line for a few hundred kilograms per hour up to a larger line, with several crushing and separation stages, for several tons per hour. The investment scales with the actual volume.
As volumes grow, a modular copper cable recycling line expands by adding extra stages: a primary shredder for thick cables, a second electrostatic separator for higher purity, or an electrolyzer for refining copper to 99.99% cathode. The new modules integrate with the existing line, protecting the initial investment.
The dry process is decisive for operators who want to simplify permitting: no wastewater, no sedimentation basins, no water treatment systems. It is faster to permit, has lower operating costs and a better environmental footprint.
Compatible Materials
A copper cable recycling line processes a wide range of used cables. For large-section cables or thick bundles, a primary shredder is recommended for pre-shredding before the crusher. The better the material is sorted by cable type, the cleaner the copper granules produced.
| Accepted material | Notes |
|---|---|
| Copper wire Ø 0.3 to 20 mm | Main range, direct separation |
| Automotive and industrial cables | Electrical wiring from vehicles and machinery |
| Installation and construction cables | Cables from residential and industrial demolitions |
| Communications cables | Data and telecommunications cables with PVC |
How It Works
1. The cables are fed into the crusher, which reduces them to small metal and plastic granules.
2. The granules pass through the air gravity separator, which separates the heavy copper from the light PVC.
3. Partially separated material is returned automatically for a second pass through the crusher.
4. The copper granules pass through the high-voltage electrostatic separator for final purification.
5. The copper granules (≥99%) and the PVC granules are collected separately.
6. The pulse filter captures fine dust along the entire length of the line.
The PLC system coordinates the stages and signals any anomaly, allowing scheduled maintenance without unplanned stops. A well-tuned line keeps the granule quality constant throughout the work shift.
Frequently Asked Questions
What purity does the recovered copper have?
The purity of the copper granules reaches about 99% through gravity separation followed by high-voltage electrostatic separation. The granules can be sold directly to smelters or sent to refining for 99.99% cathode.
Does the process use water?
No. It is a fully dry process, with no wastewater and no sedimentation basins. This simplifies permitting, eliminates treatment costs and reduces the operational footprint.
What capacity can the line reach?
The capacity is configured according to your volume, from a few hundred kilograms per hour up to several tons per hour. The sizing of the crusher, the separators and the filter is done together, for a balanced flow.
Can I expand the line later?
Yes. A modular line expands with additional stages: a primary shredder, an extra electrostatic separator or an electrolyzer for refining. The new modules integrate with the existing line, protecting the initial investment.
Why URSTAG?
URSTAG is a premium brand of recycling equipment, with over 15 years of experience. You don't just get a machine, you get a solution engineered by specialists, built from top-tier components and backed by a team that supports you from design through commissioning.
• European engineering, every machine and every complete line is designed by our engineering teams in Europe, with a focus on reliability, safety and energy efficiency.
• Premium components, we build on motors and automation from industry leaders: Siemens, Schneider Electric, ABB, WEG, SEW-Eurodrive, NORD Drivesystems and Bonfiglioli.
• Over 15 years of experience, we know how materials and machines behave in real-world operation, and we configure each solution for your flow and volume.
• New equipment, configured for you, we supply new units, made to order for your application, with complete technical documentation.
• Delivery, installation and training included, we handle transport, commissioning and operator training, with support throughout the equipment's life.
As a premium brand, URSTAG relies on European engineering, top-tier components and experience. You choose a partner that supports your production long term, with equipment built to run reliably in demanding industrial environments.
