Hub-4 Issue 20

Check out the verylatest industry news atwww.hub-4.com

Global News &Information on the BulkMaterials Handling,Recycling & Quarryingindustries

Issue 20

YourNew FuchsDealer...0845 230 1432

Whether you’re new to Fuchs machines or an existing customer in the UKor Ireland, call Blue today for any sales, service or spares enquiries:

www.bluegroup.co.uk

|FUCHS

•Scrap •Waste •Ports

Hub issue-20 [jan 2012] 17/1/12 14:19

websitea brand new

launchesHUB-4

At the beginning of February HUB-4 willlaunch it's all new website, which willinclude:

• A Fresh layout• More effective advertising options• A stronger divide between the 3 industries• Clearer categories • More efficient used equipment section

For further information or to take a look at the new website pleasevisit www.hub-4.com or get in touch now.

www.hub-4.com

Jane Layberry | [email protected] | 07761 815 975

Debbie Paton | [email protected] | 07729 422 911

Hub issue-20 [jan 2012] 17/1/12 14:19

Editors note

www.hub-4.com | p3 |

The push on recycling is set to increase to new levels throughout

2012. With the Welsh government targeting 50% waste

recycling across the board and new MRFs opening up all over

the United Kingdom creating higher efficiency, we can only

predict great things for the coming year.

2012 sees many alterations and changes to recycling as itcurrently stands, including proposals for tougher packagingrecycling targets for businesses, new domestic recycling schedulesand the additions of new and highly advanced MRFs fromcompanies such as Shanks and Casepak.

The tougher packaging targets for 2012 will make UK plasticsrecycling a key focus for the year ahead. With the UK currentlyclose to a 50% recycling total for plastic drinks bottles, the newtargets should push us into far higher levels of plastics recycling.Recent advances in sorting technology such as the specialist de-inking screen I recently saw in action at the new Casepak facilitywill also reduce waste further through more efficient processing.

An increase in waste recycling is a positive both for theenvironment and for the economy as recycling produces 10 timesthe number of jobs per tonne than sending waste to landfill. Withindustry growth at an all time high and newly opened facilitiescreating thousands of jobs every year, we can only hope for thecontinued success across the industry.

The additional objectives for 2012 will ease pressure on the UKsunrealistic use of raw materials and make higher levels ofrecyclable and recycled materials available for businesses. Thereare events and seminars being held throughout 2012 to createmore of an interest in recycling, particularly through NationalRecycle Week from 21st - 27th June, this years focus is onelectrical recycling.

Winter 2012Jane Layberry Editorial & Operations ManagerEmail: [email protected]

Debbie PatonSales & Admin AssistantEmail: [email protected]: 07729 422911

Tel: 0845 680 0024

Hub Digital Media Limited27 OLD GLOUCESTER STREET, LONDON WC1N 3AX

Casepak MRF launch, 16 Jan 2012. Casepak senior management team and Lord Taylor

In this issueCover Story 4News 6Increased recycling possibilities

Environmental efficiency award

'ROSSI FOR YOU'

Complete utilities

Top safety accreditation

Product Focus - MRF Equipment 11A complete package for waste industry

A DUO MRF

Zig-Zag separation system

Mogensen in the recycling industry

New analysis service for MRFs

UNTHA VR series shredder

Marathon Gemini-Xtreme baler

Automatic baler in third shred-it branch

SPLITTER - recycling technology

A fast and efficient way to recycle

Creative design award

Ultra flexibility in balers

Profit from waste

Recycling 26New milling technology

DISAB trucks

Weighbridges in energy from waste sites

Big push to recycle plastic

McCloskey J50 mobile crusher

Materials Handling 36Precia-Molen GeneSYS™

Dust suppression ring

New gearbox at brick maker

Quarrying 40Filter Press maintenance

Vulcan burner at shap

CMB deliver at Hanson Aggregates

Asphalt plant spares market

WCL Quarries

Washing screen to Norway

Hub issue-20 [jan 2012] 17/1/12 15:14

Waste processing equipment specialistsBlue Group are delighted to be unveiledas the new distributor of Terex® Fuchsmaterials handling equipment in the UK.Since 1999, the Hydrex Group haveacted as a hirer and as a distributor forthe German made construction andloading machines in the UK. During thisperiod, they have developed the UKmarket into one of Terex® Fuchs mostimportant globally. As part of theirmarketing strategy for furtherdevelopments, Terex® Fuchs begansearching for a new dealer and servicepartner to support existing marketsegments whilst exploring otherpotential avenues.

With Blue Group's strong presence in thewaste sector and planned expansion intometals recycling, and port handlingapplications, the synergy between the twocompanies was immediately seen asmutually beneficial for both parties. As aresult, Blue Group have taken over thedealership for the UK and Ireland withimmediate effect. “The Terex® Fuchs materialhandling machines are perfect to integrateinto the wide variety of products and servicesoffered by Blue Group for the recyclingindustry”, emphasised Mr Ron de Vries,Managing Director of Terex® Fuchs.Commenting on the appointment, Ron deVries added “We are grateful to Hydrex forall services and work performed to date andlook forward to expanding our presencetogether with the Blue Group in the UKrecycling market.”

Cover Story

Appointment ofthe Blue Groupas Terex® FuchsUK distributor


With a view to safeguarding existing jobs and ensuring optimalcontinuity for existing and potential customers, Blue Group hastaken over the staff and former Portishead premises of Hydrex, andthe newly formed Blue Machinery (Fuchs)Limited will continue to operate from theregoing forward. The now former OperationsDirector for Blue Group's Warrington depot,Terry Hughes, has been appointed ManagingDirector of Blue Machinery (Fuchs) Limited tooversee an easy integration of the staff andpremises into Blue Group's existing strategicallyplaced offices and depots in Stirling,Warrington, Bristol and London.

Hub issue-20 [jan 2012] 18/1/12 09:53

Cover Story

www.hub-4.com/directory/2260


Blue Group is a total solutions provider, offering the waste management industry a wide range of materials recoveryfacilities, shredding, composting, screening and crushing equipment for the efficient and cost-effective processing ofall waste streams. The Group has also developed and invested heavily in after sales product support with animpressive off-the-shelf stock-holding for spare parts and a team of fully trained technical service engineers giving UKwide coverage. This ethos will be carried over to support the Terex® Fuchs range, thus ensuring machine owners canrely on the product to perform to its maximum ability at all times.

Commenting on the recentappointment as UK dealer,

Brian Maxwell, director of BlueGroup added “We are delighted to

be appointed as the new distributor forTerex® Fuchs in the UK. It has been our

long term growth strategy to add a materialshandler to our existing portfolio of exclusive

brands, and we are thrilled to have secured thedealership of our number one choice in Terex®

Fuchs.” Brian added, “One of our key strengths atBlue is our strong after sales support. We lookforward to working with all existing Terex® Fuchscustomers and aim to improve the levels of servicethey have been receiving. We are looking to buildon the world class reputation and quality of theTerex® Fuchs machines and see our appointment asa long term commitment to becoming the the UK'sleading supplier of materials handling equipment.”

For all sales, service orparts enquiries, call 0845 230 1432

Hub issue-20 [jan 2012] 18/1/12 09:53

Last month Sir Steve Bullock, Mayor ofLewisham celebrated the start ofLewisham's new household recyclingcontract with a visit to BywatersMaterials Recycling Facility (MRF) atLea Riverside. Lewisham's newhousehold recycling contract marks thestart of a valuable relationship withmore materials, than ever before, nowbeing accepted for recycling.On 5th December 2011 Bywaters beganhandling all of Lewisham's householdrecycling in a contract that will run until atleast 2014 and will see Bywaters processingcirca 17,500 tonnes of Lewisham'shousehold recycling per annum. Increasedrecycling reduces waste and thereforeemissions, as well as being more costeffective.

Bywaters is a local operator with a proventrack record in increasing recycling rates inLondon Boroughs. Their state-of-the-art MRF,

Hi-Force Daventry bags 2011 EEFMidlands Region EnvironmentalEfficiency Award!!

located in nearby Bow E3, processes a wide range of materials andproduces high quality outputs for re-processing. Bywaters supplies acomplete recycling solution which includes community awareness supportand training of their staff.

By increasing the range of recyclables Lewisham residents can nowreduce their non-recycling volume as Tetra Pak, mixed plastics andaerosols, shredded paper, bubble wrap, perfume bottles and CDs arenow accepted.

Councillor Susan Wise, Cabinet Member for Customer Services atLewisham Council says: “The Council wants to raise the profile ofrecycling to reach more and more of its residents, schools and voluntarygroups and is pleased that Bywaters is able to meet this challenge”.

John S. Glover, Bywaters' Managing Director continues: “It is a pleasure tohave delivered a best in class proposal and qualified through acompetitive process. Bywaters delivers tailored solutions to LondonBoroughs and will work in partnership with Lewisham to increase overallrecycling rates”.

Where possible, Bywaters applies the proximity principle, which leads tomaterials predominantly being reprocessed in the UK. This not only helpsthe British economy and reduces transport miles and therefore carbonemissions.

News

Increasedrecyclingpossibilities onLewisham'sdoorstep




On Thursday 17th November 2011 representatives of Hi-Force Daventry werespecially invited to the 2011 EEF Midlands Region Future ManufacturingAwards Celebration lunch at the Heritage Motor Centre in Gaydon,Warwickshire. Attended by representatives of over 40 companies, that had been

shortlisted from an original list of over 800 entries, Hi-Force Daventry was selected as a finalist in four categories,namely The Outstanding Export Award (5 finalists), The Business Growth Award (8 finalists), The InnovativeOperating Practises Award (7 finalists) and The Environmental Efficiency Award (5 finalists), which saw Hi-Forcereceive a well merited Runner Up Award Certificate. Whilst presenting the award to Hi-Force Group ManagingDirector, Kevin Brown, the judging panel comments were: “The judges felt that the Hi-Force entry conveyed anintegrated method for reducing environmental impact. By encouraging a hybrid approach towards environmental initiatives,Hi-Force has worked hard to improve environmental efficiencies and to increase productivity. The judges look forward toseeing how the Hi-Force story continues to develop over the coming year.”

Commenting at the event Kevin Brown enthused: “Given that this is the first year Hi-Force has entered the EEF Awardscompetition, we are delighted to have been shortlisted in four categories, more than any other finalist. Hi-Force isdelighted to accept the Runner Up Award in the Environmental Efficiency category as this clearly demonstrates ourCompany desire to be an environmentally conscious manufacturer and employer. We certainly look forward to next years'event and to hopefully going one step further and picking up a winners award, which would take us through to theNational Finals in London. To be recognised alongside such major companies as Rolls Royce and Caterpillar is indeed agreat honour for Hi-Force. Our facilities here in Daventry, UK are indeed “state of the art” and I would like to thankDaventry District Council for their tremendous support of Hi-Force in Daventry. Through the efforts, of Daventry DistrictCouncil, to design and build Hi-Force a highly efficient and environmentally conscious facility, which has been ratedBREAM very good by The UK Environmental Agency.”

