KVZ Hintermayr has expanded its recycling capability with a Vecoplan VIZ 1700 shredder to process an unusually broad range of input streams, from pressed big bags, polystyrene and yoghurt tubs to moulded parts, foams, films, nonwovens and purgings. The family-owned recycler reports that the system delivers consistent quality, reacts reliably to foreign materials and requires minimal maintenance while offering high energy efficiency. "We recycle what many others fail to do," says Managing Director Franz-Xaver Hintermayr. The company supplies almost 6,000 tons of high-quality regrind materials and regranulates annually to customers in Germany and neighboring markets including Italy, Austria, the Netherlands and Spain. By matching the shredder’s performance to the new extrusion line, KVZ Hintermayr aims to increase throughput, stabilize operations in three-shift mode and broaden material flexibility without compromising process reliability.
From cowshed to high-performance recycler
The company’s roots date back to the mid-1980s in Gersthofen near Augsburg, where founder and master farmer Karl Hintermayr operated a cattle business. He fed the herd with agricultural by-products such as potato peelings and beet pulp, an approach he describes as an early form of recycling. Market pressure following the opening of the Eastern bloc and the BSE crisis forced a strategic shift. In 2000, the large cowshed was cleared and converted into a two-floor hall equipped with a shredder and a granulator, laying the foundation for plastics recycling.
The converted cattle farm of KVZ Hintermayr in Gersthofen.
Scaling capacity and equipment choices
To build technical depth, Franz-Xaver Hintermayr studied plastics and rubber technology and, together with his brothers Karl-Friedrich and Veit-Kilian, expanded the operation. Since 2008, a second site in Wertingen has hosted two extruder lines, with pre-shredding as a prerequisite. Films and lightweight expanded polypropylene were previously handled by a single-shaft shredder paired with a granulator, while hard plastics and polystyrene were processed on a separate shredder. Seeking higher throughput, the team selected a new extruder after visiting an Austrian supplier at Ifat 2024, and in parallel evaluated shredders capable of keeping pace and integrating into the existing line.
Vecoplan, headquartered in Bad Marienberg, develops systems for shredding, conveying, separating and storing wood, biomass, plastics, paper and waste. "We do not just put a machine down in front of our customers’ doors and leave it there. Our portfolio includes comprehensive project management, installation and commissioning, as well as a full service package," says Bastian Wienen, Regional Sales Manager at Vecoplan. The VIZ 1700’s design and flexibility prompted testing at the company’s Technikum. "Our new shredder had to be able to shred and process different materials," notes Veit-Kilian Hintermayr. The plant was delivered in December 2024 and, since commissioning of the new extrusion line, the VIZ 1700 has been operating in three shifts.
The new VIZ from Vecoplan: flexible, low-maintenance and energy-efficient.
Process flow, flexibility and throughput
At the Wertingen hall, a telescopic loader feeds the shredder. A large cutting chamber and rotor geometry produce a homogeneous mixture that a screw conveyor transfers to a suction blower and then to a storage silo before dosing into the extruder. "Thanks to its range of versatile features, the VIZ can be used in a variety of ways. It combines the properties of a classic single-shaft shredder and a grinder," says Franz-Xaver Hintermayr. "Depending on the actual operating conditions, the VIZ has a maximum throughput of around 2,000 kg for this area of application," adds Wienen. The machine targets high availability and low operating costs while handling diverse plastics. Vecoplan designed the VIZ series with a flexible cutting geometry, enabling performance tuning via rotor and blade configurations and screen selection so the output can be aligned precisely to downstream interfaces.
Drive concept and energy performance
A key factor for KVZ Hintermayr is Vecoplan’s HiTorc drive, which provides a strong start-up phase and high torque. By eliminating belt and gear drives, flywheels and clutches, overall machine efficiency can increase by up to 25 percent. Compared with other electromechanical drives, energy savings of up to 40 percent are possible, and up to 60 percent versus hydraulic drives. This lowers electricity costs and CO2 emissions. The drive’s speed range allows continuous adjustment to the optimal operating point for different inputs, for example slow for polystyrene bales and faster for filaments. A shock sensor detects foreign materials swiftly, and the drive responds immediately to minimize consequential damage. Maintenance tasks are performed ergonomically with a hydraulically operated, upwards-pivoting bottom flap, and the cutting gap is set safely from outside the machine.
The powerful motor and the V-rotor arrangement mean that the machine always starts up, reducing downtimes and the unnecessary emptying of loads
Control, connectivity and operation
The shredder is equipped as standard with the Vecoplan Smart Center, including the VSC.control operating panel. Through VSC.connect, the machine can access online services such as remote support, key performance indicators and a media database with self-service tutorials. A camera installed in the shredder enables remote monitoring, for example from a tablet on the telescopic loader. "We can intervene immediately if necessary," says Franz-Xaver Hintermayr. A hydraulic linear ram pushes material automatically and load-dependently into the rotor’s working area, and the process can be programmed on request. The inclined ram and a very slow-turning rotor allow efficient emptying, saving time during material changeovers. Veit-Kilian Hintermayr adds, "We can also change many parameters ourselves and save them as a recipe."
The shredder is equipped with the powerful Vecoplan Smart Center (VSC) digitalisation concept as standard.
Partnership and outlook
With its powerful motor and V-rotor arrangement, the VIZ 1700 starts reliably, reducing downtime and unnecessary emptying of loads. According to the company, the combination of mechanical flexibility, drive efficiency and digital support underpins stable three-shift operation and supports the processing of challenging feedstocks. Franz-Xaver Hintermayr concludes, "With Vecoplan, we have a partner who is always dependable, even when things get complicated, and that is exactly what our customers appreciate about us."
