The most common errors in the operation of industrial machinery and how to avoid them
Industrial recycling machinery requires proper use and ongoing maintenance to ensure optimal performance and a long service life. This equipment is essential in waste treatment lines, and incorrect operation can lead to productivity losses, unexpected downtime and costly breakdowns. In this article, we analyse the most common errors in the operation of industrial machinery and how to prevent them in order to improve productivity and reduce maintenance costs.
Identifying the most common errors in machinery operation and implementing preventive measures is key to maintaining process efficiency and optimizing the use of each piece of equipment.
Errors in material feeding
Overloading of machinery
One of the most common operational errors in shredding systems is overloading the feed hopper with material. Introducing large volumes of waste in a short period of time puts excessive strain on the shafts, blades and mechanical components, which can cause jams, rotor blockages or unscheduled stoppages. In addition, this practice increases energy consumption and accelerates premature wear of critical parts.
To avoid this type of incident, we recommend:
- Feed the material gradually and evenly, adapting to the capacity of the equipment.
- Implement flow or feed speed control systems, especially on automated lines.
- Monitor and prevent the accumulation of waste at the material inlet, ensuring a continuous and balanced flow.
Adopting these measures not only reduces the risk of unexpected downtime, but also improves energy efficiency and extends service life.
Introduction of unsuitable materials
This industrial equipment is designed to process specific types of waste. Introducing incompatible materials, such as heavy metal parts, can cause blade breakage, structural damage to the shafts, or rotor imbalance.
In addition to the mechanical consequences, these types of incidents entail high costs in repairs, downtime and risks to operator safety.
To prevent this, it is recommended that:
- Clearly define and identify the types of waste accepted for each piece of equipment.
- Install magnetic separators or metal detectors on the feed line to prevent ferrous materials from entering.
- Perform visual or automated inspection of the material before it is fed into the machine.
These preventive measures ensure safer operation, reduce maintenance costs and maximize operational availability.
Problems arising from insufficient maintenance
Failure to inspect blades and critical components
Blade wear is an inevitable phenomenon in any shredding process. However, failure to perform regular checks can drastically reduce the efficiency of the system. Blunt or unbalanced blades reduce cutting capacity, increase energy consumption and generate irregular or inadequately sized fractions, affecting the overall performance of the line.
To maintain optimal performance, it is recommended that:
- Establish a plan for periodic inspection of the condition of blades and critical components.
- Schedule preventive replacements, avoiding waiting until breakage or visible failure occurs.
- Use only original or manufacturer-certified spare parts, ensuring compatibility, safety, and performance.
Scheduled maintenance not only improves the quality of the grinding process, but also minimizes downtime and extends the service life of the equipment.
Poor lubrication
Inadequate or insufficient lubrication of moving components (such as bearings, gears or shafts) increases internal friction and accelerates wear. Over time, this lack of lubrication can lead to serious mechanical failures or even total machine shutdown. In fact, most technical incidents recorded in industrial equipment are caused by errors in lubrication procedures.
To avoid this, it is essential to:
- Always use the lubricants recommended by the manufacturer, observing their viscosity and technical specifications.
- Follow a lubrication schedule adapted to the plant’s operating regime and environmental conditions.
- Periodically check the correct operation of automatic lubrication systems, if any.
Inappropriate use of control systems
Ignoring warning signs
Industrial recycling machinery now incorporates advanced control systems capable of detecting anomalies in real time and issuing preventive alerts. Ignoring these signals is a critical error that can lead to costly breakdowns, unexpected downtime, and safety risks for personnel.
Likewise, to ensure safe and efficient operation, it is recommended that:
- Train staff in the correct interpretation of alarms and warning signals.
- Immediately address any incident detected, even if it seems minor.
- Establish clear protocols for action in response to each type of alert, avoiding improvised decisions.
Incorrect handling of operating parameters
Modifying critical equipment parameters such as rotation speed, working pressure or feed flow rate can lead to operational inefficiencies, accelerated wear or structural damage to equipment components. Machine settings must always comply with the manufacturer’s recommendations to ensure performance and safety.
Key preventive measures:
- Restrict access to control panels to authorized and trained personnel only.
- Document the optimal operating parameters for each type of waste, providing quick references at the plant.
- Only make adjustments under technical supervision, avoiding improvisations that could compromise the machinery.
Economic and technical consequences of operational errors
Impact on production costs
Errors in the operation of industrial machinery not only affect this equipment, but also have a direct impact on the profitability of the plant. The most common consequences include:
- Increased energy consumption resulting from inefficient operation or equipment overload.
- Reduced productivity due to unexpected downtime or lower-than-expected yields.
- Increase in maintenance costs, both corrective and preventive, due to accelerated wear and tear.
- Dependence on urgent spare parts, with significant economic and logistical implications.
Structural damage and prolonged downtime
Poor operating and maintenance practices can result in serious damage such as:
- Broken axles or bearings.
- Premature wear of critical components.
- Deformations in the structure of the equipment, compromising safety and stability.
These failures often cause prolonged downtime, affecting the entire production chain and generating significant economic losses.
The implementation of appropriate operating protocols, preventive maintenance, and control of critical parameters is key to minimizing risks, protecting investment, and ensuring the operational continuity of the plant.
How to avoid them: best practices
Preventive maintenance protocols
The implementation of preventive maintenance protocols is essential to avoid the most common errors in the operation of industrial recycling machinery. Recommended practices include:
- Regularly inspect critical parts such as blades, shafts, and bearings.
- Implement performance monitoring systems to detect anomalies before they become major problems.
- Document all interventions and replacements carried out, ensuring a complete maintenance history.
Operator training and continuous supervision
The human factor is crucial to the safe and efficient operation of this equipment. Well-trained and supervised personnel significantly reduce the likelihood of errors and operational failures.
It is recommended:
- Train operators in the specific use of the equipment, including identification of alarm signals and handling of compatible materials.
- Conduct regular technical refresher sessions, adapted to new technologies or changes in the recycling process.
- Ensure constant supervision at the plant, guaranteeing that operating and maintenance protocols are followed.
The most common errors in the operation of industrial recycling machinery can be avoided by applying appropriate maintenance protocols, ensuring material compatibility, and training staff in the responsible use of equipment.
At Silmisa Maquinaria, we develop industrial recycling machinery designed to minimize risks, guarantee process continuity and provide maximum value to our customers.
Prevention is the best investment. Committing to responsible use and planned maintenance ensures not only the durability of the equipment, but also the competitiveness of the recycling plant as a whole.