Accompanying Kevin at the awards ceremony were Group Finance Director, Mrs. Lin Whaymand, Sales Manager,Adam Turnbull and Human Resources Manager, Julie Preston. Kevin also expressed his gratitude to Adam and Juliefor all their hard work in preparing our entry in the four categories that Hi-Force was shortlisted to win.

For more information about Hi-Force Hydraulic Tools please visit www.hi-force.com

Hub issue-20 [jan 2012] 17/1/12 14:19

Habasit Rossi Ltd. is an affiliatedcompany of Rossi SpA situated inModena Italy, one of the largestmanufacturers of Gear Reducers andGear motors in Europe. Rossi UK adivision of Habasit Rossi UK LTDcontinues to restructure its operation inthe UK in line with its growth objectivesfor the future. The underlying reason forthis restructure has been to ensure thatthrough every process and activity, thecustomer needs are fully understoodand acted upon by talented individuals.

Rossi geared products have a strongreputation for excellent quality and thegroup has recognised that customerscontinue to demand greater value for theirmoney. As such the focus is to ensure agreater competitive position is achievedthrough the improvement of the Operationalstructure as well as the development of alocal Technical department in order toprovide complete technically designedsolution tailored specifically to eachcustomer's application within the timeconstraints set by our customers.

The Company has established a strongtrack record in providing tailored technicalsolutions for a wide range of applications,such as Material Handling Conveyors,Mixers & Agitators, Quarrying, MobileAggregate Machine, and Recycling centresand believes that it is well placed todevelop the market through investment inkey areas.

Habasit Rossi UK has embarked on acampaign of Creating “ROSSI FOR YOU”specifically focused towards our customers.

News

Focusing on customerswith 'ROSSI FOR YOU'


This campaign is underwritten by investment into key areas within theorganisation. The first phase of this investment started with therecruitment of 5 new members of staff in 2011 in order to enhancethe skills base of the company in areas such as the Supply chain,technical support and Stock management. The company will continueto invest in the training of its entire staff in order to be the mostcompetent and efficient in its industry.

Further investment will continue through 2012 and beyond with thedevelopment of customer portals such as the “ROSSI FOR YOU” portaland the re-launch of a new simplified and updated website. Thesetools will enable our customer to review the status of their orders inreal time along with 3-D drawing download capability, order historyand many more tailored functions. The launch of this portal isexpected in Q3 of this year.

The group has also invested in a new modern operating computersystem and has chosen the Oracle JD Enterprise One system, that willalso go live in the UK in Quarter 3 2012. This investment is to ensurethat Rossi can meet the growing demands and customer expectationmore rapidly, efficiently and control delivery parameters moreaccurately. The group believes that moving from a unix based systemto the ultra-modern Oracle system, further improves in thedependability the group achieves with its customer.

In UK we have an inventory value in excess of £1.0 millioncomprised of the Company's comprehensive range of electric motors,brake motors, gear reducers and gear motors. Our stock profileincludes more than 10.000 assembled gear units and electric motorsallowing for immediate dispatch throughout the UK and Ireland.Habasit Rossi can offer gear units with a torque capacity of20.000Nm from stock in the UK and gear units up to 400.000Nmfrom stock held in Italy.

The UK subsidiary was established in the Midlands nearly 25 yearsago, the UK Company has set ambitious growth objectives for thefuture. This growth objective has been fully supported through RossiSPA, Italy where over the last 5 years the company has invested Euro75 million in new machinery, production facilities and staff to meetthe growth trends as the group expands its global foot print.


Hub issue-20 [jan 2012] 17/1/12 14:19

News

Complete UtilitiesBeat Blue-chipCompanies toWin NationalAward withDUO WashPlant.National Joint Utilities Group (NJUG),the UK's only Trade Association forstreet works issues, have held theirannual awards ceremony in House ofCommons Members Dining Room,hosted by Louise Ellman MP (Chair ofthe Transport Select Committee). Theawards were designed to recognise,promote and reward instances of bestpractice within the street worksindustry, with all winning entries to beused as examples of best practice anddistributed throughout the industry.Complete Utilities were one of fourcompanies shortlisted for the NJUGSustainability Award. The award recognisesthe company's work in maximizing thesustainable use of materials with its recyclingwash plant which was supplied by DUOEquipment.

The Gloucestershire based firm, who provideexcavation, backfilling and reinstatementservices to the

utilities industry, made the decision to beginwashing having previously dry screened theirmaterial. The driving force behind thisdecision was that the required standard ofproduct is only available for six months of theyear due to the weather when dry screening

and even then the quality could not beguaranteed.

The Recycling Wash Plant

The two main components of the installationare the Powerscreen Aggwash , which is anaward winner in its own right having pickedup the Series Innovation Category Award atthe 2010 World Demolition Awards, and theDUO Mobile Water Treatment Plant. TheAggwash provides for the first time rinsing,screening, scrubbing and sand washingcapabilities on a single transportable chassis.Complete Utilities are running the Aggwash at50-60 tph to process their material forbackfilling and remediation purposes. DUO'smobile water treatment solution perfectlycomplements the Aggwash, eliminating silt andwater being dispatched to a lagoon. Thesystem, which is based on a centrifuge, is of

compact size relative to its production levels which was a necessity inthe design of the installation due to space restrictions on-site. Thisclosed circuit system produces a very manageable material, the lowmoisture content of which is vital to Complete Utilities in ensuring it isworkable for blending as clean soils as well as any surplus beingtransportable to, and accepted by, landfill and tipping sites.

Winning Washers

Complete Utilities, who were shortlisted alongside Balfour Beatty UtilitySolutions, Laing O'Rourke and North London Gas Alliance, won theaward with their wash plant which delivers a recycling rate of almost100%. The benefits of this project, which were the backbone of thewin, are financial, legislative and environmental.

Taking into consideration landfill costs, the cost of replacementprimary aggregate for trench backfill and including the high capitalinvestment of the new plant system, the company can still match thelandfill and replacement aggregate costs when recycling trench spoilback into a high quality aggregate product.

Regarding legislation, the recycling operations exceeds the targets of'Halving Waste to Landfill by 2012' and also can realistically achieveZero Waste to Landfill.

From an environmental perspective, the operation mean less landfillingof trenching spoil, less demand for primary aggregate and areduction in carbon emissions as haulage distances are reduced; thecarbon savings on the type 1 alone in the first 6 months would be inthe region of 6 tons.

Speaking after receiving the award Steve said "It is great to getnational recognition for the work we do - we're committed toenvironmental issues, minimising our waste and recycling as much aspossible. This award shows how the hard work of my team and howour recycling plant makes a real difference. I'm delighted particularlygiven how tough the competition was. The investment in the Aggwashhas definitely taken our business to the next level."

Lucy Binnie of Land and Mineral Management who advise CompleteUtilities on environmental matters commented after the award wasannounced “This is testimony to the way that Complete Utilities haveconsistently striven to be the best in their field and do so in a way thatis friendly to the environment. Steve and the team are realprofessionals who care for the environment and thoroughly deserve tobe recognized in this manner.”

DUO Sales Manager - Luke Talbot, who worked on the project added“It's great that the efforts of Steve and the rest of the Complete Utilitiesteam have been recognized. We're pleased to be associated withtheir success and look forward to helping other customers achievesimilar success in the future.”



Hub issue-20 [jan 2012] 17/1/12 14:19

Top SafetyAccreditation forAlchemy MetalsAlchemy Metals is one of the latestsuccessful companies to join a leadingedge scheme, designed to help industryimprove its safety record.The Stevenage based firm recently receivedaccreditation from SAFEcontractor, a programmethat recognises very high standards of health andsafety practice amongst UK contractors.

Specialising in the purchase of ethically sourcednon ferrous scrap metal, the company'sapplication for SAFEcontractor accreditation wasdriven by the need for a uniform standard acrossthe business.

SAFEcontractor accreditation is expected toenhance the company's ability to attract newcontracts and its commitment to safety will beviewed positively by its insurers when thecompany liability policy is up for renewal.

SAFEcontractor is applicable to most sectorsalthough it is particularly relevant to UKmanufacturing.

John Kinge, Head of Risk at SAFEcontractor said,“Major organisations can no longer run the risk ofemploying contractors who are not able to provethat they have sound health and safety policies”.

“More companies need to understand theimportance of adopting good risk management inthe way that Alchemy has done. The firm's highstandard has set an example, which hopefully willbe followed by other companies within thesector”.

Under the SAFEcontractor system, businessesundergo a vetting process, which examines healthand safety procedures and their track record forsafe practice. Those companies meeting the highstandard are included on a database which isaccessible to registered users only via a website.

Employer-organisations who sign up to the schemecan access the database, enabling them to vetpotential contractors before they even set foot onsite. These employers agree that, as users of thescheme, they will only engage with those whohave received accreditation.


News


Hub issue-20 [jan 2012] 17/1/12 14:19

Hub issue-20 [jan 2012] 17/1/12 14:19

For more information or to book an advertisement in thenext feature please contact: Tel: 0845 680 0024

www.hub-4.com

MRF Equipment Product Focus

January 2012

ECS Limited A2 Varis Business Park, Challenge Way, Blackburn, Lancs BB1 5QB

Tel: 01254 699200 www.autobaler.co.uk

Hub issue-20 [jan 2012] 17/1/12 14:19

During the current economic climateit makes sense to source reliableand efficient bulk handlingequipment for waste processing.Canning Conveyor has suppliedmany solutions for waste processingsites in the UK, consistentlyproviding top quality equipmentbacked by top class service, whichas MD - Andrew Canning says, “Inthis economic client it is important tooffer a full package to the client”This package includes being able tooffer customers a single componentpart to full turnkey packages, fromdesign concept to full installationand commissioning of a completeplant.

With the expertise and experience fromover 45 years in the bulk handlingindustry Canning Conveyor Canninghas successfully adapted to customerrequirements as the industry changes.”Customers want products that workefficiently in arduous conditions at avery competitive price, he says. “AtCanning we have successfully installedan extensive amount of plant andequipment to the full satisfaction of theclient. Furthermore we also offer theback-up of a full after sales servicesupplied by our skilled engineers,including site surveys of existing plant tocover belts, idlers, rollers and drums.

Viridor Waste Management

Designed, installed and commissionedat Century Wharf in early 2007Canning installed a fully integratedconveyor system across the 10 acre sitewhich are part of the paper and plasticline of the MRF

With an initial order for three transferconveyors and a screen feed conveyorCanning subsequently supplied twoquality assurance stations complete withstructures to carry the new conveyorswhich included picking chutes, floors,stairs and hand railing. A third contract

Product focus

A CompletePackage ofProducts andServices for theWaste Industry

involved the supply of two troughed belt conveyors and a 90 metrefeed conveyor which handles mixed plastics at a height of six metreswhich runs parallel to an existing building discharging directly into thenew sorting plant feed hoppers.

