Railway Sleeper Shredding with the Lindner Urraco 95DK

Railway sleepers are among the most demanding materials encountered in waste wood recycling.

Made from extremely hard wood and often containing iron plates, screws and nails, decommissioned railway sleepers can put considerable demands on shredding equipment.

For Austrian waste management company Gojer, Kärntner Entsorgungsdienst GmbH, processing large volumes of railway sleepers required a machine capable of combining high throughput, durability and resistance to unshreddable material.

The solution was the Lindner Urraco 95DK mobile twin-shaft shredder.

After more than a year of operation, the results were impressive: the machine had processed over 24,000 tonnes of waste wood, including more than 10,000 tonnes of decommissioned railway sleepers.

Why Are Railway Sleepers Difficult to Shred?

Railway sleepers are very different from conventional waste wood.

They are manufactured to withstand significant loads and harsh environmental conditions, meaning the timber can be extremely dense and resistant to breakage.

Used sleepers can also contain metal components such as:

• Iron plates
• Screws
• Nails
• Other fixings

This creates a particularly demanding application for a railway sleeper shredder.

A machine needs to cope with the hardness of the timber while also dealing with potentially unshreddable metal.

For Gojer, this was one of the most important requirements when selecting its shredding technology.

The Lindner Urraco 95DK

The Lindner Urraco 95DK is a high-powered mobile twin-shaft shredder designed for demanding waste processing applications.

The machine used by Gojer is equipped with a 770 HP engine, providing the power required for high-volume waste wood and railway sleeper shredding.

Its tracked mobile design allows the shredder to operate flexibly around waste processing sites and stockpiles.

The Urraco 95DK combines:

• High engine power
• Twin-shaft shredding
• Robust construction
• Automatic reverse functionality
• Load-dependent control
• Mobile operation
• Remote control
• High throughput

These characteristics make it well suited to challenging waste wood applications.

Over 10,000 Tonnes of Railway Sleepers Shredded

The real-world results from Gojer’s operation demonstrate the capabilities of the Urraco 95DK.

During its first period of operation, the machine processed:

24,000+ tonnes

of waste wood in total.

Of this:

10,000+ tonnes

were decommissioned railway sleepers.

This represents a significant volume of some of the most difficult waste wood to process.

The material was sourced from Austria and neighbouring European countries before being processed for onward treatment.

Up to 140 Tonnes Per Hour

Throughput is a major consideration when selecting an industrial wood shredder.

According to Gojer Managing Director Oskar Preinig, the Urraco 95DK can process up to 140 metric tonnes of waste wood per hour, depending on the material and processing requirements.

The high throughput potential means operators can process substantial quantities of material without compromising the overall efficiency of their operation.

However, actual throughput will always depend on factors including:

• Material type
• Material density
• Feed size
• Contamination
• Required output size
• Feeding method
• Machine configuration

For a specific application, material testing and an application assessment are the best way to establish realistic production rates.

900 Hours Before the First Shaft Replacement

Perhaps one of the most impressive performance indicators from the Gojer case study is the Urraco 95DK’s shaft life.

The machine completed almost 900 hours of shredding before its first shaft replacement.

For an application involving extremely hard railway timber and metal contamination, this demonstrates the importance of robust shaft and cutting-system design.

Gojer’s operations manager highlighted the stability of the shaft system, which incorporates:

• Two shafts measuring 2,500 mm each
• Four crushing and cutting actions per shaft rotation
• Automatic load-dependent reverse
• Robust cutting technology

These features help the machine maintain performance even when dealing with challenging material.

Handling Metal in Railway Sleepers

One of the biggest challenges associated with railway sleeper recycling is the presence of metal.

Sleepers can contain iron plates, screws and nails, which can potentially damage conventional shredding equipment.

At Gojer, the metal components are separated from the shredded material using downstream overbelt magnets.

The Urraco 95DK is also designed to tolerate unshreddable material, with its automatic reverse functionality helping the machine deal with challenging objects.

This combination of robust shredding and downstream metal separation provides an effective approach to processing decommissioned railway sleepers.

What Happens to Shredded Railway Sleepers?

After shredding, Gojer’s processed material is transported to an incineration plant in Austria equipped with a specialist filtering system for the incineration of treated railway sleepers.

This demonstrates an important point about railway sleeper recycling.

The correct processing route depends heavily on the condition and treatment history of the timber.

In particular, operators must consider whether sleepers are:

• Untreated
• Treated
• Contaminated
• Suitable for recycling
• Suitable for energy recovery

The downstream destination should therefore be established before selecting the shredding and processing system.

Efficient Waste Wood Processing

The Urraco 95DK isn’t only designed for railway sleepers.

Gojer uses the machine to process a wider range of waste wood, demonstrating its versatility within demanding recycling applications.

The ability to process different grades of wood can be valuable for operators looking to maximise the utilisation of their shredding equipment.

Potential waste wood streams can include:

• Railway sleepers
• Demolition timber
• Construction wood
• Pallets
• Bulky wood
• Industrial timber
• Mixed waste wood

The correct configuration will depend on the characteristics of the feedstock and the required output.

Automatic Reverse Protects the Shredding System

Unshreddable material is an unavoidable part of many waste processing operations.

Rather than allowing difficult material to continue putting excessive load on the cutting system, the Urraco 95DK incorporates automatic load-dependent reverse functionality.

This can help:

• Reduce stress on the cutting system
• Handle difficult material
• Protect components
• Maintain machine availability
• Improve operational efficiency

For railway sleeper shredding, where metal contamination can be expected, this is an important feature.

High-Powered Mobile Shredding

The Urraco 95DK combines high power with mobile operation.

