Fully electric high-torque drive solution for shredders
Maximum energy efficiency
High peak and nominal torques, low inertia of torque motors, and dynamic control of the drive system. These characteristics contribute to high energy efficiency and increased output. Baumüller’s fully electric high-torque drives are drive systems with DST2 torque motors that deliver high torques even at zero speed and replace conventional hydraulic or asynchronous drives in shredders. Baumüller’s fully electric high-torque system solution thus offers both shredder manufacturers and recycling plant operators a future-oriented solution. As a specialist in high-performance electric drives, Baumüller offers electric high-torque drives that often enable a reduction in energy consumption of more than 30 percent in shredders.
Baumüller, founded in 1930 and headquartered in Nuremberg, is a specialist in electric drive systems and a pioneer in direct drive technology. Torque motors have thus been part of our product range since 1991. By way of the DST2, Baumüller offers high-torque motors for industrial applications with outputs of up to 875 kW. Recycling is thus one of our core industries. Baumüller has implemented various drive solutions of single shaft and twin shaft shredders with or without feeding. Machines equipped with our drive systems are used to shred a wide variety of materials such as biomass, residual and commercial waste, plastics or cables, metal and aluminum — or for processing waste into substitute fuels (EBS) or secondary fuels such as RDF (refuse-derived fuel).
Our high-torque drives are ideal for various types of rotating recycling machines such as shredders, pre-shredders, rotor shears, granulators and shredders, and offer significant advantages over hydraulic drives or electric drives with standard motors.
High-torque drive: Low operating costs – high machine availability
By way of the fully electric high-torque drive system, Baumüller has developed a forward-looking drive system that is powerful, low-maintenance and energy-efficient. High throughput and maximum machine availability lead to high productivity. For example, the resulting substantially lower operating costs provide significant advantages compared to a hydraulic drive. The in part higher acquisition cost of a high-torque drive thus pays its way within a very short time.
Potential savings at a glance
- Often more than 30% energy savings
- Reduced maintenance costs
- Lower manufacturing costs for the end product
- CO₂ reduction
What advantages do high-torque motors and servo drive technology offer over conventional hydraulic and electric solutions?
Eliminating the hydraulic drive offers many advantages for shredders with high-torque motors: The number of wear-and-tear parts is reduced because vulnerable components such as hydraulic hoses and hydraulic units are no longer required. Regular hydraulic oil changes are also no longer necessary. Compared to drives with asynchronous motors, no maintenance of belts or pulleys is required. If less maintenance-intensive components are used, maintenance intervals can be minimized. Skilled personnel required for this are available for other tasks, and machine downtime is also significantly reduced.
The low inertia of the high-torque motors, combined with the powerful b maXX drive electronics, enables faster free running and restarting of the machine shaft, even with the hardest materials. Thanks to its motor characteristics, the DST2 high-torque motor facilitates high peak and rated torques across the entire speed range. The maximum torque from zero speed also allows restarting when the machine is full, for example. The highly dynamic drive system significantly increases productivity.
The biggest advantage is energy efficiency. Thanks to the b maXX servo drive, the high-torque motor is very easy to regulate and control and only draws energy when it is needed in the process. During phases when no power is required, the motors are at rest and do not consume any energy. In addition to the huge amount of saved energy, the noise level is also reduced, which benefits all employees.
Energy efficiency can be further maximized with a intermediate circuit network because two shafts of a shredder share the drive energy. The
Modernization instead of replacement: Sustainable increase in efficiency: A new shredding system need not necessarily be purchased to benefit from the energy efficiency of the highly dynamic high-torque drive system. If the mechanics are still in good working order, a shredder can also be brought up to date by upgrading the drive system. This typically comes at significantly lower costs—and often faster turnaround—than purchasing a new machine.
Overcoming challenges –
the advantages of a fully electric high-torque drive system
- High energy efficiency
Although the fully electric system solution is in no way inferior to the torques and speeds of conventional drive solutions, it nevertheless offers hugely improved energy efficiency. - Coordinated system components
The close system partnership between Baumüller and Nidec Desch ensures that all components of the drive system can be designed to work together perfectly. - No hydraulic oil
Using a hydraulic unit is no longer necessary, eliminating the need for large quantities of hydraulic oil. - Reduced noise pollution
Elimination of the hydraulic unit and belt transmission significantly reduces noise pollution during operation. - Low maintenance
Thanks to the reduction in wear-and-tear parts in the drive, virtually no maintenance work is required. This increases machine availability and thus productivity. - Easy integration in existing concepts
Thanks to the various mechanical connection options and the ability to accommodate customer-specific special dimensions, easy integration in existing concepts is possible without any problems. - Reduction in operating costs
Higher energy efficiency and less maintenance result in lower running costs and thus more economical operation.