To complete the project a further supply of seven conveyors includedCanning 'SuperDrive' motorised drums and modifications to threeexisting conveyors. All the 'SuperDrive' drums are fitted with extra,external non-regreasable steel labyrinth seals to eliminate the ingressof cassette tape, glass, plastic thread and steel or copper wires thatcan become trapped and wind themselves around critical areas suchas shafts and seals. These seals ensure that the pulley can operatewithout constant attention consequently fulfilling its life potential.

Reuse Glass UK Ltd

A recently completed project in the recycling Industry for Reuse GlassUK Ltd at Knottingley, West Yorkshire involved the supply andinstallation of a new transfer conveyor and associated equipment.Reuse Glass are glass recyclers who manage a daily incoming mixedstream of waste glass. Needing to upgrade and modify their existingprocessing system the company contacted Canning Conveyor tosupply a new transfer conveyor.

Canning Conveyor were tasked with the supply of a 3.5 metre longtransfer conveyor which was supplied with a crown and lagged drivedrum with scraper, tail drum and adjustable 3-roll idlers. Canning alsodesigned manufactured and supplied a new two way head chutecomplete with hood and associated chutes.

Further work involved modifications to an existing elevated conveyorwhich involved splitting and then raising the back of the conveyor.Canning then fitted a new discharge end (complete with magneticdrive drum) to feed onto a repositioned 'eddy current' separator. Theexisting eddy current discharge chute was then modified to feed theglass stream onto a new tail end/feed unit which was fitted onto theother half of the split conveyor allowing any non-ferrous metals to befed by chute into an existing mobile skip. To ensure the ferrousremoval the back end of the conveyor was fitted with a chevron belt,and the front end fitted with a wide plain belt.

The equipment for the whole project was subsequently installed on-siteby Canning engineers.


Hub issue-20 [jan 2012] 17/1/12 14:19

Product focus



John Witheford - Production Manager ofReuse Glass, commented, “The Canningteam were very professional and completedthe project within the allotted time framewhich left no room for error due to tightproduction schedules. Furthermore theywere also very competitive with theirpricing.”

Magna Engineering

A third project in the Waste Industryinvolved the supply and installation of aconveyor system at the laminated glassrecycling site at Burn near Selby. MagnaEngineering who are based in Wakefieldare a member of the MAGNA Groupplc. who are specialists in recycling. Thegroup has developed an effective systemto handle laminated glass and separatethe glass from the PVB, to enablerecycling of both glass and PVB forcommercial use, The project has includedthe supply of conveyors for the laminatedglass processing and recovery line withthe first phase involving the supply ofmodular feed and discharge conveyorsfor the first MAGNA separator. Fivemore modular conveyors were suppliedfor the second stage of separation into

different product streams. Further modular conveyors will be supplied tofulfil the need as the process and the plant expands to achieve its fullpotential.

As one of the country's leading specialists in the supply of bulk materialshandling technology Canning expertise covers a diverse range ofindustries including: Power, Waste, Marine, Quarrying, Food andAgriculture.

Canning Conveyor Ltd.T: 01909 486166E: [email protected]: www.canningconveyor.co.uk

Hub issue-20 [jan 2012] 17/1/12 14:19

Dartford based waste and recyclingcompany Easy Load are now operatinga new waste sorting plantmanufactured and supplied by DUOManufacturing, part of the DUO(Europe) plc group.

Easy Load is a family run business that hasbeen working in the waste industry since1968, have upgraded their facilities toincrease the efficiency of their wastesorting. Receiving waste through their skipbusiness which operates across Kent, SouthLondon and Essex, Easy Load provide theirwaste removal services to individualhouseholders, schools, governmentcontracts, local builders and nationalconstruction companies.

The new waste sorting plant, which isdesigned to handle up to 50 tph, will beprocessing a variety of material types,although a sizable portion will beconstruction and demolition waste. Prior tothe commercial and domestic skip wastebeing fed to the MRF it is pre-sorted toremove the +600mm material, +25kgmaterial and any combustible or corrosivematerials.

It is after this pre-sorting stage that thebusiness reaps the reward of theirinvestment. Once separated the wastematerial is sold to local business whichreduces the waste to landfill. Prior to theinstallation this was a time consumingexercise that, apart from the use of amobile screen to remove oversize, wasdone entirely by hand.

The Plant

The process is very simple with incomingwaste materials being fed by wheeledloader into a feed hopper, which wasdesigned and manufactured in-house byDUO. Materials then pass through avibrating feeder and onto an inclinedconveyor which subsequently feeds into a 6bay trommel screen, which was also

Product focus

A DUO MRF wasan 'Easy' decision



designed and manufactured in-house by DUO. The heavy-duty,9.4m x 2.4m trommel mechanically grades the fines fraction intotwo sizes by further screening. DUO Director - Dudley Lloydcommented on the trommel selection “The right size trommel is keyto the efficiency of any installation; we looked at Easy Loadsapplication and rather than trying to compete purely on price we'vemade sure they have the right equipment for the job”.

All oversize material exits the trommel and is fed onto a linkconveyor to the 10 man picking station. This link conveyor is fittedwith an air knife blower, situated just below the head drum thisblower separates any oversize lightweight materials which arethen transferred to a lights cage through a totally enclosed steelduct.

All heavy materials then move onto a 1200mm wide picking beltwithin the picking station which conveys the material past a teamof operators, each operator manually selecting and rejectingspecific materials not required in the end product via dischargechutes into the bays below. Any unpicked material then passesunder an overband magnet to remove any ferrous metals beforegoing on to be stockpiled via a discharge chute at the end of thebelt.

The picking belt is enclosed within a 17.5m cabin and isequipped with a continuous, centrally positioned tensioned pullwire above the belt for emergency stop situations creating a safeand hospitable environment for sorting waste.

An 'Easy' Decision

For Easy Load, DUO Manufacturing stood out in what is a highlycompetitive market.

“We've developed a good relationship with DUO, they have helpedus a great deal from our initial discussions through to the support theycontinue to provide.” commented Easy Load Owner - Tommy Lee. Headded “We've been looking to invest in this type of facility for acouple of years now and in that time we've visited several sites toview similar operations and the specification and build quality of allof DUO Manufacturing's plants has been very impressive”

Tommy commented further “Every element has been designed to lastand the maintenance requirements are very simple.”

Tel: 01373 836451, www.duoplc.com

Hub issue-20 [jan 2012] 17/1/12 14:19

Product focus

Impact's Zig-Zagseparationsystem - Seeing isbelieving!


Impact Air Systems' most recent success has been their Zig-Zagseparation system. The simple but highly effective system pulledcrowds onto the stand at the Recycling & Waste Managementexhibition in Birmingham and at the Recycling exhibition in Poland.They used a demonstration unit to show how they could removelightweight contaminants from recyclable materials thus improvingtheir quality and value.

Although they showed how they could separate paper from pingpong, golf and tennis balls, it was the glass, rubber and plasticssamples that really wowed the visitors.

Since the exhibitions they have had requests for over 30 samples tobe put through their test facility at their headquarters in Leicester inthe Midlands and are now processing many of those samples so thatpotential customers can see the results for themselves.

Customers have been so impressed by the improvement in qualitythat they have even asked Impact not to tell their competitors abouttheir solutions!

The most recent installations include removing paper, label, woodand dust from shredded and granulated rigid plastic, removingpaper and dust from plasterboard nuggets and also systems withinvarious glass processing plants.

Due to unprecedented demand, Impact have established tradepartners in USA, Canada, Mexico, Poland, Russia and Japan.

Impact Air Systems' solutions come with the benefit of support fromtheir sister company Impact Technical Services who have a team ofhighly skilled engineers who pride themselves on their technicalknowledge and reputation for a quality service. Impact TechnicalServices provide everything from contract maintenance, breakdownresponse and spare parts through to specialist on-site services suchas LEV testing, noise and air quality monitoring.

For more information about how Impact can help you, call the salesteam on +44 (0)116 2448855, visit the website www.impactair.co.uk orlook at their videos on YouTube.

Impact Air Systems' recycling solutionsare slowly becoming a globalphenomenon within the recyclingindustry.

Impact offer a number of air based solutionsto separate, clean and transport recyclablesincluding air knives, glass cleaning systems,plastic granule cleaners and film handlingsystems as well as solutions to improve theworking environment and cleanliness ofmaterials such as dust control and LEVthorough examination and testing.


Hub issue-20 [jan 2012] 17/1/12 14:19

Axion Consulting, one of the UK's leading resource andrecovery specialists, has expanded its range of services forMaterials Recovery Facilities with a new Material Analysis andSampling Service (MASS) for mixed material streams.

MASS has been developed by Axion's process engineers to combinecommon-sense, practical measuring methods with the correctapplication of statistical formulae. The collected composition data isprocessed on-the-job, so exactly the right sample size can be taken toremove background variability.

This means that optimum sampling can be carried out in the minimumrequired time, yet still gives the customer high confidence in thevalidity of the results obtained.

Providing a rapid and factual analysis of mixed material streams, theMASS service can be accessed as a standalone package; or it canfollow on from the more comprehensive MRF Health Check that helpsmanagers get the best from their waste sorting operations.

Axion's extensive experience over the past decade encompassessampling and analysis techniques covering diverse waste streams,from plastic pots and trays to mixed bread, cakes and doughnuts.

“We believe many MRF operators and owners are not carrying outstatistically valid sampling and analyses of their infeed and outputstreams,” explained Axion Director Keith Freegard. “As their main taskis to recover valuable materials at high purity from comingled waste, it isessential to know exactly what they're dealing with to gauge preciselytheir plant's overall performance.

“The composition and volumes of these complex material waste streamschanges over time. That's why accurate and representative measurementis vital to identify any necessary responses to optimise operationalefficiency - and maximise profits,” he added.

Axion Consulting, part of the Axion Group, develops and optimisesprocessing and collection methods to recover value from wasteresources for a wide range of clients within the recycling and processindustries.

Axion designs and builds innovative process plants for companies inthe recycling sector, advising on plant design and equipmentselection. Its specialist teams have particular expertise in mixed wasteplastics and biofuels.

For more information, contact Axion Consulting on 0161 4267731 or visit the website - www.axionconsulting.co.uk.

Mogensen in therecycling industry

Most recycling plants findit essential to usevibratory equipmentsomewhere in the

process to loosen,carry out a preliminary

separation on, spreadand/or size theincoming materials.

Examples of processes,which would not beable to operateeffectively without this

sort of assistance, includemagnetic, eddy current, ballistic, optical-electronic and air separation, all of whichare to be found in the recycling industry.Mogensen, as a specialist manufacturer ofvibratory screens, feeders, conveyors,Sizers and the open-ended, non-clogginggrizzlies known as Divergators™, hasexperienced a steady increase in businessfrom the recycling sector over the pastdecade. This development was recentlyconfirmed at this year's RWM show, whichwas marked by an encouragingimprovement in the volume and quality ofenquiries compared with the two previousexhibitions. Within the recycling sector theprocessing of waste materials from theconstruction industry has shown the mostmarked increase in recent years. Thisincludes not only the dewatering and sizingof sand and recycled aggregates, thesizing of wood products and glass butalso, notably, the screening of wasteplasterboard following upon the banning inthe EU of consigning such material tolandfill.

Mogensen has supplied numerousmachines for processing shreddedplasterboard, ranging from small singledeck screens to 3-metre wide, 5-deckMogensen Sizer/spreader feedercombinations. These units have been usedto perform simple duties such as theremoval of paper and production of coarsegrade recycled gypsum, and also the moredemanding duties such as the production ofmultiple fine-grade fractions compliant withBritish Standard PAS109:2008.Mogensen equipment is used, for example,to process shredded plaster board at ratesof up to 80TPH performing separationsdown to below 1mm.

When it is considered that more than500,000 tonnes of scrap plasterboard arealready recycled annually in the UK alone,the environmental benefit is very clear,especially as clean, recycled board isabout 97% re-usable in the manufacture ofnew plasterboard, cement manufacture, theproduction of bricks and building blocks forinternal use and for soil improvement.

Product focus


Axion Consulting launchesnew analysis service forMRFs

www.hub-4.com/directory/14174www.hub-4.com/directory/583

Hub issue-20 [jan 2012] 17/1/12 14:19

After 40 years in the industry, manyorganisations would find it difficult tomaintain an innovative edge. Yetrenowned for pioneering developmentswithin the shredding technologymarketplace, UNTHA has managed tocontinuously design and manufacturenew and exciting machinery throughoutthe decades.

The key driving force behind the inventionof all UNTHA shredders is, 'what do clientswant'? This was certainly the case whenUNTHA introduced the TR series for RDFshredding in 2009. Yet the beauty behindthis most recent innovation - the VR seriesshredder - is that UNTHA has not onlylistened to industry requirements. The teamhas also created a piece of engineeringthat some clients would have never evenconsidered, simply because they didn't thinkit was possible.

UNTHA UK managing director ChrisOldfield explains: “Designed purposefully tosatisfy the need for high-quality precisionshredding, the VR is able to achieve incrediblyaccurately-sized particle reduction thanks to anumber of configurable screens. Suitable forlow-volume RDF, clean and dirty wood,plastics, film, mixed rigid plastics and evencarpets, the VR can handle large volumes ofwaste that can be reduced to a particle sizeof 15-80mm depending upon applicationrequirements.

“Consistency of particle sizing is incrediblyimportant if the shredded waste is to be usedin alternative fuel production, as biomassburners or gasification plants need small yetequally sized particles to get the best charge.”

With five models available from a VR60through to a VR160, the shredder iscapable of achieving throughput of two toeight tonnes per hour depending upon theapplication and required particle size.

Such impressive throughput is possible dueto the VR's unparalleled new drivemechanism. This has not been used in ashredder before but is more commonly seenin heavy-duty applications such as miningand road-planning machines.

Product focus

Getting to knowthe UNTHA VRseries shredder


UNTHA's head of engineering management Christian Lannerexplains: “The gearbox sits neatly inside the shredder's rotor - what isnow the largest in the UK's marketplace - and drives through the full700mm diameter as opposed to only a small diameter stub shaft.Because the rotor diameter is so great, the rotor speed can be reducedwithout compromising the cutter tip speed. Even with reduced RPM thereis an unparalleled rate of throughput. Clients could expect to shred up to7 tonnes of plastic bottles per hour, or 5 tonnes of wooden pallets perhour for example.”

Operational simplicity is achieved by using touch screens, plus allclients' shredding data can now be digitally logged and sent toUNTHA's Austrian headquarters for interrogation. Ongoingassessment of running conditions not only prevents things going wrongbut it also helps to ensure continuous efficiencies for the client longafter the initial installation.

Other features include better foreign object detection, a maintenance-free ram device and interchangeable and indexable cutters. All of thiscombines to ensure outstanding reliability and consistently high resultseven under the most difficult conditions.

Considering its positioning in the marketplace, Chris believes that theVR really does represent the next generation of shredding technology,commenting: “It illustrates the evermore intelligent nature of wastemanagement solutions. Clients continually want more and more from theirmachinery. The VR has therefore been developed to closely fit therequirements of modern waste applications - to achieve greaterefficiencies and encourage smarter working.”

Whilst not essential, the VR looks the part too. It's somewhat ironicthat a machine which deals with materials that other people andorganisations discard as rubbish, is so technically and aesthetically sosophisticated.

Contact UNTHA UK on T: 0845 450 5388 or visitwww.untha.co.uk for more information.


Hub issue-20 [jan 2012] 17/1/12 14:19

Blue Group is the appointed Europeandistributor for the successful range ofMarathon 2 RAM, horizontal andchannel balers. Having launched thenew Gemini-Xtreme model at this year'sRWM Show, the company reportsconsiderable success with this versatileclosed end horizontal baler, confirmingeight models sold, seven of which arealready installed. Blue Group is soconfident of the continuing success ofthis machine that they have placedstock orders with USA based Marathonto ensure off-the-shelf availabilitythroughout next year.

New owners of the Gemini-Xtreme balingpresses cover a broad spectrum of wastemanagement expertise from wasteprocessing to demolition and baling a widevariety of recyclable materials.

Commenting on their recently purchasedMarathon Gemini-Xtreme baler, JamesNolan. owner of Nolan Recycling,

Product focus

Bridgend, Glamorgan said “Our new balerhas exceeded all expectations. It is extremely

versatile, enabling us to bale a wide range ofmaterials including cardboard, paper, polythene,hard plastics, bottles and cans.” James added”The quality of bale produced is fantastic,

especially those of the rigid plastics which weigharound 460kg, enabling us to transport this awkward

material more easily, thus opening new doors for ourrecyclables back into the market.”

Tom Paterson, Managing Director of Patersons Waste in Glasgow,stated, “To supplement our recent MRF installation, we purchasedthe Marathon Gemini-Xtreme baler to enable us to handle andtransport our recyclables more efficiently. We are delighted withthe baler's performance both in terms of throughput and versatility.All products recovered from our MRF are now baled includingpapers, films, cardboard and rigid plastics, ensuring a moreefficient and profitable operation“.

Other Gemini-Xtreme baler installations in the past two monthsinclude specialist companies such as F. D. O'Dell & Sons andHawes in London, Armstrong based in Bolton, DRS Demolition inCornwall and TOM Waste in Scotland.

The Gemini-Xtreme is a mid-capacity, closed-end, multi-materialbaler with a vertical tie system, which is ideal for baling lightalloys, paper, plastics, PET and similar waste stream materials,producing a standard 762mm X 1219mm X 1524mm bale withan average cycle time of 34 seconds. The full penetration ramensures optimum compaction and full bale ejection. Theprogrammable controller allows both manual and semi-automaticoperation and the twin cross cylinders have power to spare fromthe 20HP motor. Wire guides ensure quick and efficient bale tyingand the guide design allows easy clean-out. The Gemini-Xtremealso features a reversible and adjustable bolt-on shear blade andis also available with an optional hydraulic bale door releasesystem and variable speed conveyor. The Gemini-Xtreme can beinstalled with an above floor or pit conveyor as required.


Blue GroupPresses OnWith The NewMarathonGemini-XtremeBaler!


Kenburn installsfully automaticbaler in thirdShred-it branchKenburn Waste Management Ltd hasrecently completed the installation of afully automatic Avermann HorizontalBaler and Conveyor system at the Leedsbranch of Shred-it, a world leading onsite document destruction company.Kenburn has previously supplied theGlasgow and Bristol branches of Shred-itwith similar equipment to meet theirwaste handling requirements.Leeds General Manager, Doug Badger said thatthe decision to use Avermann equipment wasbased on the success of the previousinstallations, where the quality of the equipmentand the after sales support offered by Kenburnhad already been proven. Shred-it investsheavily in the security of customer information,and baling shredded documents so they aresent straight to the mill for pulping is part of thissecure process.

Kenburn has been the UK distributor for Avermann Baler and Conveyorsystems since 1997. Many solutions, including fully automatic andsemi-automatic balers with bin-lift or conveyor feed options have beeninstalled within the UK.

The company is totally committed to provide bespoke customer solutionsto specification, on time and at a competitive price. Key AccountManager, Martin Slough, believes that this commitment explains why asignificant proportion of sales come from existing customers.

Kenburn has a National Service Team, with the capacity to install andsupport all the supplied systems. Additionally, Kenburn can repair andmaintain any make of baler or compactor and supply a full range ofconsumables. They are also UK distributor for the Bramidan andBergmann ranges of waste handling equipment.

For more information, visit Kenburn at www.kenburn.co.uk,email [email protected] or call 01727 844988


Hub issue-20 [jan 2012] 17/1/12 14:19

Wartenberg. Whether residual waste, compost, bulky waste, organic waste, old wood, woody biomassor stones, soils as well as mixed building waste - the SPLITTER handles almost everything. The unique,patented spiral shaft separator for separating extremely difficult materials is always at hand, even fortreating mono charges such as old tyres and scrap steel. It ensures perfect screening without blockagesand wrappers. "The secret of such extreme screening performance over a minimum area is thesimultaneous axial and lateral spread of waste materials", says Bernd Günther, owner of AnlagenbauGünther GmbH in Wartenberg, the company which developed and successfully sells this innovativescreening system on the international markets.

Mr. Günther explains that the wear resistant SPLITTER with its low energy consumption is available in mobile andstationary configurations, because "last but not least, flexible customized solutions are our field of expertise". Theparticularly powerful receiving dosing unit TAKER for forwarding and dosing material onto downstream conveyorunits surely also belongs to the range of best-sellers from Anlagenbau Günther. "This system convinces with largecapacity and application related flexibility", the owner of the company explains. No question: With itscomprehensive product portfolio and its own sales activities covering the fields of receiving - dosing - conveying -separating Anlagenbau Günther is the ideal partner for the entire process.

And this for a good reason, because this German machine and plant manufacturer already looks back on 25 yearsof experience - last but not least also in the development and production of star screening machines with self-cleaning system. At Anlagenbau Günther 120 employees stand up for our customers, work out individual andeconomical recycling technologies to suit man and environment. "We are your self-reliant partner from A to Z", BerndGünther emphasizes, "from consultation through planning, execution and assembly, all the way to our highly professionalAfter Sales Service - worldwide."

Private independent disposers, local authorities, waste management companies and energy producers and heatingplant operators are among the clients of this third generation family enterprise. "They appreciate our modular conceptplants, which seamlessly fit into their existing production processes", says Günther. The high number of possiblemodifications also convinces the customers. The screen gap sizes on the SPLITTER can e.g. be matched to the actualrequirements "and thus ensures highest efficiency".

Product focus

SPLITTER - wide range spiral shaft separator Powerful recycling technology with individual solutions from Anlagenbau Günther


www.hub-4.com | p19|

Hub issue-20 [jan 2012] 17/1/12 14:19

As the price of raw materials continuesto rise and energy costs remainunpredictable, recycling in all areas ofindustry is becoming more important.Mike Redmond of Bosch Rexrothdiscusses the machines and hydraulicsystems that are providing a fast andenergy efficient way to make the mostof the materials that are available now.

