If you have been exploring data destruction equipment, you have probably encountered the terms granulator and disintegrator. They are often used interchangeably, which can make it difficult to understand whether they refer to the same machine or two different types of equipment.
A granulator is a high-end industrial shredder that reduces numerous bulk materials into fine, uniform particles called granules using rotating knives, stationary knives, and a screen. The word originated in the plastics market, where granulators were developed to process plastic scrap for recycling. The product is used to convert plastics, paper, cardboard, CDs and DVDs, credit cards, ID badges, flash drives, VHS tapes, cassette tapes, silicone chips, books and magazines, and other industrial materials into small fragments. Granulators are commonly utilized in the plastics recycling, electronics recycling, pharmaceutical, waste and recycling facilities, and general manufacturing industries.
A disintegrator is a specialized type of granulator designed for high-security destruction. They are used to destroy classified and highly sensitive information by the military, intelligence agencies, federal government, and organizations handling top secret information. Like any granulator, a disintegrator operates using rotating and stationary knives to cut materials into minute particles. Nevertheless, it is constructed to take in significantly greater volumes and can accommodate much smaller screens when security requirements demand tinier particle dimensions. Disintegrator motor sizes range from roughly 1.5 HP to more than 200 HP, which makes them fit for centralized destruction facilities and organizations with demanding workloads.
Why Use a Disintegrator Instead of Burning or Shredding Materials?
Burning has become an inappropriate method of destroying old documents and plastics. Incineration is not a safe or practical data destruction solution, and the U.S. Environmental Protection Agency does not allow it. The plastics and coatings on materials that need to be demolished can generate toxic environmental contaminants when burned. In fact, sometimes residues harden on the internal components of incinerators. This results in expensive and time-consuming repairs.
Some people think they can feed their shredders plastic and items with metallic coatings. However, this can lead to damage if huge amounts of these materials are fed into shredders. The plastic and metallic coatings will melt, cool, and solidify on the shredder.
It is best to use a disintegrator for eradicating plastics, metallic coatings, and light metals, rather than shredding or burning. This is because it uses a constant and cooling flow of air through its cutting chambers to automatically bag disintegrated waste containing plastics, metallic coatings, brass, and aluminum. These materials will not damage the disintegrators.
In addition, disintegrators have a longer service life than shredders, and have a higher throughput. Shredders have a lifespan of five years, while disintegrators have a lifespan of 20 years. High-capacity, high-security shredders are rated to destroy up to approximately 100 lbs. per hour. Nonetheless, if you have massive quantities of materials to obliterate, you should use a disintegrator. The machine can break down anywhere from approximately 500 to 7,500 lbs. of material per hour, depending on the model and screen size.
How Does a Granulator and Disintegrator Work?
Granulators and disintegrators operate using the same basic size-reduction technique. Both machines have a high-speed rotary knife mill, which uses a number of rotating and stationary knives working together to produce a scissor-like cutting action.
Step 1: Material is Fed Into the Machine
The operator inserts materials such as paper, hard drives, solid state drives (SSDs), optical media, plastics, or other items into the machine through a feed opening or conveyor system.
Step 2: Rotating Knives Cut the Material
Inside the cutting chamber, an open rotor consisting of two to five rotating hardened steel knives passes through two stationary bed knives (0.005” gap) at 500 to 3,600 revolutions per minute for up to 6,000 cuts per minute. These rotating knives work against stationary knives to repeatedly cut, shear, and reduce the material into smaller pieces.
Step 3: The Material is Continuously Recirculated
Unlike a shredder, which typically makes one pass before discharging the material, a granulator or disintegrator keeps the material inside the cutting chamber. The debris is continuously cut over and over again.
Step 4: A Screen Controls Particle Size
Beneath the cutting chamber is a perforated metal screen. The screen acts as a filter. Gigantic pieces stay inside the unit and keep being cut. On the other hand, pieces that are small enough move through and exit the machine with the help of a vacuum or fan cyclone system that draws air through the device. This process is what enables both granulators and disintegrators to construct uniform particle sizes.