Permanently reduce operating costs –
switch from hydraulic drive to fully electric high-torque drive
Practical example: Customer system:
The efficiency increase is about 38% when switching from a hydraulic drive to a fully electric high-torque drive. Costs can be permanently reduced at an average wave power of 200 kW and a production of 3,840 hours per year.
Savings:
- Approximately €60,000 savings per year (based on energy costs of 18.31ct/kWh (BDEW, 2025)
- Lower manufacturing costs for the end product
- Approximately 122 tons of CO2 reduction per year
Everything from a single source -
a complete package tailored to your needs
Baumüller offers a system solution for shredders consisting of control and drive technology. The powerful PowRex drive system, in conjunction with the DST2 High-Torque motors and b maXX servo drives, forms the basis for our fully electric high-torque drive solution. The Baumüller drive system can be easily integrated in third-party control systems and can thus be ordered without a Baumüller control system.
At control level, Baumüller offers the b maXX PLC mc, a combination of industrial PC and classic PLC control unit.
Efficient overall system: The powerful PowRex drive system, comprising high-torque motors and servo drives, in conjunction with control and special visualization, facilitates productive shredders for various areas of application.
Baumüller can also supply the right drive system for large shredding systems, such as car shredders. Thanks to the modular b maXX 5500 drive electronics, with the help of multiple-winding systems, even the large motors of the DST2 series can be used and combined to form multi-motor solutions.
Thanks to the modular use of components, this drive system kit enables us to realize a very wide range of shredders with minimum variance in the drive system. This very much simplifies the order process as well as warehousing/replacement part stocks for the customer.
Perfect connection of the drive to the rotor shaft – system solution comprising motor, gearbox and slip clutch
In close cooperation with the drive supplier Nidec DESCH Antriebstechnik GmbH & Co. KG, we can offer a coordinated complete system comprising a motor, gearbox and slip clutch. The advantage for you is a perfect and flexible connection between the rotor shaft and the drive train – all from a single source.
Baumüller’s powerful PowRex drive system achieves high torque even at low speeds. Combined with the Tevox®, a gearbox/slip clutch combination from Nidec Desch, facilitates a coordinated connection of the drive to the rotor shaft, resulting in the best possible output for your machine.
Conventional drive systems are reaching their limits
Economic recycling poses challenges such as increasing efficiency, reducing operating costs and at the same time working reliably under demanding conditions. But how do conventional drive systems perform in this regard? In the past, two drive systems have become established as standard for shredding machines. The hydraulic drive system and the electric drive system with an asynchronous motor.
Hydraulic drives are considered to be particularly powerful. Due to their complex drive train with a large number of components such as pumps, motors, valves, and large quantities of oil, they also require a high level of maintenance. If system pressure and volume flow are regulated using valve technology, high energy losses can also occur at the valve. If fluctuating hydraulic power requirements arise due to the nature of the process, hydraulic systems operate inefficiently in terms of energy consumption and thus have a lower degree of efficiency.
Electromechanical drives equipped with standard motors and belts, gearboxes or flywheels have better energy consumption statistics than hydraulic drives. However, compared to high-torque drives they have a deficit in terms of responsiveness in process dynamics.
What are the strengths of our fully electric high-torque drive system?
Powerful
- Torque curve matches the shredding process
- Flexibility in torque and speed through the use of gearboxes
- Peak torque is also available when stationary
High energy efficiency
- High system efficiency due to efficient individual components
- System components with less impact on efficiency
Dynamics
- Dynamic control of the drive system by powerful servo controllers (short cycle time = fast response)
- Low inertia of torque motors enables faster acceleration
Low maintenance cost
- No maintenance required for belts and pulleys
- No maintenance of a hydraulic system
Protection
- Using a wet slip clutch protects the drive train and tools from damage in the event of a blockage.
Easy integration into existing systems
- Three standard options for connecting to the machine shaft
- Customization
- Standardized interface between engine and transmission
Environmental compatibility
- No hydraulic oil required
- Lower CO2 emissions
- Low-noise drive system
Low running costs
- Reduced energy costs due to high energy efficiency
- Low maintenance costs
- High machine availability
Precisely tailored and customized -
from high-torque motors to complete drive systems
As a partner, Baumüller supports the implementation of customer-specific solutions with its expertise in drive concepts. Baumüller offers the exact service you require - from individual motors and components to comprehensive drive systems with control technology. We always support your precise needs. Baumüller is a partner for machine manufacturers and a supplier of complete systems.
from the motor to the overall system
customized
Single and multi-shaft shredders
for system optimization
By way of its components and services, Baumüller offers the largest scope of systems for shredder drives. As a drive and automation manufacturer, we have many years of experience in equipping shredders and, as a full-range supplier, we are at your side from the planning through to commissioning and service.
