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:
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➡️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 Stripping Line: Start with Essentials, Expand Anytime
Some copper plants prefer to begin with essential units and scale automation gradually. Our modular approach makes that easy—start simple, upgrade without redesign.
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 >99.9% 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 Decide 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.