In the last few years, the price of rawmaterials and the cost of energy have risensignificantly due to the continued imbalanceof supply and demand. The rapiddevelopment of technology and thestandard of living in Asia, Eastern Europeand South America has also undoubtedlycontributed to this situation and is notexpected to change. We must therefore usethe resources we do have more efficiently,not only reusing raw materials but avoidingwaste. Recycling technology is alreadybecoming a more readily accepted way ofcutting costs and making processes moreefficient. The demand for machines, such asFragmentizers, scrap shears and pressescontinues. The need to keep improving theefficiency and the performance of thistechnology is where hydraulic systems offersuch powerful and attractive solutions.

There are many applications in metalrecycling that take advantage of the shearforce and flexibility of hydraulics to handlethe moving, cutting, squashing and liftingneeded. From simple shears that cut metalinto shorter lengths to massive shears andpresses.

There are numerous hydraulic products onthe market and each one differs in terms ofperformance, quality and function. Onesuch piece of technology is a scrap press,which is used to compress scrap into thesmallest possible volume, forming a singleblock for ease of transport. In order tocompress the scrap as uniformly as possibleit is pressed from the side, from each endand from above. After pressing, the gate isopened and the compressed scrap ispushed out. Typically four hydraulic cylinderaxes are used. In order to reduce the totalcycle time these machine are often fittedwith a 'skip'. During compression of thematerial, a crane fills the skip with the nextcharge of scrap. At the beginning of thenext cycle the previously prepared charge issimply tipped into the press. The skip alsofunctions as a measuring device so that thepress is always filled with the optimumamount of scrap. By employing thisprocess, transport, storage and disposal aremade easier and more efficient.

Another option is a scrap shear. This iswhere the scrap is first compressed as in ascrap press, but rather than being formed

Product focus

A fast andEfficient Way toRecycle


Hub issue-20 [jan 2012] 17/1/12 14:19

Product focus


into a block, the material is pushed out insmall steps by means of an end pusher andcut into sections. In order for this cuttingprocess to be as efficient as possible, thescrap is pre-compressed directly at the shearblade and firmly held by a 'hold downcylinder'. Cutting scrap into small equallysized pieces makes it suitable for furtherrecycling processes.

The need for high forces, robustness,reliability and short cycle times means thatscrap shears must use hydraulics. Thehydraulic system is key to the overallefficiency of the shear and it is thehydraulics that makes the difference inperformance.. A high performance scrapshear requires hydraulics that allows shock-free switching of large flows and shock-freedecompression. Cutting shocks must beavoided with low energy consumption andfirst procurement costs ensured.

Hydraulic systems are also used in pre-shredder Fragmentiser technology whichfurther improves productivity, efficiency andsafety.. A pre-shredder uses low power andspeed to pull pressed materials to pieces,effectively 'unbaling' them to produce alighter material that is ready forfragmentation. This makes the hammermillmore productive and reliable, not just in theshredding operation but also in the feedingprocess stream where the conveyor can befully loaded. Also, further down the processline, it enables better sorting efficiency dueto the better fragmentation. The hammersand other parts will also have less wearproviding longer life savings on maintenancecosts. By using a pre-shredder, capacity canbe increased, allowing transport journeys offeedstock to be reduced to ultimately savefuel costs and reduce emissions.

A pre-shredder works by simply dropping thematerial, whether a car or bale, into the topwhere two rotorspull them in and then pullthem apart. The loose material that has beencreated then drops out at the bottom readyfor the fragmentation process. The twohorizontal rotors with direct hydraulic drivecan be geared together or independentlydriven and the speed is controlled and ifnecessary reversed. A hydraulic push plateis added to press the material against therotors, preventing slippage. The directhydraulic drives produce full driving force(torque) in forward and reverse and nogearboxes are needed to keep the drivearrangement simple and effective. Althoughit's a low speed process, the force neededfor this type of operation is incredibly high,making a direct hydraulic drive system anadvantage..

The use of a pre-shredder can also be usefulin exposing fraudulent attempts to increasethe weight of feedstock bales. Should therebe any fuel in a flattened car, the slowprocess of a pre-shredder will expose theproblem and by tearing the tanks apartcarefully, will virtually eliminate the threat ofexplosions.

The fragmentiser where all our cars, lightscrap and white goods end up usually has

an inclined steel belt conveyor drivenhydraulically which is fully loaded with scrapmetal. The scrap drops down a chute to theroll feeder, also driven hydraulically, whichfeeds the scrap into the hammermill at theoptimum rate, holding it so as not to getpulled in too quickly to ensure the bestproduction in relation to the power of themill.

Other functions of the mill are alsohydraulically operated such as theraise/lower of the feed rolls, the reject doorand maintenance functions like hood lift, pinpuller etc. The main rotor lubrication systemis also hydraulic.

Whilst all hydraulic systems need to bedesigned properly with reference topressures, temperatures, filtration and oilgrade issues, environmental concerns are anincreasing concern. The larger the plant andhydraulic components, the moreconsideration is needed in regards to themassive forces involved and the power ofthe fluid forces and how to control them.Most products are designed for a specificapplication and it also needs to beremembered that using it outside these areasmight not be appropriate. This is true forinstance, in the case of mobile equipment asopposed to industrial equipment. The bestway to ensure the products used are wellmatched and fit for purpose is to order thecomplete system from a well-respectedmanufacturer which can provide a completesystem design, including controls. This willgive you an efficient, workable solutionwhich meets the appropriate standards.

The larger hydraulic companies have beenaddressing these issues for many years.Rexroth, the market leader in hydraulics hasthe knowledge and experience to draw onwhen supplying hydraulic systems as well asrules and procedures to control inherent risks.My advice is that all customers need to beable to satisfy themselves as to the reliabilityand security of the technology including itsefficiency. All round performance is requiredshort term, but the reassurance of qualityservice and ongoing support will be neededin the long run.


Hub issue-20 [jan 2012] 17/1/12 14:19

The first Made in Wales Awards were held at theMercure Holland House in Cardiff on 20th Octoberand we are delighted to have been amongst thewinners picking up the Creative Design award forthe development and manufacture of our newBM60 fully automatic baler.

Established over 12 years ago, the company has beenrefurbishing, servicing, repairing and supplying parts forall kinds of recycling machinery, but despite moving intomainstream equipment design and manufacture for thefirst time, such is the innovative nature of the design, wefought off challengers including global multi-national GEAviation to secure the honours. The main feature thatmakes the new baler so impressive is that the balingcapacity of the machine can be increased withoutchanging the chassis, by way of adding more cylindersand motors.

With recyclers and waste management companies oftenuncertain of the eventual volumes of waste to berecycled when purchasing the necessary equipment,more often than not, levels are exceeded well beforethey had budgeted for, with the result that the baler has

to be replaced. Clearly a very costly situation, but withour new baler, we can increase capacity on the existingchassis, taking the capacity up to 80 tonne, then 100tonne, if required. There is nothing like this in the market,hence we are particularly proud of the research anddevelopment that has taken us to this level.

Commenting on the Award, Managing Director NigelDavies said “to have beaten off so many excellententries from some of the world's leading manufacturers istestament to the hard work and determination from allour staff. It is a fantastic achievement and we arenaturally very proud of the achievement.

The company is now embarking on a significant growthprogramme and is in the process of identifying newmarkets where this technology will be sought after. Weare already servicing clients in the UK/Ireland, as wellas New Zealand and the US, but we are onlyscratching the surface in this growing sector. We arealso pursuing India as a potential, so clearly these areexciting times”.

Product focus

Recycle Direct wins creative design award atthe Inaugural Made in Wales Awards 2011



Hub issue-20 [jan 2012] 17/1/12 14:19

Almost gone are the days where abaler is bought to processes a certaintonnage of a certain material for aspecific number of shifts per day.Nowadays customers are requiring farmore flexibility, of variable tonnage,variable materials and not only theability to scale up tonnage but also theability to scale 'up' or 'down'according to the season or even thetime of day and remain efficient.

Jeff Jones, MD, of the UK company.Autobaler looks at this new trend anddiscusses how they have changed to caterfor this new model.

Whether in normal times or current,businesses should be looking at ensuring thebest return on their investment whenconsidering any purchase of capitalequipment. At Autobaler we have foundthat clients seldom have a constant volumeof material to process and often haveconsiderable seasonal changes to manage.

Whereas previously an automatic balermight be purchased for doing a specificjob, we're getting more and more enquiriesabout balers being able to swap materialgrades and types with minimal disruption.

Product focus

Ultra Flexibility nowrequired forAutomatic balers


The important factors are scalability and energy efficiency.

The vast majority of our clients have peaks and troughs in theirbusiness and need equipment to be as flexible in meeting thesedemands. With ever increasing operating costs (e.g. electricity andlabour) energy efficiency and machine capability are in the forefrontof our clients minds. Often Clients need to process higher 'ondemand' volumes in the same time frame as they would the lowervolumes. Thus, having the ability for the machine to detect anincrease or decrease in throughput required and automatically adjustit's capacity, has been invaluable to our clients.

As the markets strive for better and better quality our clients alsorequire flexibility in being able to change from one material grade toanother, on a bale by bale basis. This is being driven by their aim tomaintain or improve the saleability of the baled material. (e.g. 'whiteoffice' is valued more than 'mixed office' paper).

When selecting an automatic baler, it is also vitality important tounderstand how the client intends to operate their plant. This simplebut vital step is often overlooked but is essential to ensure a robustand flexible solution.

Flexibility = Efficiency = ROI

As economic times get tough, flexibility and creativity are paramount.Being able to provide better utilisation of equipment has never beenmore necessary. The old saying 'Use it or lose it' has never beenmore prevalent and baler manufacturers will need to maximiseutilisation for their customers in order to grow. It may be a tough timebut such times encourage us to be more creative and flexible.


Hub issue-20 [jan 2012] 17/1/12 14:19

Minimising the volume of material sentto landfill makes good environmentalsense but local authorities are reluctantto spend more than is absolutelynecessary on recycling, especially inthe present economic climate.Fortunately, technology is coming to therescue by reducing the cost ofprocessing waste and, in someinstances, turning a cost into a profit.

The key to making money from waste is tosort the incoming waste stream intoseparate fractions as economically aspossible. Sorting technology from S+SInspection Limited, part of the Germanbased, S+S Separation and SortingTechnology Group, covers the whole gamutfrom simple, permanent magnetic devicesfor removing ferrous material tosophisticated equipment using a range ofsensing technologies to sort on the basis ofcolour or material type. Typically, thisapproach is being used to sort plastics,metals and glass, which, once sorted, canbe sold for reuse or further processing,converting a liability into an asset. ManyUK commercial recycling companiesalready use S+S sorting technology toprofitably sort and recycle waste from avariety of sources. For example, the BiffaPolymers plant on Teesside is using acombination of S+S VARISORT bulk sortersto separate plastics from the stream ofmixed materials, such as metal, cardpaper, etc. and Flake Purifiers to process15,000 tonnes per annum of mixedplastics into high grade, reusable material.

