Empirical OPEX comparison model for diesel Stage V vs. electric E-PU shredders at 10,000 operating hours: energy costs EUR 280,800 vs. EUR 177,100, maintenance costs EUR 45,000 vs. EUR 8,000, yielding a total OPEX saving of EUR 140,700 (43% reduction).
Empirical OPEX comparison model for diesel Stage V vs. electric E-PU shredders at 10,000 operating hours: energy costs EUR 280,800 vs. EUR 177,100, maintenance costs EUR 45,000 vs. EUR 8,000, yielding a total OPEX saving of EUR 140,700 (43% reduction).
Ficha táctica
›Location: Main Hub
›Tech Index: AXE_TCO_25
›Sys Time: 10:00:00
›Event Log: 4
›Data Stream: 2
TCO Savings
43%
Nominal
STD 69.6200% In Spec
Maintenance Interval
5000hrs
Nominal
STD 81.6500% In Spec
ROI Engine · Per Shift
CAPITAL_ESCUDO_FISCAL: 1998,81 EUR
Landfill fee €25/t, fuel consumption 0.27 l/t, and wear factor 0.85 are locked into the shift model.
Summary
Empirical OPEX comparison model for diesel Stage V vs. electric E-PU shredders at 10,000 operating hours: energy costs EUR 280,800 vs. EUR 177,100, maintenance costs EUR 45,000 vs. EUR 8,000, yielding a total OPEX saving of EUR 140,700 (43% reduction).
// KEY ENGINEERING TERMS
tensile fracturetensile fractureFractura por tracción: modo de fallo del material donde los ejes de la trituradora tiran y desgarran la carga, dominante a alto régimen y baja carga específica., cutting regimecutting regimeRégimen de corte: modo de funcionamiento donde las cuchillas de los ejes cortan la carga por cizallamiento, preferido para una fracción de salida limpia., TCOTCOCoste total de propiedad (TCO): el coste completo durante la vida útil incluyendo precio de compra, combustible, piezas de desgaste, mantenimiento y depreciación del valor residual., OPEXOPEXGastos operativos (OPEX): costes recurrentes de funcionamiento de la trituradora — combustible o electricidad, reemplazo de piezas de desgaste, mantenimiento programado y salarios de operadores. — wear cassettewear cassetteCassette de desgaste: conjunto de insertos de corte modulares y reemplazables montados en el eje de la trituradora. El sistema de intercambio rápido minimiza los tiempos de inactividad durante el mantenimiento., twin-shafttwin-shaftDiseño de doble eje: dos ejes contrarrotativos equipados con cassettes de corte intercambiables que funcionan en conjunto para triturar residuos industriales.
Technical Analysis
MACROECONOMIC INPUTS (EUROPE, 2026)
Electricity: Despite stabilization of wholesale prices at approximately 95 USD/MWh, the retail industrial tariff in the EU (including grid costs, renewable energy levies, and supplier margins) averages 0.23 EUR per kWh.
Diesel Fuel: The weighted average industrial price of diesel fuel in Europe (excluding recoverable VAT but including excise duties) is assumed at 1.50 EUR per liter.
AdBlue (DEF): For Stage V compliance, engines are equipped with Selective Catalytic Reduction (SCR) systems. AdBlue consumption is approximately 6% of fuel consumption. AdBlue cost is 1.00 EUR per liter.
Equipment Profiles (Arjes Impaktor 250):
- Diesel version (EVO II): Volvo Penta TAD581VE engine, 129 kW (175 HP). Fuel consumption under 70% load during concrete shredding: approximately 18 liters per hour.
- Electric version (E-PU): 160 kW electric motor. Average energy consumption at 70% load: 110 kWh/hour (accounting for peak starting currents and hydraulic station operation).
OPEX COMPARISON: TABLE OF 10,000 OPERATING HOURS
Energy consumption per hour: Diesel 18.0 L/h (diesel) + 1.08 L/h (AdBlue) vs. Electric 77.0 kWh/h.
Energy cost per hour: Diesel EUR 27.00 + EUR 1.08 = EUR 28.08 vs. Electric EUR 17.71. Hourly saving: EUR 10.37.
Energy costs (10,000 h): Diesel EUR 280,800 vs. Electric EUR 177,100. Total energy saving: EUR 103,700.