- Dimensioning
- Commissioning
- High-torque motors
- Servo drives
- PLC control unit
- Control cabinets
- Load distribution / synchronization
- Block monitoring
- Commissioning mode
- Control interface
- Improved diagnostic possibilities (HMI)
Fully electric drive system – Scalable technology from Baumüller
The PowRex drive package, consisting of DST2 high-torque motors and b maXX 5500 servo drives, forms the basis for our shredder drive solution. Our system solution extends beyond PowRex and includes the complete main drive system, including switch cabinet construction and control technology with hardware and a comprehensive software package specifically designed for shredding systems. The drive unit is configured individually depending on the required power.
PowRex drive package: High-torque drive system for shredders
Software solutions for shredders
Save time and money with our complete software package. The software contains a large number of the required machine functions as well as motion modules for actuating the servo motors, templates for the machine visualization, and functions such as EtherCAT diagnosis, commissioning mode, load balancing and water-cooling control.
Machine functions for higher performance
- From small to large: One template for all expansion stages
- Multi-motor shaft: If a shredder shaft is driven by more than one motor, load balancing on the shaft is already preprogrammed, ensuring stable, consistent operation.
- Blockage monitoring: Rapid monitoring for blockages and automatic reverse protection safeguard the shredding shaft, motor, and gearbox.
Standard control cabinets through to completely wired special control cabinet
For many years, we have been implementing custom solutions for renowned machine and plant manufacturers - from the standard control cabinet through to the completely wired special control cabinet. You receive everything from us, a single source that can therefore deal optimally with your needs and wishes:
Planning – design – sheet metal production – serial production – assembly – installation
FAQ
Frequently asked questions about Baumüller’s high-torque shredder drive
Do you have any questions about our high-torque drive? You can find answers here. Whether retrofitting, material suitability, or maintenance requirements. Our FAQs provide initial assistance. If you require further information, please send us a message.
General information
A high-torque drive is an electric motor with high torque that delivers high torque even at low speeds. This makes it ideal for industrial shredders that need to shred high-resistance materials.
Our drive systems are designed for a wide range of applications – from plastics, wood, paper, and tires to metals, electronic scrap, and biomass.
Electric high-torque drives are more energy-efficient, require less maintenance, are quieter and enable more precise torque control. In addition, the use of hydraulic oil is eliminated, which protects the environment.
Performance & conversion
Thanks to high efficiency of up to 95% and demand-controlled torque control, Baumüller drives combined with highly efficient planetary gearboxes can save up to 50% energy compared to hydraulic systems.
Yes, Baumüller offers retrofit solutions for modernizing existing systems. In conjunction with our system partner Nidec Desch, we can also offer customized drive solutions for existing machines – including controls, gearboxes and interfaces.
Installation & maintenance
Baumüller drives are delivered ready for connection. On request, Baumüller will also assist you with installation and commissioning worldwide.
Very little. Electric high-torque drives require neither oil changes nor maintenance of belts or pulleys. Only the manufacturer-specific bearing service life needs to be observed.
Yes, Baumüller offers worldwide technical support, spare parts, and maintenance contracts – with remote access for diagnostics and software updates upon request.
Offer
Via the Baumüller contact form https://www.baumueller.com/en/contact. Please specify material type, throughput, desired torque, and space requirements.
You can find the necessary information in Baumüller’s technical questionnaire » Download
The circular economy meets energy efficiency: 30 percent lower energy costs thanks to direct drive technology
Working with Baumüller, WEIMA Maschinenbau GmbH developed a high throughput single shaft crusher with high-torque drive
Your path to a qualified quote
Interested in a no-obligation consultation or an offer? Then contact our experts.
We discuss the relevant technical data with you and together we define the requirements. Only then do we undertake the qualified design of the complete drive system. After checking the specifications, you receive a qualified offer from us.
Baumüller is your partner for the design and optimization of your drive system. As a non-group-affiliated, mid-sized company, we are able to respond to our customers’ wishes quickly and efficiently with innovative drive solutions. This makes us the perfect partner for challenging projects and future technologies.
Write us a message, our sales experts will be happy to advise you.
Partners and References:
Our components for industrial shredders:
Our components for industrial shredders:
