Service in Life:
maximum uptime for your system, every day
Unplanned plant downtime is one of the main financial risks in industrial recycling processes. Every hour of downtime for a shredder or a separation line results in production losses, delivery delays and unforeseen logistics costs.
The Zato Service in Life programme is designed to support the plant throughout its operational life: with immediate corrective support, data-driven preventive maintenance, operational supervision and active safety management. An integrated system designed to minimise downtime, optimise performance and protect the value of the investment in the long term.
Corrective Support
Zato’s corrective support service is designed to minimise the time between the occurrence of a fault and the restoration of full operational capability, ensuring an immediate technical response.
Guaranteed service standards:
- Initial technical contact: typically within a few minutes of the report
- Remote diagnosis: initiated promptly using the available diagnostic tools
- Service restoration: in 90% of cases, the issue is resolved remotely, without the need for an on-site visit
Preventive Maintenance
A machine that is running smoothly today can deteriorate silently over time. Slightly higher vibrations, rising fuel consumption, irregularities in the cycle: these are signs that often go unnoticed until they result in an unplanned machine shutdown at the worst possible moment. Zato’s preventive maintenance uses real-time machine data to anticipate problems and schedule replacements at the right time. How monitoring works — thanks to integrated connectivity, key parameters are transmitted continuously:
- Operating hours and actual cycles
- Temperatures of critical components
- Vibrations and mechanical faults
- Power consumption and trends
- Hydraulic pressures and actuator status
What do we do with this data:
- We identify wear and tear and faults before they cause breakdowns
- We plan replacements in advance, when they can be scheduled — not as a last-minute emergency
- We update the maintenance plan based on actual usage patterns, not a standard calendar
The result: fewer unplanned downtimes, more predictable maintenance costs and a longer service life for the plant.
Supervisory Operations
When a machine is no longer performing as it should, every day spent trying to identify the cause is a day of production below potential. The Supervisory Operations service provides in-depth technical support, either on-site or remotely, to pinpoint exactly what is limiting performance and how to address it.
Technicians analyse the shredding process as a whole, the machine’s behaviour during the actual cycle, cut quality and uniformity, material flow, set parameters compared to optimal ones, and operating conditions. This enables the rapid identification of inefficiencies, configuration errors or conditions that increase wear, consumption and the frequency of downtime.
The service is particularly useful when:
- The machine is no longer operating at its expected capacity
- The output is uneven or the cut shows irregularities
- The shredder malfunctions during operation
- Frequent unexpected stoppages or blockages occur
- You wish to prevent a more serious problem before it leads to a plant shutdown
How to contact us:
- Chat: send us a video, photo or description of the problem in real time
- Remote connection: our team accesses the operating parameters directly
- Dedicated video call: visual supervision of the process with a Zato technician
SAFETY OF SHREDDING PLAMTS
In crushing plants, high forces, high operating speeds and interactions with heterogeneous materials are common: conditions that can give rise to significant risks. For this reason, safety must be managed proactively, before a critical incident occurs.
Key operational risks in shredding plants:
- Overloading and the introduction of non-compliant materials
- Unauthorised access to operational areas during operation
- Ignored alarm signals or unfamiliarity with emergency procedures
- Maintenance carried out without the correct isolation measures
- Unmonitored wear and tear leading to sudden failure
Every plant is configured with active and passive safety systems right from the set-up phase. During training, operators learn to recognise critical signals, manage emergency procedures and work safely. A safe plant is a plant that never stops: every safety measure correctly implemented means one less unplanned shutdown, costs avoided and operational continuity guaranteed.
