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creating efficiency.

Metallekompakt - your independent partner for professional resource management with a practical approach and expertise in materials and technology. Together we will optimise material cycles, maximise scrap revenues and reduce costs. With technology that creates added value

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About me

Graduated engineer (FH) Andreas Jeßberger

Studies at the Technical University of Applied Sciences, Berlin
focus on expert reports, manager of a recycling plant and sales in the field of recycling - machines for metal processing and recycling.
Environmental approval activities

>25 years

experience in recycling

>100 projects

successfully implemented

>100 materials

in the loop

Machine and process

collecting & logistics

Optimizing of internal processes including scrap collection and container management. We help you to organise your chip handling – beginning with the chip discharge of the machining centre – and to make your external logistics more efficient. With customised solutions, you can increase your productivity and reduce costs - for cost-effective material sale.

Scrap & material pretreatment

Selection of suitable processes and evaluation of scrap and material treatment technology to generate additional revenues and improve ROI. Creation and implementation of tenders and optimisation through briquetting, centrifuging, suction, shredding, de-oiling, drying and dust removal - with a focus on metal chips and grinding sludge

Resource efficiency

Materials:

Metal swarf: aluminium swarf, non-ferrous metal swarf, cast iron chips, steel hips and turnings, aluminium briquettes, cast iron briquettes.

Metals: nickel, lead, copper, zinc, tin, iron, aluminium, precious metals and other

Metal-containing waste: grinding sludge, sludge, dust, hazardous (metal-containing) waste, general waste.

Increase revenues

Evaluation and optimisation of marketing channels. Keywords are transparent, indexed invoicing, shortening the trade chain and more efficient logistics - for maximum, sustainable revenue growth and legally compliant sale. Where possible, reuse of cooling lubricants, implementation of closed-loop systems and cradle-to-cradle principles to achieve ambitious environmental targets.

Reducing costs

Optimisation of disposal routes and the circular economy, with a focus on metal-containing and hazardous waste. Goal: Reduce costs and organise processes more efficiently.

Other activities

In addition to the activities described above, I also work on related topics, such as research into available technology for recycling processes, as well as disposal research for hazardous waste, metal mixtures and other material mixtures for separation, as well as biogenic fractions for the use as substitute fuels.

The goal is best practice in reutilisation of resources or use as an alternative energy source. I have access to a network that has grown over many years: smelting plants for various metals, foundries, processors and recyclers, or experts for various issues relating to recycling technology and foundry and smelting operations. I also provide support in the management of licences and authorities, and assist with issues relating to licensing and waste legislation. Examples include licence applications in accordance with the Federal Immission Control Act (BImSchG), auditing waste disposal facilities and waste disposal routes and concepts.

References

References in the automotive, aviation industry, mechanical engineering, manufacturing industry, metal processing industry, waste disposal companies, recycling companies, scrap recyclers, metal smelters, aluminum industry, wood industry

facts and figures

> 100 successfully implemented projects, including

≈ 10 environmental authority permits in accordance with the Federal Immission Control Act (BImSchG), responsible person for certificate of qualified recycling company, expert reports and projects of contaminated site remediation

≈ 30 recycling orders for hazardous waste, with a focus on grinding sludge and ferrous dusts

≈ 15 recycling orders for various metal-containing waste, foundry sands, electroplating sludges, etc.

≈ 50 projects pretreatment of scrap, focus on briquetting metal chips, dusts, wood briquettes and grinding sludge, sale of systems

≈ 15 consulting projects in recycling, waste stream utilisation research, marketing research, technology research

Examples from

consulting projects & resource efficiency

from the production of components for industrial use

“Hazardous waste” with > 100 to/a, in various modifications

Research Implementation and support of a recycling solution

Very high cost savings as a result, with reuse of the metal
Grinding (automotive sub-supplier) produces waste with a high oil content

Hazardous waste (120118*), around 300 tons per year

the waste is processed by briquetting in an external recycling plant with its own BImSch authority permit

the extracted oil is quality-tested and returned to the customer, who reuses it. The briquettes produced are sold externally

