The right fit: sticking to tradition and buying too large of a scrap handler could harm a recycler's bottom line. (Scrap Handling Equipment Focus).

What size scrap handling machine should a yard use? The answer to that question can be complex, and sometimes is filled with emotion. Understanding a bit of the history of hydraulic scrap handlers in North America helps identify where some of the emotion comes from. The machines evolved from used hydraulic log loaders with three-piece fronts. Some of the log loaders were fitted with different attachments and moved into scrap yards to replace cable cranes.

The early customizing practices soon evolved. Scrap yard operators started purchasing used excavators, replacing components and adding key aftermarket components such as purpose-built material handler fronts, counterweigh t boxes to increase the weight of the counterweight, cab risers, and hydraulic and belt driven gen sets to complete the package.

The size of those first excavators (often Cat 235s and LinkBelt 5800s) reborn as material handlers still influences scrap yards today. The 235-size machine, from the scrap yard manager's perspective, was a perfect match for the cable cranes being replaced. The excavator could reach out more than 50 feet and could stack material just as high, and it could handle a 25-kW genset with a 72-inch scrap magnet. The performance specs were approximately the same as the old cable cranes that scrap yard managers had grown so accustomed to using. The 235s and 5800s were viewed as the ideal size.

The evolution toward purpose-built material handlers came next. As the scrap business grew and companies consolidated, the demand for hydraulic scrap handlers also grew. Scrap yard managers sought improved reliability and purchased new machines to meet their needs.

Machines with specially designed upper frames, wider car bodies, cab risers, specialty hydraulics, and factory designed and built fronts enabled manufacturers to offer full factory support.

SMALLER MAY BE BETTER. During the evolution of material handlers, scrap yard managers came to understand that the key to longevity of material handlers is the life of the structures.

Hydraulic pumps and cylinders can be rebuilt or remanufactured. Engines can be rebuilt or remanufactured. But when the frame and front structure start going bad, the cost to fix or replace them often can be too high to justify. The decision to replace the machine becomes clear.

Scrap yard managers often purchase larger machines due to the longevity they can get out of the structures. I had one customer tell me that he typically sizes his work tools to handle about 60 to 65 percent of the machine's lift capacity--just to ensure adequate structure life. Large machines have heavier structures that may last longer and provide second and third lives through component rebuilding.

But in my opinion, too few scrap yard managers seriously consider smaller machines.

If a smaller tracked or wheeled machine will do the material handling job required, the question becomes: Why spend the extra money on a larger unit? The decision is really all about economics.

At the end of 10,000 or 12,000 hours the pumps, cylinders, and engines are approaching the time for some major rebuilding. Also, as machines age, the need for repairs increases, dependability begins to fall off and repair bills begin to increase.

When a scrap operation--with intent to get long life from machine structures--purchases a machine larger than what is really needed to do the work, the operation commits to rebuilding and economically rejects the option to replace the machine. On the other hand, if the smaller machine has gotten the job done at less cost, the used machine can be replaced and potentially sold or transferred to a smaller feeder yard where uptime and duty cycle requirements are not as high.

The author is Material Handler Market Manager--North America for Caterpillar Inc., Peoria, Ill.