Maintenance cost per hour: Diesel EUR 4.50 vs. Electric EUR 0.80. Hourly saving: EUR 3.70.
Maintenance costs (10,000 h): Diesel EUR 45,000 vs. Electric EUR 8,000. Total maintenance saving: EUR 37,000.
Total OPEX (10,000 h): Diesel EUR 325,800 vs. Electric EUR 185,100. Total saving: EUR 140,700.
Cost per operating hour (OPEX): Diesel EUR 32.58/h vs. Electric EUR 18.51/h.
Note: Calculations are based on algorithmic financial modeling of heavy machinery load profiles.
MAINTENANCE: DIESEL STAGE V VS. ELECTRIC MOTOR
The enormous gap in maintenance costs (EUR 4.50/h vs. EUR 0.80/h) is driven by the radical complexity increase of Stage V diesel engines. Diesel requires strict adherence to maintenance schedules:
Daily maintenance: Checking oil separators, coarse fuel filters, and draining condensate to prevent Common Rail injector corrosion.
250-500 hour intervals: Engine oil replacement (approximately 15-20 liters of specialized Low SAPS oil to protect the DPF), along with oil and fine fuel filter replacement.
1000-3000 hour intervals: Inspection and potential replacement of Crankcase Ventilation (CCV) valves, DPF cleaning or replacement from accumulated ash, and SCR/DEF injection system diagnostics.
In contrast, the electric drive (E-PU) requires only periodic inspection of power cables, insulation checks, visual inspection of electrical switchgear, and bearing grease lubrication (often integrated into an automatic lubrication system). The absence of ICE vibration also extends the service life of hydraulic fittings and high-pressure hoses (HPH). The total saving exceeding EUR 140,000 over 10,000 operating hours (approximately 4-5 years of intensive operation) fully covers the difference in initial capital expenditure (CAPEX) for the electric shredder version.
INTERACTIVE DATA VISUALIZATION
LOADING CHART DATA...
Reference machine vs Competitor
ARJES Impaktor 1250 E vs TANA Shark 4400 — Electric Flagship vs Single-Shaft Shredder
TANA Shark 4400 — a single-shaft slow-speed shredder (32 t, Cummins 400 kW) with adjustable counter-screen for RDF-fuel fraction control, weighed against the ARJES Impaktor 1250 E electric flagship (500 kW VFD dual asynchronous motors) on 10,000-hour energy TCO and rebar wrapping failure modes. The same critique extends to the Komptech Terminator 6000 single-shaft architecture (28 t, CAT 440 kW).
480k EUR electric vs 675k EUR diesel — 30% energy cost delta over 10,000 h
The ARJES Impaktor 1250 E ships with dual 250 kW asynchronous electric motors driven by VFDs.
Under load the machine draws an average 320 kW·h per operating hour — over 10,000 hours at 0.15 EUR/kW·h industrial tariff that is 480,000 EUR.
The TANA Shark 4400 with a 400 kW Cummins diesel burns ~45 l/h, costing 675,000 EUR at 1.50 EUR/litre over the same horizon.
The 195,000 EUR energy delta is compounded by zero DPF/SCR service, zero oil filters, zero injector maintenance, and zero AdBlue consumption on the electric machine.
Advantage
Single-shaft spool effect vs asynchronous self-cleaning
The TANA Shark 4400 and Komptech Terminator 6000 use a single-shaft rotor with stationary counter-knives.
On C&D waste with rebar mesh, wire, and sheet steel, the rotor acts as a spool — wire wraps around the shaft body, extrudes the Hardox side seals, and invades the bearing journals.
The ARJES Impaktor 1250 E uses two asynchronous shafts rotating at different speeds and directions: the differential shears the wire, the counter-rotation strips it off the shaft body, and the machine self-cleans without operator intervention.
Advantage
Hydraulic damping vs planetary gear shear on rail / I-beam drop
When a TANA or Komptech single-shaft rotor ingests a rail section, tank track, or I-beam, the tramp metal jams between the rotor and the stationary counter-knife.
The entire kinetic load transmits through the planetary gear train into the flywheel and engine — bursting hydraulic motors or shearing planetary teeth.
The ARJES Impaktor 1250 E uses independent hydraulic drive per shaft with high-resolution pressure sensors: the SCU detects the pressure spike in milliseconds, halts the blocked shaft, and reverses it while the second shaft continues to push the obstruction out.