In total, this results in a 6-digit annual savings volume
automotive sub supplier with grinding operations. The resulting grinding sludge is briquetted and the oil is reused directly in production

research is carried out to find an efficient recycler for the briquettes

Cross-border marketing is made possible through lengthy negotiations with the local authorities responsible

very high additional annual revenue from briquette sales
a contract machining company and manufacturer of assemblies supplies parts to various industrial sectors

among other things, various aluminum alloys are processed

these are produced by alloy and also mixed, with a total of less than 100 tons per year

An innovative marketing and logistics concept generates significant 5-digit additional revenue per year
A mechanical engineering company processes the 5083 alloy

Recycling takes place in a “closed loop”

Material goes directly to the smelting plant

Company receives credit on a metal account, offset against delivery of new goods

This generates significant additional revenue, and - safeguards material procurement, and - against fluctuations in metal prices

machine & process

The component plants of a large automotive OEM generate large quantities of grinding sludge during the grinding process

Quantity per site 800 - 2000 to/a

Offer preparation, sales, contract negotiation, project coordination of briquetting systems for the compaction of grinding sludge

Sale of a total of 10 systems over a period of 6 years at 4 locations

Incl. trouble-shooting and adaptation to constantly new requirements in extensive specifications

Estimated quantity of cooling lubricant (mainly oil) recovered per year: > 2,000 tons.

Savings on the purchase of fresh oil. Benefit therefore cumulatively > EUR 2 million per year
A Tier 2 sub supplier manufactures powertrain aluminum components

Production of aluminum chips, 1500 - 2,000 to/a. (casting alloy)

For a closed-loop solution, briquettes must be produced with a high density and quality

Carrying out several pressing tests, coordinating the briquette quality with the customer

Quoting, sales, contract negotiation, project coordination of the briquetting plant

Throughput 500 kg/h, reuse of the pressed cooling emulsion

Use of the briquettes in the remelter, which remelts cast alloys from them; successful implementation of the closed-loop approach
Dust and chips are produced during the processing of ship propellers; material is dry

Aluminum nickel bronzes, e.g. CuAl10Ni5Fe4

Long-term project development for the implementation of a highly specialized briquetting solution

Preliminary discussions, tests, rental plant, adaptation to plant regulations and technical design specifications, contract negotiations, sales, project management

The successful implementation of the recycling solution allows direct melting, resulting in increased efficiency and reduced burn-off
A customer foundry buys oily scrap (swarf)

various copper alloys such as gunmetal and brass

with briquetting the following advantages:

De-oiling of the chips, thus minimizing smoke in the furnace

Compaction improves the chargeability

Increasing the metal yield

This increases the efficiency of the overall process, with the processes of continuous casting, centrifugal casting, mould casting
The cast iron foundry produces complex components for various industries at different locations

The site in Latin America manufactures cylinder crankcases and cylinder heads in GJV, including mechanical processing

Development of a briquetting solution according to specifications, tests, contract negotiations, with several visits on site

Validation of briquette quality with the “drop shatter test”

Sale of several systems with a total capacity of 3.5 tons/h, which are melted down with 20% in the charge in the cupola furnace
An analysis of the internal material flow “steel chips from the machining center” revealed high potential savings

These were achieved by compacting the chips: internal logistics significantly reduced (forklift) rides, distances, (workstaff) time and therefore costs

The 100CrMo 7-3 chips can be marketed at higher prices
Project development with the investigation about different process routes

Feasibility study with various pulverized residues (powder and dust), organic and metallic

Binder comparison

... work in progress ...

environmental authority permits & expert reports

Tendering & construction supervision of soil excavation

Authority management and reporting

Handover of the remediated site to the client
Preparation of the application according to BImSchG. Management of the environmental authorities

Content: Operation of a recycling plant with a total turnover of several 10,000 tons per year. Focus on scrap, scrap metal, construction waste, commercial waste

Incl. oil separator and 10 yard vehicles and facilities for waste treatment
Preparation of the application in accordance with BImSchG. Authority management for this

Content: Plant for the storage and treatment of metal grinding dust, sludge and chips

Chip bunker, storage boxes, mixing equipment, briquetting

With special issues of fire protection, noise protection, olfactory issues
For recycling operations and chip briquetting

Monitoring of official requirements, reporting

Creating the “qualified waste management company” manual

Carrying out trainings and instructions

Carrying out regular audits with the external inspection body in accordance with the KrWAbfG and relating environmental regulations