Similar technology can be used toprofitably recycle other materials includingglass, plastics and metals to meet thedemands of a wide variety of recyclingchallenges, including the WEEE Directive,cost effectively and, in many cases,profitably.

One of the most widely used sortingsystems is the S+S VARISORT COMPACTwhich can be fitted with a range of sensingsystems to handle a wide variety ofmaterial. In operation, this machinerequires little, if any operator input onceset-up for a particular material and can beeasily reset as the needs of the recyclingplant develop.

The VARISORT COMPACT can sort a wide variety of materials,but the input stream does need to be pre-sort to remove non-compatible materials, such as paper, card and similar materials.With its extensive experience of sorting waste for recycling, S+SInspection Limited has the capability to design and supply acombination of technologies to convert an input stream of mixedwaste into high purity, high value output streams for sale to themanufacturing sector.

This approach doubles the environmental benefit by reducingthe pressure on landfill and replacing virgin raw materials, oftenhydrocarbon based, with less costly and less energy consumingrecycled materials; a real win-win situation.

Product focus

Profit from Waste


The input stage at the Biuffa Polymenrs plant where unwantedmaterials, such as paper, metal and glass are removed toleave a stream of mixed plastics for further processing.

The S+S VARISORT COMPACT which can be fitted with arange of sensing systems to sort a wide of variety ofmaterials.


Hub issue-20 [jan 2012] 17/1/12 14:19

Crusher Manganese Steels Limited

Vulcan Way, Hermitage Industrial Estate, Coalville, Leicestershire, LE67 3AP, United Kingdom.T. +44 (0) 1530 817 000F. +44 (0) 1530 817 111E. [email protected]

www.cmscepcor.com

Europe’s leading aftermarket manufacturer and supplier of precision crusher spare parts andpremium manganese wear parts for the Quarrying, Demolition and Recycling Industries.

Hub issue-20 [jan 2012] 17/1/12 14:19

By George Ord‚ managing director ofInternational Innovative TechnologiesLtd. New patented milling technology hasthe potential to meet the fine grindingrequirements of minerals andmanufactured materials that werepreviously regarded as uneconomic.

The new grinding technology developed bythe UK based International InnovativeTechnology (IIT) combines low energyconsumption with a compact size andpowerful grinding force.

In traditional minerals processing andmaterials handling applications‚ this newtype of mill is suitable for the fine grindingof a wide range of natural raw materialsand other industrial products. However‚because of the low energy consumptionassociated with the new technology‚ thehighly efficient and versatile milling systemalso has considerable recycling potential byproviding the means to convert by-productscurrently regarded as waste‚ intocommercially marketable powder products.

New patented design

The majority of traditional grindingprocesses are air swept systems in whichthe feed materials are introduced into thegrinding chamber in a stream of air.

However air swept mills require significantpower to maintain flow through the system.In addition‚ many conventional ball mill andsimilar grinding systems involve the fairlyrandom application of the attrition force onthe material in the mill.

Recycling

New millingtechnologyopens uprecycling markets

The new vertical mill developed and patented by IIT comprises atechnically advanced modular design capable of grinding soft‚medium and hard materials to 9.5 on the Mohs scale and with90% passing 45 microns and below.

Compact and powerful‚ the centrifugal grinding mechanism of them-series is extremely efficient‚ with the vertical material flow pathand special roller assembly ensuring that the force produced istranslated into maximum particle grinding power.

In the new m-series mill‚ the product in-feed mechanism andchamber comprises a rotating spreader plate which throws thematerial outwards (by centrifugal force) against the wall of thegrinding chamber and downwards (by gravity) through thegrinding module.

As the material descends‚ it is forced between the rollers and theouter grinding ring on the inside of the mill housing (barrel) and isreduced to a powdered form.

All material introduced into the mill must come into contact withthe grinding module. The rotational speed of the rollers (typically300 rpm) carrying the grinding heads controls the crushing forceapplied and the diameter of the mill housing determines thethroughput volume.

Multi stage grinding is achieved through the incorporation of anumber of grinding modules in series with particle size controlledboth by the number of modules and rotational roller speedapplied.

Typically‚ a standard 600mm mill barrel operating at 300 rpmproduces a very fine powder output at up to 5 tonnes per hourand multi-mill configurations are available to meet capacities of upto 50 tonnes per hour.

As a result of this configuration grinding efficiency is maximisedwith very low electrical energy input being required relative to thefineness and volume of powder produced. For example‚depending on the specific milling application‚ the energyconsumption typically associated with the new m-series is between5kWh/T and 10kWh/T. By comparison‚ traditional millingprocess typically utilise between 3 and 10 times higher energylevels.

As a result‚ material previously regarded as waste can now beeconomically reduced to powder for recycling applications.

Recycling of plastic waste

Glass Reinforced Plastic (GRP or fibreglass) is used in thousands ofconsumer and building products. However‚ because GRP is anotoriously difficult materials to break down‚ the effective disposalof waste GRP is a significant problem worldwide.


Hub issue-20 [jan 2012] 17/1/12 14:19

For many years it has been widelyregarded that the only viable option fordisposing of waste GRP was landfill andin the UK alone it is estimated thataround 150‚000 tonnes are sent tolandfill every year.

To help overcome such problems‚ duringthe last 18 months IIT has successfullyworked with a UK GRP manufacturer aspart of its sustainable manufacturingprogramme to explore methods ofrecycling GRP.

As a result of the research anddevelopment work undertaken during thisperiod a successful GRP recycling plant isnow fully operational - and has overcomeconcerns that GRP is too hard andabrasive to be recycled cost effectively.

This process involves GRP waste firstbeing converted into flakes beforesecondary reduction is carried out in anm-series mill which successfully convertsthe flakes into a fine powder of generallyless than 100 microns.

Tests - and subsequent production runs -have shown that the inclusion of apercentage of this powdered materialback into the primary batch for new GRPproducts has no detrimental effect onGRP in terms of strength‚ lighttransmission‚ light diffusion or durability.

The company has now incorporated afully operational recycling plant as part ofits primary production facility. As a resultof the mill's ability to successfully convertwaste into recycled powder‚ the quantityof GRP going to landfill has beenreduced and the costs associated withthe use of some traditional batch rawmaterials has also been cut.

However one of the key benefits for thecompany involved is that is can nowclaim genuine 'recyclable' credentialswhich significantly enhance its corporatereputation and product marketability.

Commercial applications for wasteglass

In the glass industry work has beencarried out to show how the economicfine grinding of glass waste can also besuccessfully utilised for commercialapplications.

Historically the unfavourable economicsassociated with the fine milling of glasswaste in conventional grinding systemssuch as ball mills has largely ruled outpotential applications in the brickmanufacturing industry and in filtrationprocesses.

As part of its work on the economic,practical and technical challengesassociated with the recycling of glasswaste‚ the UK's Waste & ResourcesAction Programme (WRAP) has identifiedthe considerable potential for powderedglass to act as a fluxing agent in themanufacture of bricks.

Recycling


This work has shown howthe addition of powderedglass can successfully reducethe firing temperaturesrequired during brickmanufacture - particularlywhen used with those typesof firing clays that demandthe highest energy levels.

However IIT has successfullyundertaken the milling ofglass waste to 50-75microns to demonstrate thefeasibility and cost effectiveproduction of powderedglass product.

WRAP has estimated that the UK domestic window replacement sectorgenerates around 90,000 tonnes of glass every year. Until now, all ofthat glass has gone straight into landfill and these figures are expectedto rise to between 160,000 and 250,000 tonnes per year over thenext 10 years.

The ability to economically mill and recycle glass powder couldtherefore significantly reduce waste management costs associated withlandfill disposal of waste glass and at the same time provide acompletely new income stream from this commercial application.

In addition‚ similar opportunities for powdered glass are also providedby in water filtration and sports turf applications - both of which havealso been researched and developed by WRAP.

With the new mill size and energy costs of converting granular materialsinto a fine powder no longer an inhibiting factor‚ volume powder millingapplications can now be easily integrated into previously inaccessiblelocations.

It follows that the energy efficiency associated with the new technologytherefore brings new opportunities for the fine grinding of thosematerials that were previously regarded as uneconomic and regardedas waste.


Hub issue-20 [jan 2012] 17/1/12 14:19

Hub issue-20 [jan 2012] 17/1/12 14:19

United Utilities is the largest watercompany in the UK, and Ian Smith,the Vactor Services Manager looksafter the cleaning requirements of its650 waste water treatment plants,220 portable water treatment plantsand 2,500 pumping stations in thesewer network in the North ofEngland

“We use DISAB trucks because there'snothing else that does what they can do.They've got a blowing as well as suckingcapability, airflow of 8,500 cubic feet at80% vacuum, and with its Boom, franklyyou'd have to see it shift wet as well asdry material and the speed at which itcan do it, to believe what these trucksare capable of. There's nothing thatmatches their longevity and reliabilityeither.”

As Gotland is part of the DISAB Group,world leaders in low-noise mobile andstationary vacuum systems, we thoughtwe'd take a closer look at theseextraordinary machines. The DISABGroup is best known for its unique, highpowered truck mounted vacuum systemsthat are used for sucking, blowing andtipping all kinds of dry and wet material.They represent the ultimate in usablevacuum power for industrial applications.

What are DISAB trucks used for?

Ian continues: “We bought our first DISABtruck back in 2006 and it became obviousthat we needed another two on the fleet,because with such a large number of assetsto look after, there's a constant demand forboth the DISAB trucks we have and forthose we can hire from our approvedcontractors. The most recent DISAB truckwas purchased in March 2009.”

“On a daily basis we're dealing with andmaintaining the deep lifting of sludge andgrit from detention tanks, storm overflowsand so on. One of the deepest we haveon our books is 40 metres deep;underneath of all places the car park atBlackpool FC!”

“Maintaining these facilities means theywork efficiently. If we didn't do this thesewer and water systems would soonbecome unserviceable and our industrialand residential customers would soonnotice the difference. A 30 metre lift ofseveral tonnes of heavy wet material is verytypical of a day's work for the DISABtrucks, but one of the most unusual tasks

Recycling

So what can aDISAB truck do?


was when we used their power to blow pea gravel UP 30 metres into abiological filter plant at Birkenhead.”

“We had to shift 1,200 tonnes of this gravel and it took two DISAB truckstwo weeks. There was a compliance issue with this particular plant, so wethrew everything we had at it. Because we had the DISAB trucks, wereckon it took us half the time it would have done by standard liftingtechniques and several operatives on site.”

DISAB's uniqueness and reliability

A DISAB truck's power can work both ways, as Ian explains: “It's theDISAB truck's blowing as well as its sucking capabilities that make it soincredibly versatile. Our units were specially made for us by DISAB usingstainless steel so that we can handle all sorts of toxic sludge and hazardousliquids, another unique ability for United Utilities.”

“I can honestly say there's nothing like these specialist vehicles for theirreliability and longevity, let alone their versatility

“All this means we can genuinely be ready for action whenever any part ofthe United Utilities asset portfolio needs a DISAB truck's capabilities, andkeep one of the UK's largest water asset portfolios working efficiently todeliver clean water and waste water removal 24 hours a day, to its millionsof customers.”


