As the recycling industry evolves, the need for efficient, high-yield recovery of metals from Automotive Shredder Residue (ASR) — commonly referred to as car fluff — has never been greater. ASR represents one of the most challenging material streams in the metals recycling sector, containing a highly variable mix of non-ferrous metals, ferrous particles, plastics, fibers, and dirt. The complexity of this material demands far more than conventional sorting and separation equipment. It requires a fully engineered, integrated solution designed around the unique characteristics of each operation.

At Engineered Recycling Systems (ERS), we specialize in delivering advanced, custom-built ASR processing systems that recover the maximum possible value from this difficult material. Our modular designs seamlessly combine primary separation, fines recovery, and metal refining technologies, tailored specifically for ASR applications.

Comprehensive, Engineered Solutions for ASR Fines

Typical ASR processing leaves valuable metals entrapped in mixed waste, resulting in lost revenue opportunities and increased disposal costs. ERS addresses this challenge by integrating high-performance eddy current separators, induction sorters, air classifiers, and sensor-based sorting technologies into a streamlined, multi-stage process. These systems efficiently separate non-ferrous fines and recover residual metals from previously discarded material streams.

Our systems are particularly effective in handling ultra-fine and light fraction materials, refining mixed products such as Zorba, Zurik, and other non-ferrous grades into clean, high-value commodities. Through optimized material flow, dust control integration, and process flexibility, ERS solutions ensure consistent, high-purity output that meets market requirements.

Process Intelligence and Real-Time Optimization

ERS systems are engineered for adaptability in an environment where material composition and market demands constantly shift. By incorporating data-driven process controls and real-time system monitoring, operators can fine-tune system performance based on material flow, recovery rates, and product quality metrics. This intelligent integration ensures optimal recovery efficiency, reduced downtime, and maximized profitability.

Sustainable Recovery, Enhanced Profitability

Beyond operational efficiency, ERS solutions support sustainable recycling practices by reducing landfill volumes and reclaiming valuable finite resources. By transforming mixed ASR waste streams into concentrated, saleable metal products, our systems contribute to both environmental responsibility and bottom-line improvement for our customers.

Whether upgrading an existing plant or developing a new ASR recovery line, Engineered Recycling Systems provides comprehensive design, manufacturing, and installation services, backed by deep industry expertise and ongoing technical support.