For waste wood processors, mobility can provide additional flexibility when handling large stockpiles or processing material at different locations.

Rather than relying on a fixed installation, a mobile shredder can be positioned where processing is required.

This can potentially help reduce unnecessary material movement and improve site flexibility.

The Urraco 95DK’s tracked design and remote-control operation make it suitable for demanding mobile waste processing environments.

One-Person Operation

Another advantage highlighted by Gojer’s machine operator was the ease of operation.

The Urraco 95DK can be operated using a radio remote control, while the machine can be fed using a wheel loader.

According to Gojer, one person can operate and feed the machine, helping simplify the processing operation.

The intuitive joystick remote and onboard touch display were also highlighted as convenient features.

Cost-Effective Railway Sleeper Shredding

High throughput is only part of the equation when calculating shredding performance.

Operators also need to consider:

Throughput + Fuel Consumption + Wear + Maintenance + Downtime = True Processing Cost

Gojer reported that the Urraco 95DK was cost-effective when considering its performance alongside fuel consumption.

After a year of operation, the company also reported that the shredder had significantly reduced costs per metric tonne.

For businesses processing thousands of tonnes of waste wood, even relatively small reductions in cost per tonne can have a substantial impact.

Choosing a Railway Sleeper Shredder

Selecting a shredder for railway sleepers requires careful consideration.

Before investing in equipment, operators should assess:

Material Type

Are the sleepers treated or untreated?

Metal Content

How much iron, steel or other metal is present?

Throughput

How many tonnes need to be processed per hour?

Output Size

What particle size is required?

Downstream Process

Will the material be recycled, recovered or sent for energy recovery?

Mobility

Does the equipment need to move around the site?

Wear-Part Requirements

How frequently will shafts, cutters and other wear components need attention?

Fuel Consumption

How efficiently does the machine operate at the required throughput?

The right answer will vary from one application to another.

Railway Sleeper Recycling with Lindner

The Gojer installation demonstrates the capability of Lindner technology in one of the more challenging areas of waste wood processing.

With more than 10,000 tonnes of railway sleepers processed, almost 900 operating hours before the first shaft replacement, and throughput of up to 140 tonnes per hour depending on material, the Urraco 95DK has demonstrated its ability to handle demanding timber streams.

It is a strong example of why application-specific shredder selection matters.

Mach Tech Services, Lindner Shredding Technology

Mach Tech Services is the sole distributor of Lindner Recyclingtech shredders in the UK and Ireland.

We provide shredding solutions for demanding applications including:

• Railway sleeper shredding
• Waste wood recycling
• Timber recycling
• Pallet recycling
• Bulky waste
• RDF and SRF production
• Plastics recycling
• Metal recycling

Our support doesn’t stop when the machine is delivered.

Mach Tech provides:

• Application consultation
• Installation
• Commissioning
• Preventative maintenance
• Breakdown repairs
• Genuine spare and wear parts
• Precision engineering
• Welding
• Hardfacing
• Machine rebuilds
• Technical support

With more than £1 million of spare and wear parts held in stock, we can also help customers minimise downtime when replacement components are required.

Looking for a Railway Sleeper Shredder?

If you’re processing railway sleepers, treated timber or difficult waste wood, selecting the right shredder is critical.

The Lindner Urraco 95DK provides a high-powered mobile solution designed to handle demanding materials while delivering high throughput and robust performance.

Mach Tech Services can assess your material, required throughput and output specification and recommend the most appropriate Lindner shredding solution.

Call Mach Tech Services on 01706 838 246 to discuss your railway sleeper shredding requirements.

Frequently Asked Questions

What is a railway sleeper shredder?

A railway sleeper shredder is an industrial shredder designed to process decommissioned railway sleepers and other heavy, difficult waste wood.

Because sleepers can contain extremely hard timber and metal fixings, the shredder needs to be robust enough to handle challenging feedstock.

Can the Lindner Urraco 95DK shred railway sleepers?

Yes. The Urraco 95DK has been used extensively for railway sleeper shredding at Gojer’s facility in Austria. The machine processed more than 10,000 tonnes of decommissioned railway sleepers during the case study period.

How much railway wood can the Urraco 95DK process?

The case study reports that the machine can process up to 140 tonnes of waste wood per hour, depending on the material and requirements. Actual throughput will vary according to the specific application.

Can railway sleepers contain metal?

Yes. Decommissioned railway sleepers can contain iron plates, screws, nails and other metal components. Gojer’s operation uses downstream overbelt magnets to separate metal from the shredded material.

How does the Urraco 95DK handle unshreddable material?

The machine features an automatic load-dependent reverse system designed to help deal with unshreddable material and reduce stress on the shredding system.

How long do the Urraco 95DK shafts last?

In the Gojer case study, the machine completed almost 900 operating hours before its first shaft replacement while processing large quantities of waste wood and railway sleepers.

What size does the Urraco 95DK produce?

The Gojer installation was configured to achieve an output size of approximately 150 mm. The actual output size depends on machine configuration and application requirements.

Can the Urraco 95DK process other types of waste wood?

Yes. The machine can be used for a range of demanding waste wood applications in addition to railway sleepers.

Are treated railway sleepers recyclable?

The appropriate treatment route depends on the sleeper’s condition, treatment history and the regulations governing the material. Treated railway sleepers may require specialist processing and disposal or energy-recovery routes.

Is the Urraco 95DK mobile?

Yes. The Urraco 95DK is a tracked mobile twin-shaft shredder designed for flexible waste processing applications.

Can Mach Tech supply a railway sleeper shredder in the UK?

Yes. Mach Tech Services is Lindner Recyclingtech’s UK and Ireland distributor and can help businesses assess their railway sleeper, timber and waste wood shredding requirements.