Hub issue-20 [jan 2012] 17/1/12 14:19

IntroductionLove them or hate them, the number ofEnergy from Waste (EfW) sites in the UKis growing steadily and, withencouragement from the CoalitionGovernment, this trend is set to continue. Despite continued opposition from residentgroups around the country, it is estimated thatthe UK could be generating six percent of itsenergy from waste by 2015. Thisdevelopment could play an important role inhelping the UK meet its internationalobligations to reduce the emission ofgreenhouse gases, in particular carbondioxide, by replacing fossil fuels as a sourceof energy. Given the restrictions on land fillsites, burning non-recyclable waste to produceenergy is now becoming a necessary evil.Modern waste to energy plants are primarilymoving grate incinerators: the waste is slowlypropelled through the furnace by a movingmechanical grate. Waste continuously entersat one end and the ash is discharged at theother. Combustion technologies haveadvanced significantly over the past decadeand pollution levels have been reducedsignificantly. The electricity generated from atypical 100,000 tonnes per annum facility issufficient to provide power for approximately10,000 homes, whilst any excess heatproduced by the plant can be used inindustrial or district heating schemes ifappropriate.

The role of weighbridge systems at EfWsWeighbridges play a vital role at EfW plantsand, in accordance with the WasteIncineration Directive (2000/76/EEC),provide essential weight data relating toquantities of waste arriving on site andincinerated by-products (primarily ash andresidues) leaving the plant. However, asWeightron Bilanciai's Sales Director EmlynRoberts explains, modern weighbridgemanagement systems provide much more thanjust weight data, with the weighbridgesthemselves acting as critical control points forall vehicles entering and leaving site. In thiscapacity, the weighbridge installations atentry/exit points provide the ideal locationsfor implementing vehicle check points andinstalling radiation detection systems.

The weighbridge system can act as aneffective site vehicle management system forboth weighed and non-weighed vehicles,reducing waiting times and improving sitesecurity. Depending on the design layout ofthe site and any space restrictions, vehicles tobe weighed pass across the weighbridges,whilst non-weighed service vehicles may bedirected to enter or leave either over theweighbridge itself or via an adjacent bypass

Recycling

The role ofweighbridges inenergy fromwaste sites

lane. Vehicle access is typically controlled via driver-operated terminalswith card readers, barriers and traffic lights.

Versatile weighbridge softwareThe development of versatile open architecture web-based softwarepackages, combined with the latest security and communicationtechnologies, has brought sweeping changes to weighbridge systems.Weightron Bilanciai's Winweigh IV uses fast client-server techniques,providing the ultimate in flexibility and connectivity. The easy to usedatabase capabilities offer fast data access and extensive searchfacilities. Winweigh IV can be used for single installations with oneweighbridge right through to multi-weighbridge, multi-site installations,allowing centralised remote access for optimum operational control.Winweigh readily interfaces with a wide range of peripheralequipment, including barriers, traffic lights, automatic number platerecognition cameras, unmanned terminals, electronic signature padsand PDAs.

Weightron's latest PC based driver-operated terminals, in conjunctionwith Winweigh, provide a wealth of features to help guide driversthrough entry exit procedures. The user friendly programmablepictograms and graphics, together with the voice activation featurestreamline the weighing process. In addition to this, in its vehiclemanagement role, the system can also provide drivers with printedroute directions within the site, based on the type of material they aredelivering or collecting.

In a typical installation, the weighbridge software not only overseesthe vehicle weighing procedures, but also controls the entry/exit ofnon-weighed vehicles via card readers and processes data from theradiation detection systems. A key feature of Winweigh is its versatileconnectivity with plant management software such as SAP, Sage,Oracle (JD Edwards) & Microsoft Navision. This provides seamlessintegration for operational procedures including administration,planning and invoicing.

A wide range of smart card technologies can be employed, includingRFID and magnetic. Using driver-operated card readers ensures accessis only permitted to pre-registered vehicles whose details are stored inthe site data base; thereby improving site security and speeding upprocedures. Dual height card readers accommodate different drivingheights of commercial vehicles, vans and cars. Vehicles visiting sitecan be issued with either permanent or temporary cards: temporarycards are deposited in the card swallower when the vehicle leavessite.

Radiation Detection SystemsAs more and more materials are recycled and as waste sourcesbecome more complex and diverse on an international basis, there isa growing need to monitor waste material for traces of radiationbefore it is incinerated or reprocessed. In parallel, heightenedawareness of the possibility of terrorist attacks on soft targets mandatesthorough checking of waste for radiation entering EfW plants. If anyradioactive material goes undetected, then once it has beenprocessed or burned, the problems can be multiplied many times over.In addition to health and safety concerns, clean up costs resulting fromcontamination can be significant. By preventing any such material


Hub issue-20 [jan 2012] 17/1/12 14:19

entering facilities and refusing to accept suspect vehicles, operators canprotect themselves from the costs and implications associated with anycontamination.

As the loaded vehicle passes through the large sensitive radiationdetector plates, positioned each side of the weighbridge, it is scannedfor traces of radioactivity. The system can be programmed for specificradiation thresholds and if it determines that a radioactive source ispresent, either in the load or the vehicle, the system actuates an alarm toimmediately notify site security. The system provides a full radiation profileof the vehicle and its load and can also be linked to an automaticnumber plate recognition system to capture vehicle identification.

Recycling


ConclusionModern weighbridge systems offer awide range of operational benefitsfor EfW plants, extending theircapabilities way beyond simpleweight data capture. As an integralpart of the plant control system, theycan provide extensive vehiclemanagement capabilities. Remoteaccess to the hardware and softwarevia secure web servers facilitatessystem updates and predictivemaintenance, without the need forengineers to visit site.

www.weightron.com


Hub issue-20 [jan 2012] 17/1/12 14:19

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Hub issue-20 [jan 2012] 17/1/12 14:19

Cold extrusion is playing an evergreater part in recycling of wasteplastic, and the Department forBusiness and Enterprise is sponsoringresearch into development of themachinery necessary for such work.

Engineers at Bradford University have builta pilot plant and are running a series oftrials with different processes, feedplastics, additives, and final products.Leader of the project, Dr Raj Patelexplains:

“We started out comparing cold extrusionand warm extrusion, in which the material isheated prior to processing, and quicklyrealised that cold extrusion was more suitedto recycled plastic. Our process now is togranulate the recycled materials to aconsistent size, mix in binders asappropriate to basically, glue theparticulates back together, and cold extrudeit into sheets or blocks.”

“The extrusion process is the critical stage,so we are monitoring many parametersrelating to this.”

The single most important parameter istorque in the extruder drive. This indicatesthe force required to process the materialand hence both the power requirementsof the drive and the viscosity of theplastic. It is measured using a digitalTorqSense torque sensor, which usesSurface Acoustic Wave techniques toprovide a non-contact method ofmonitoring continuous rotary torque,allowing accurate modelling of theinstantaneous load changes. It is in effecta frequency dependent strain gaugeoperating at ultrasound frequencies andconsists of a transducer mounted on themixer's rotating shaft to monitor variations

Recycling

Big push torecycle plastic


in its resonance frequency as the torsional load varies. An RF (radiofrequency) link is used for wireless transmission of signals to an adjacentcouple so that rotation is unhindered. It is manufactured by SensorTechnology in Bicester, Oxon, which developed the underlyingprinciples into a practical technology and is now recognised globally asa leader in the field.

“With research work, there is an inordinate amount of dismantling andreassembling equipment,” says Patel. “This can be time consuming andtherefore expensive, but TorqSense being non-contact does not need to bedismantled. It is also naturally robust, important in the laboratory and criticalsince it is likely to be used on the full scale plants that we will ultimatelydevelop.”

Currently the project is sending its recycled plastic off to be made intoacoustic baffles for use in new buildings. “This is a ready market, drivenby new Building Regulations and the higher acoustic standards required forhigh density building.”

However it is not the only market open to Bradford's recycled plastic.Their best results are indistinguishable form virgin plastic, so can beused in the most demanding applications, and there are many uses forthe standard quality output.

The pilot plant is also being used to work on design and developmentof full scale plant, which will eventually be used at waste processingand recycling plants across the country.

Click for further information: www.sensors.co.uk/hub

Contact: Tony Ingham, Sensor Technology Ltd, Apollo Park,Ironstone Lane, Wroxton, Banbury, OXON, OX15 6AY. Tel: 01869238400, [email protected]


AGGREGATE PROCESSING & RECYCLING LTD - HEDGING LANE, WILNECOTE, TAMWORTH . B77 5EXTEL +44 (0)1827 280139 FAX +44 (0)1827 287770 Email: [email protected] www.agg-pro.com

GipoCOMBI RC130FDR J50 Jaw Crusher

Hub issue-20 [jan 2012] 17/1/12 14:19

The WARMAN® WGR Pump has beenspecifically designed for use with abrasivematerials and a wide choice of pump sizes makes it well suited for slurry pumpingduties. Unique hydraulic designs areparticularly focused on reducing internalturbulence and minimising power draw.

The streamlined design allows easy access to all parts of the pump and the internalcomponents, making servicing easier and reducing downtime.

Combining the long service life of our parts and the proven performance of ourproprietary LINATEX® Premium Rubber, we provide pumping solutions that demonstrate the lowest total cost of ownership inoperation.

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Hub issue-20 [jan 2012] 17/1/12 14:20

Recently supplied by the UKdistributor, Tamworth basedAggregate, Processing and RecyclingLtd (APR), Oakfield Construction hasinvested in a new McCloskey J50Tracked Jaw Crusher for duties withintheir Recycling Division.

Based in Nottingham, OakfieldConstruction was established in 1987,initially carrying out work as sub-contractengineers working for local groundworking contractors as well as nationalconstruction companies. This led to thecompany moving into civilengineering/groundwork's working forlocal and national companies. Today thecompany is divided into three companieswithin the Construction, Plant andTransport and Recycling Industries.

Oakfield Recycling is based at WigwamLane Industrial Park, Hucknall inNottinghamshire where the newMcCloskey J50 Tracked Jaw Crusher isemployed on processing incoming wastefeeds. These waste feeds originate fromthe general public and industry andmainly consist of brick, concrete, tiles,tarmac and topsoil which the companyprocess and recycle into end products.

These end products include 6f2, hard-core, type 1 consisting of concrete andtarmac, road planings, fill sand andtopsoil and various size gravels which arethen sold back to the general public,industry or used for Oakfield projects.

The J50 has proved to be an efficient andreliable workhorse. Mark Flint - Director,

Recycling

Oakfield Recycling invests in a newMcCloskey J50 Mobile Crusher.


commented, “Overall we are very pleased with the machine; it hasprovided us with greater productivity with less fuel usage.”

Offering quality, durability, and productivity the J50 provides throughputand capacity for a wide variety of applications. Weighing in at48,000 kg the versatile performer is powered by a 350HP CAT C9engine and processes material through a 50'' wide Telsmith Jawincorporating a user friendly control panel with excellent machinediagnostics.

