Halcor, the copper and alloys extrusion division of ElvalHalcor, has recently completed a significant technological upgrade at its Foundry with the installation of an automated copper scrap sorting line based on X-ray fluorescence (XRF) technology. The investment strengthens the efficiency, accuracy and consistency of scrap processing, supporting higher-quality feedstock for melting operations.
The new line is fully integrated into the plant’s production flow, starting from scrap size reduction and preparation. Following shredding, the material undergoes magnetic separation to remove ferrous impurities and is subsequently classified by size through screening. This staged preparation ensures uniform material characteristics and optimised performance during the sorting phase, enhancing overall process stability.
At the core of the system lies XRF technology, which enables real-time identification of the chemical composition of each scrap particle. By analysing the characteristic X-ray emissions of materials, the system accurately distinguishes between different copper grades and alloys, including pure copper, brass and bronze. This high level of precision allows to produce clean, homogeneous material streams, ensuring optimal input quality for downstream melting and casting processes.
XRF-based sorting is non-destructive, fast and highly resistant to dust, making it particularly suitable for continuous industrial operation. The automation of the sorting process significantly reduces variability in scrap quality, minimises the presence of undesirable impurities and improves overall yield from recyclable materials.
The investment delivers tangible operational and environmental benefits. It enables improved optimisation of scrap fed into melting furnaces, increases recycling efficiency, and reduces material losses. At the same time, it contributes to cost optimisation by limiting the need for corrective processing and lowering dependence on primary metal. Environmental performance is also enhanced, as greater use of recycled copper supports lower energy consumption and reduced carbon footprint across the production cycle.
Through this investment, Halcor further reinforces its strategic focus on advanced process control, technological modernisation, and circular economy practices. The adoption of cutting-edge sorting technology underlines ElvalHalcor’s commitment to sustainable industrial development, resource efficiency and long-term value creation within the European metals value chain.