Heavy-Duty Mattress Shredder

Product Introduction

Used mattresses are one of the most stubborn items in the waste stream. They’re bulky, heavy, and built from a tough mix of steel springs, polyurethane foam, felt, coconut fiber, and stitched fabric. Manual dismantling is slow, labor-intensive, and exposes workers to dust, pathogens, and sharp steel. Standard shredders either choke on the tangled springs or wrap the foam and fabric around their shafts until they stop.

Our Heavy-Duty Twin-Shaft Mattress Shredder is the brute-force solution. With immense low-speed torque and aggressive counter-rotating blades, it grips and rips apart entire mattresses — springs, foam, fibers, and all — in a single pass. No pre-cutting, no spring removal, no wrapping. Steel springs are sheared into short arcs, foam is torn into chunks, and fabric is shredded to liberate the materials. The result is a mixed output stream perfectly conditioned for magnetic metal separation, foam recovery, and textile recycling. Turn a disposal headache into a material recovery business.

Product Features

Twin-Shaft, High-Torque Tearing Force Two counter-rotating shafts drive massive, through-hardened alloy blades at very low speed (12–25 rpm). The extreme torque tears through the toughest mattress constructions — including double-layer pocket springs, latex cores, and densely stitched coconut fiber pads — without stalling or overheating. The low-speed action produces no sparks, eliminating fire risk from steel-on-steel impact.

Aggressive Anti-Wrap Rotor Design Mattresses are a nightmare of long fibers, tough foam, and steel coils that love to wrap around shafts. Our hook-shaped rotor profile and precision blade clearance actively prevent material accumulation. The geometry ensures that springs are cut immediately, foam is torn away cleanly, and nothing spins uselessly around the rotor.

Intelligent Auto-Reverse & Hands-Free Operation The PLC control system continuously monitors shaft torque. When an exceptionally tough section — such as a heavy border wire or metal bed frame fragment — is encountered, the rotors instantly auto-reverse to eject it, then resume. This self-clearing action keeps production moving without operator intervention, critical for the high hourly throughput mattress recycling demands.

Heavy-Duty, Re-Sharpenable Cutting System Blades are forged from high-alloy tool steel, through-hardened for maximum toughness and wear resistance. They withstand repeated contact with steel springs without catastrophic chipping. Thick cutting edges accept multiple re-sharpening cycles, and large access doors allow one operator to service the entire set quickly.

Controlled Output for Downstream Separation Interchangeable sizing screens on a hydraulic cradle let you dial in output size from 30mm to 100mm+. The shredded mix is ideal for a downstream magnetic separator to pull out spring steel, followed by air separation to isolate foam from textiles. One shredder feeds a complete material recovery line.

Technical Parameter

Model	Motor Power	Rotor Diameter	Chamber Size (L×W)	Blades Qty	Max. Input Width	Capacity (Mattresses per Hour)
MTSH-600	30+30 kW	300 mm	600×800 mm	30 pcs	600 mm	15–25 units/h
MTSH-800	45+45 kW	350 mm	800×1000 mm	40 pcs	800 mm	25–40 units/h
MTSH-1000	75+75 kW	420 mm	1000×1200 mm	50 pcs	1000 mm	40–60 units/h
MTSH-1200	90+90 kW	480 mm	1200×1500 mm	60 pcs	1200 mm	60–90 units/h
MTSH-1500	132+132 kW	550 mm	1500×1800 mm	80 pcs	1500 mm	90–130 units/h

Capacity estimated for mixed single-size mattresses (spring and foam) fed whole. Throughput varies with mattress size, construction type, spring density, and desired output size. Custom configurations available for specific mattress recycling line integration.

Applicable Material

Mattress & Bedding Materials We Shred

Spring Mattresses: Bonnell spring, pocket spring, and continuous coil mattresses. Steel spring units are sheared into short, manageable arcs, while fabric and foam are liberated for separation.
Foam Mattresses: Polyurethane memory foam, latex foam, and high-resilience foam beds. Torn into clean chunks for reuse in carpet underlay, pet bedding, or energy recovery.
Futon & Fiber Mattresses: Cotton, wool, and coconut fiber futons and mattresses. Fibers are shredded to a uniform consistency for textile recycling or composting.
Mattress Toppers & Pads: Memory foam toppers, feather beds, and mattress pads. Processed alongside whole mattresses without adjustment.
Sofa Beds & Upholstered Furniture: Fold-out sofa beds, upholstered chair cushions, and padded furniture components. High torque dismantles mixed wood, metal, and foam assemblies.
Hotel & Contract Bedding Waste: Bulk disposal of retired hotel, dormitory, and hospital mattresses. High-volume shredding meets the demands of institutional mattress recycling contracts.

Why Choose Us

Factory-Direct Mattress Shredding Expertise: You work with engineers who understand the unique mechanical demands of shredding mattresses — from spring shear forces to foam tear-out dynamics. We build rotors, gearboxes, and controls in our own facility, delivering industrial shredders at a factory price without distributor overhead.
12-Month Comprehensive Warranty: All core mechanical, hydraulic, and electrical systems are fully covered. If a production issue arises, our remote team provides video-guided diagnostics within 12 hours to get you back to full throughput quickly.
Fast-Response Spare Parts & Honest Operational Support: We keep blades, spacers, seals, and screens in ready stock for immediate dispatch. Our maintenance guidance is based on real mattress processing data: we teach your crew how to maximize blade life, plan maintenance around peak collection seasons, and avoid unnecessary part consumption.
Complete Mattress Recycling Lines: Beyond the primary shredder, we integrate magnetic separators, air classifiers, granulators, and balers to deliver a turn-key mattress recycling plant that outputs clean separated steel, foam, and textile fractions — each ready for sale.

Tell us about your mattress waste volume and the types of mattresses you handle. Send photos or a brief description today. Our application engineers will design a customized shredding line and return a detailed proposal, throughput forecast, and transparent pricing within 24 hours.

FAQ

Can the shredder handle a whole mattress without removing the springs? Yes. That is the core design function. The twin-shaft shear shredder is engineered to tear through the complete mattress assembly — fabric, foam, fiber, and steel springs — in a single pass. No spring removal is necessary.

What happens to the steel springs inside the mattress? The springs are sheared into short arcs, typically 50–150mm in length. They are discharged mixed with the foam and textile shreds. A downstream overband magnetic separator (which we supply as part of the line) cleanly extracts the spring steel for recycling.

Does the machine wrap the foam and fabric around the rotors? No. Our rotor geometry is specifically designed to prevent this. The aggressive hook profile and tight blade-to-blade clearance continuously cut fibers and foam, preventing the build-up that shuts down standard shredders on mattress materials.

What are the separated materials worth after shredding? Shredded mattress steel is sold as scrap steel. Polyurethane foam can be sold for carpet underlay, rebond foam, or pet bedding. Clean textile fibers can be used in industrial felt or energy recovery. One fully recycled mattress can generate $3–$8 in commodity value, turning a disposal cost into a profit center.

How often do blades need sharpening when shredding mattresses? Mattress processing is moderately abrasive due to dirt and steel contact. Typical blade re-sharpening intervals are 500–800 working hours. Blades can be re-sharpened 5–7 times before replacement, making them highly economical.

Can you supply a complete mattress recycling system with material separation? Absolutely. We design and deliver full mattress recycling plants: primary shredder → magnetic separator → air classifier → foam and fiber outputs. We provide complete engineering, installation support, and operator training.