When designing a cathode stripping machine, the key question for copper producers is simple: How can we minimize upfront investment and long-term operating costs without compromising efficiency?
At PRS, the answer lies in customized solutions and smart technology integration. By tailoring designs to client-specific needs—such as production capacity, site constraints, and future scalability—we help clients reduce costs by 10% to 50%.
Let me explain how we achieved this for a 6,000-ton-per-year copper electrowinning plant through two cost-saving innovations.
Cost-Saving Design #1:
Rotating Transfer Arms Over Robots
Why Robots Aren’t Always the Answer?
For low-to-medium capacity plants (<50,000 tons/year), industrial robots often represent unnecessary overengineering. Instead, we deploy rotating transfer arms—a simpler, more economical solution.
Design Details:
- 90° Transfer Rotating Arm: Transfers cathodes between the receiving/washing conveyor, stripping station, and blank cathode discharge conveyor.
- 180° Transfer Rotating Arm: Transfers unqualified cathodes from the discharge conveyor to the reject conveyor.
- Low-Power Servo Motors: Consume only 2.2 kW per arm, cutting energy costs by 62% compared to robotic systems.
Component | Robotic System | Rotating Arm System | Savings |
Initial Cost | $120,000 | $45,000 | 62.5% |
Annual Energy Use | 8,400 kWh | 3,200 kWh | 61.9% |
* This table is for reference only
When to Choose Robots?
We recommend robots only for high-capacity plants (>50,000 tons/year) where speed is critical to meet tight production schedules.
Cost-Saving Design #2:
3-Stage Stripping Technology
Our patented 3-stage stripping process ensures maximum efficiency with minimal energy consumption:
Stage 1: Pneumatic Hammer Stripping
(95% Stripping Success Rate)
- How It Works:The pneumatic hammer removes the copper sheets through rapid and controlled impacts and vibrations.
- Energy Use: 0.5 kWh per batch.
- Best For: Standard cathode copper sheetswith low adhesion.
Stage 2: Stripping Knife Insertion + Pull
(99% Stripping Success Rate)
- Trigger: Sensors detect that copper sheets do not fall offafter Stage 1.
- How It Works: 4 stripping knives insert andslice 20–30 cm downward, then pull sideways to peel off sheets.
- Energy Use: 1.2 kWh per batch.
Stage 3: Full-Length Cutting
(100% Success Rate)
- Trigger: Activated if Stages 1–2 fail (<1% of cases).
- How It Works: 4 stripping knivescut from top to bottom in one rapid motion.
- Energy Use: 2.0 kWh per batch.
Why This Matters:
By prioritizing low-energy methods first, plants reduce average energy consumption by 20% compared to single-stage systems.
Modular Design: Start Small, Scale Smart
Not every plant needs a fully automated system upfront. Our modular approach lets clients begin with essential units and expand later:
Base Configuration (6 Units for 5,000–10,000 Tons/Year)
- Cathode receiving/washing conveyor
- 90° rotating transfer arm
- Stripping station (with 3-stage technology)
- Blank cathode discharge conveyor
- Copper sheet sliding buffer device
- Stacking device
Future-Proof Expansion Options
Module | Function | Recommended Capacity |
Reject conveyor | Sorts defective cathodes | >8,000 tons/year |
Random sampling device | Automated quality checks | >8,000 tons/year |
Weighing & bundling unit | Prepares copper for logistics | >10,000 tons/year |
Key Benefit: Redundant space and interfaces are pre-designed, ensuring seamless upgrades without downtime.
Case Study: 18% Cost Reduction for a Copper Plant in the Philippines
Challenge: A 6,000-ton/year plant needed to minimize upfront costs while ensuring >99% stripping success.
Our Solution:
- Rotating transfer arms instead of robots.
- 3-stage stripping technology with real-time sensors.
Results:
- $150,000 saved on initial procurement.
- At least 15,000 kWh/year energy reduction.
- At least 2 fewer operators per shift.
Conclusion：Your Needs Dictate Our Design
At PRS, we reject one-size-fits-all solutions. Whether it’s selecting rotating arms over robots or implementing modular scalability, every decision prioritizes your operational efficiency and long-term ROI.
Ready to Optimize Your Cathode Stripping Process?
Contact us for a free preliminary technical proposal and quotation tailored to your plant’s capacity and goals.
