Discover how a Hypertherm plasma cutter helped one metal recycler overcome production challenges and achieve a 300% boost in productivity.
Aço e Ferro, a metal recycling company in Castanhal, Pará, Brazil, recently overhauled its operations with the Hypertherm Powermax105 SYNC®, resulting in a remarkable increase in daily output, with a single operator achieving 3 tonnes/day. After struggling to keep up with demand using outdated oxyfuel methods, the company made the switch to plasma and hasn’t looked back since.
The Challenge: Cutting Bottlenecks and Safety Concerns
For over 15 years, Aço e Ferro has specialised in the purchase and resale of recyclable metals, processing large volumes of scrap, particularly thick materials ranging from 12 to 16 mm. However, as incoming scrap volumes surged, the company’s existing oxyfuel cutting system became a bottleneck.
Not only was the process too slow to meet demand, but it also raised ongoing safety concerns due to the use of flammable gas.
The Solution: Hypertherm Powermax105 SYNC®
Looking for a faster, safer alternative, Aço e Ferro explored plasma cutting and tested several systems, most of which failed to withstand the tough working conditions of a scrapyard. The turning point came when Hypertherm demonstrated the Powermax105 SYNC® on-site.
“We were impressed with the robustness of the equipment and the ease of use for the operator to handle it.”
— Aço e Ferro
Why Powermax105 SYNC® was the Right Fit
Designed for industrial-grade cutting and gouging up to 32 mm, the Powermax105 SYNC® is a professional plasma cutter equipped with features that simplify operation, boost productivity, and stand up to harsh environments:
- Cut speeds up to 3x faster than oxyfuel on 12 mm mild steel
- RFID-enabled SmartSYNC® torches for automatic setup and error-free operation
- Single-piece cartridge consumables with usage tracking and end-of-life detection
- SpringStart™ technology for consistent starting
- Duramax™ torches engineered for high-impact, high-heat resistance
- Drag-cutting capability for easier handling and longer consumable life
Unlike other plasma systems that require steady stand-off control, Hypertherm torches allow operators to drag the torch directly on the material for more accurate and efficient cutting.
300% Increase in Daily Output
Before switching to plasma, Aço e Ferro needed three to four operators to cut around 900 kilos of scrap per day. With the Powermax105 SYNC®, a single operator now cuts up to three tonnes daily: a more than 300% productivity increase.
“With Powermax SYNC, one operator can cut around three tons per day.”
— Aço e Ferro
Other benefits include:
- Significantly improved cut quality and reduced material loss
- Greater operator safety with no flammable gas required
- Less operator fatigue and faster workflow
- Proven durability in tough scrapyard conditions where other brands failed
“When I worked with oxyfuel, it was very exhausting… With plasma, it’s easier, faster, and safer.”
— Neir Antonio da Silva, Plasma Operator
This success story highlights the true value of Hypertherm’s Powermax SYNC® series—and why fabricators, recyclers, and industrial operators around the world are making the switch. Rugged, intelligent, and incredibly efficient, it’s a system designed to meet today’s productivity challenges head-on.
Interested in transforming your cutting operations?
Get in touch with the SMENCO team today.