Step 5: The Destroyed Material is Collected
Once the particles travel through the screen, they are discharged into a waste collection container such as a drum, bag, cart, or dumpster for disposal or recycling.
The Key Difference Between a Granulator and Disintegrator
While every disintegrator is a granulator, not every granulator is a disintegrator. The key difference between the two products is the screen size and certification. A granulator can use a wide variety of large screen sizes, and the biggest screen for a granulator yields a particle size of 3” (76.2 mm). In contrast, a disintegrator uses a small 3/32” screen that delivers a particle size of 3/32” (2.4 mm) and has been tested and approved by the National Security Agency (NSA) for destroying classified information.
Because of the small 3/32” screen, material inside a disintegrator is processed for a longer period before it can pass through, producing much finer particles than a granulator. Finally, granulators are used for destroying plastics, recycling, waste reduction, and general data destruction. Disintegrators are granulators built for high-security data destruction that are used to decimate confidential and highly sensitive information.
Our Disintegrator Recommendations
The Datastroyer 125 Data Disintegrator
Our Datastroyer 125 Data Disintegrator is approved by the NSA and is on the NSA/CSS Evaluated Products List for High Security Disintegrators. The device is also TAA compliant. It transforms materials such as paper, CDs, DVDs, credit cards, ID badges, and more into ultrafine fragments. The product has a 10” x 12” throat size, along with a small hopper and chamber, which makes it suitable for disintegrating smaller materials. It is equipped with a standard 15 HP motor. What is impressive about the Datastroyer 125 is that it has a classified throughput rate 525 lbs. per hour using a 3/32” screen.
Moreover, it also accommodates screens that are 1/8,” 3/16,” 1/4,” as well as larger screen sizes. Its cutting system features seven blades, including five rotor knives and two reversible bed knives that work together to produce consistent particle sizes while providing long-lasting performance. The disintegrator is outfitted with NEMA 12 electrical controls that are designed to protect its electrical components from dust, dirt, lint, fibers, plastic, and liquid drips. It is available in 220 V, 460 V, and international voltage configurations.
For streamlined waste collection and cleaner operation, the Datastroyer 125 has a X2-1 Single Bag, Fan Cyclone Waste Evacuation System with a Bottomless Filter Kit. The integrated evacuation system continuously removes processed material from the cutting chamber, helping maintain productivity. On this item, we offer a break-fix service agreement and a predetermined number of annual blade sharpenings. The service plan keeps the cutting knives in optimal condition and the machine operating efficiently.
The Datastroyer 310 Data Disintegrator
Our Datastroyer 310 Data Disintegrator is a larger apparatus than the previous model, and is a heavy-duty machine. However, like the Datastroyer 125, it is approved by the NSA and is on the NSA/CSS Evaluated Products List for High Security Disintegrators. In addition, the piece of equipment is TAA Compliant. Its 14” x 24” throat size is built for higher-volume destruction environments, and can process bulky materials and light metals as well as paper, CDs, DVDs, keytape, and credit cards.
While the Datastroyer 310 is available with a 25 HP motor, it can be upgraded to a 40 HP motor, which makes it possible to cut through greater thicknesses. With a 3/32” screen, the disintegrator delivers a throughput of 1,050 lbs. per hour. If you need to meet high security standards, then this screen size is perfect. Additionally, it accepts 1/4,” 1/8,” 3/16,” and bigger screen sizes. There are also five rotor knives and two reversible bed knives that can break down your materials into the particle size you desire.
The device is engineered with NEMA 12 wiring, and has 220 V, 460 V, and international voltage options. Furthermore, the machine features an X-3 Dual Bag, Fan Cyclone Waste Evacuation System with a Bottomless Filter Kit so there is no need to manually clean the dust particulate out of the filter bag on the evacuation system. To help keep the disintegrator performing at its best, we provide a break-fix service agreement and a predetermined number of blade sharpenings each year. The service agreement helps extend the life of the cutting unit while reducing downtime and maintaining consistent destruction performance.
Other Disintegrators We Carry