Supplied with several optional features the McCloskey J50 TrackedCrusher specification at Oakfield Recycling includes:

• Side conveyor

• Overband magnet

• Remote control feeder

• Remote control tracking

• Dust suppression spray bars

• Recycling jaws

• Deflector plate

• Hydraulic raise and lower conveyor

With branded components throughout and a high efficiency dieselhydraulic system providing higher throughput and lower fuelconsumption the new machine is backed by a professional parts andservice package supplied by APR who has an accumulation of overthirty years of experience in the construction industry. This experiencehas been gained from design, manufacture, sales and servicing of alltypes of construction equipment, specializing in crushing and screeningequipment.

Employing all their own fully trained service staff within an 18,000 sq.ft. workshop facility complete with all the necessary equipment toservice, or if necessary manufacture new parts at their Tamworth site,APR maintain full control of their staff and facilities allowing thecompany to operate at maximum efficiency, offering a total after salesservice package.


Hub issue-20 [jan 2012] 17/1/12 14:20

Following increased demand for wheattonnage and with a growingmembership the Mereworth, Kent basedco-operative Weald Granary hasinstalled a Precia-Molen GeneSYS™Enterprise Software system as part ofan on-going development programme.

Owned by a membership of local farmersWeald Granary is a non-profit makingorganisation functioning as a grain drying,cleaning, handling and marketing facility.Serving Kent, Sussex, Surrey and Essex thefacility is one of a number of co-operativestores in the UK and Scotland, being partof the Openfield Store Network (OSN).

A recent further investment of £1.75m in aphase 8 development has provided a 26%increase in storage capacity to 80,000tonnes. With the impressive facilitiescurrently handling approximately 100,000tonnes per annum from 192 farmersalongside an annual projected growth of 4-5,000 tonnes from a projected 10-12 newmembers the Precia-Molen GeneSYS™Enterprise system has changed thefundamental time resource completely,throughout the stores, administration,marketing and stock control of the products.

Key criteria:

Weald Granary chose the Precia-MolenGeneSYS™ Enterprise Software because itmet four criteria:

• To bring the entire vehicle unloadingoperation, including contract validation,sampling, laboratory testing, weighingand discharge on two Precia-Molenweighbridges under the control of asingle PC network.

• To be fast enough to cope with theincreased traffic in 'harvest time' andensure that they have all been tested andaccepted for delivery.

• Flexible enough to adapt to any futureneeds of Weald Granary, allowing newcommodities to be added to thedatabase if necessary.

• To be fully supported with technical back-up and updates.

Materials Handling

Precia-MolenGeneSYS™EnterpriseSystem providestotal efficiencyfor WealdGranary.

A smooth transition

Currently employing seven HGV staff and five store personnel theWeald Granary team are supplemented by casual staff in harvesttime (8-10 weeks); when at its peak 3500 tonnes per day isdelivered in from farmer members to the facility.

With each member requiring quality confirmation and weight datafrom the granary, the GeneSYS™ Enterprise Software was installedwith the addition of a second weighbridge (VS400). This hassmoothly accommodated the transition to phase 8 providing totalfarm management through the integration of the weighing systemwith the stock management system, allowing the farmers easyaccess to their data through the web portal.

An assurance scheme:

One of the major features of the GeneSYS™ Enterprise system isthat it maintains the traceability of assured combinable crops afterthey have left the farm, which complies fully with TASCC guidelines.TASCC was developed because farmers and end users wanted tobe sure that crops of grain, oil seeds and pulses were treatedresponsibly once they left the farm. That includes wheat processedby flour millers and malting barley for the brewers and distillers inthe drinks industry. It also provides independent verification that thetrade is meeting food safety laws. The scheme is audited andcertified by an independent certification body, in accordance withthe internationally recognised standard EN45011. This means thatthe certification body is itself independently assessed every year toensure that the standard is implemented and administeredconsistently and fairly. The Scheme is made up of a SchemeManual and four codes of practice (Storage, Haulage, Merchantsand Testing Facilities). The Storage Scheme is operated to a jointscheme with the Grain and Feed Trade Association (GAFTA)covering combinable crops and feed materials.


Weighbridge & Sampling Reception

Bulk Outloading

Hub issue-20 [jan 2012] 17/1/12 14:20

Materials Handling

www.hub-4.com | p37|

Any incoming load whether dry or wet can be dealt with effectively asthe load can be calculated as a dry net weight through weight losscalculations within the GeneSYS™ Enterprise System (throughalgorithms). The system through its database will automatically calculatethe moisture content in any grain type and through this calculationsubsequently provide data on the parameters of protein, (example -Hagburg-suitability for dough in bread making), specific weight andscreenings (cleanliness).

Outgoing deliveries of grain are handled by the partnership with DHLwith trucks entering the one- way system passing onto the incomingweighbridge and then to the appropriate silo for loading. Exiting thesite they move onto the outgoing weighbridge for sampling andweighing of the load. Here again a sample is then drawn off by aremotely operated vacuum spear sampler adjacent to the weighbridgeand sent to the on-site laboratory for sampling. The results obtained fromthe outgoing load are then retained by the GeneSYS™ EnterpriseSystem which can be remotely accessed by OSN to check the qualityparameters of each individual load if required.

Further added benefits:

Overall the Precia-Molen GeneSYS™ Enterprise software has providedfurther added benefits to the marketing of the products to the market:

• Speed of uplift, drying, cooling and total management of thecondition of the crop.

• Material availability to the market through OSN to maximise theprofit, which would not be available off a farm.

• Vendor assured quality on outgoing loads which enables end users toreduce their own lab staffing costs as they will be assured of thequality being delivered.

• Reduction of rejection levels of delivered grain to a minimum,resulting in major logistical savings (Lorries not waiting for results,etc.)

• Vendor assured grain = big future market!

For the project Precia-Molen installed one surface mounted weighbridge-type VS400, capacity 50,000kg, one RFID reader, ticket printer and adialogue display.

John Smith-Managing Director - Weald Granary, commented, “Theinstallation of the GeneSYS™ Enterprise System is proving an important partof our ongoing site expansion & development program here at WealdGranary. This IT platform has provided customers & farmer members with allthe information they require at the time they want it, it has reduced dataentry & double handling of data freeing up staff to focus on other tasks. Ithas also reduced data inputting errors, improved efficiency and visibility ofdata on site. The site operation is a lot more organised and less stressfulnow with staff having easy access to all the information they require to carryout their job roles.

A testament to the benefits of the GeneSYS™ Enterprise System is that weincreased storage capacity at the Mereworth site by 26% for harvest 2010with no additional staffing requirement.''

An achievement:

Since the installation the GeneSYS™Enterprise software has provided anexpandable system which has providedmany benefits including:

• Reduction in staffing levels.

• Increased overall efficiency.

• Decreased phone communication, asmost communications are nowthrough the web portal.

• Decreased paperwork and decreasedmanagement of paperwork.

• System can be accessed remotely byOSN.

• Management of incoming loads,variety, etc.

A simple and effective system:

Gaining access to the site is through aone-way system which directs the driverto the incoming weighbridge where thedriver gains access by receiving a cardfrom the Precia-Molen automatic carddispenser. The driver then enters therelevant information including referencenumber, vehicle registration, andcontractor code and commodity type.The GeneSYS™Enterprise System thenretrieves the contract details from thedatabase and checks that thetransaction is valid. Should there be aquery on a load the system incorporatesa search facility (truck/member/quality)which allows the operator to quicklyinterrogate the database ensuringminimal time delays. Having already un-sheeted the load a sample is then drawnoff by a remotely operated vacuumspear sampler adjacent to theweighbridge and sent to the on-sitelaboratory for sampling.

By the time the sample arrives at thelaboratory, the GeneSYS™ LIMS modulelaboratory Information ManagementSystem will already have printed off asample document with a check list of thequality tests required for this load. Theresults of each test are keyed in bylaboratory staff and automaticallychecked against the pass/fail criteria. Ifthe sample passes all the quality teststhen the driver is given permission tounload. If the sample fails for any reasonthen the vehicle is put on 'waiting' statusand the test details are flagged up onthe screen. This allows staff to contactthe supplier to inform them the load hasbeen rejected, or to negotiateacceptance below contract specification.Having received a 'pass' the driver thenmoves forward to transfer his load intothe appropriate silo. When he hascompleted his delivery the driver thendraws away from this area andproceeds to the site exit via the outgoingweighbridge. www.hub-4.com/directory/683

Driver Operated Weighbridge

Hub issue-20 [jan 2012] 17/1/12 14:20

An innovative new dust suppressiondevice has been introduced specificallyfor use at conveyor discharge points,designed to create a virtual curtainaround the material flow for outstandingparticle containment. The DustBoss®

DB-RTM Ring from Dust ControlTechnology is engineered for industrialstrength and longevity, built with a high-quality stainless steel ring outfitted witha network of atomizing nozzles thatdeliver millions of 50-200 microndroplets per minute. By surrounding thedischarge flow on all sides, theDustBoss Ring provides simple, focuseddust management that's well suited tocontinuous duty, such as radial stackers.

Materials Handling

Dustsuppressionring designedfor conveyingdischargepoints


“This design was first developed for a coal application,” explainedDCT CEO Edwin Peterson. “The momentum created whiledischarging dry coal was propelling large amounts of dust into theair, and the customer was looking for a way to specifically addressthe material as it came off the conveyor. The solution was simple buteffective, and we're finding that it's well suited to conveyor dischargeof sand, aggregates, biomass or other traditionally dusty materials,”he said.

The DustBoss DB-R is available in five standard sizes, from 17"(43.2 cm) to 100" (254 cm) in diameter. All five can becustomized with DCT's Variable Particle SizingTM technology,allowing customers to specify different droplet size ranges tomatch specific materials.

“The greatest chance of a collision between a dust particle and adroplet is present when the droplet and dust are roughly the samesize, avoiding the slipstream effect,” Peterson reminded. “If we canincrease the chances of collision with a given particle size, weimprove the effectiveness of the suppression.”

Designed without any moving parts, the intrinsically safe DB-R isintended for elevated mounting. It requires no electrical power orcompressed air. The water supply hose is connected directly tomale pipe threads on the ring: 3/4" NPT for the 17" model, and1" NPT for the three intermediate sizes: 22.5" (57.2 cm), 25.5"(64.8 cm) and 42" (106.7 cm). For large applications, thecompany also offers the 100" diameter model, which is suppliedby a 1.5" NPT hose.

Available options for the DB-R include a booster pump to elevatelow water pressures, a variety of nozzle sizes and configurations,and a water filter. Customers can also order the units with a 2-way valve and/or hose included.

The number and size of the spray nozzles vary by model. Thesmallest model features 30 brass nozzles that produce 3.25 GPM(12.3 LPM) of water flow. The 22.5" unit is designed with 18medium-flow nozzles, with a water usage of 11.34 GPM (42.9LPM). The 22.5" and 42" models feature 30 high-flow nozzlesthat deliver 18.9 GPM (71.5 LPM), and the 100" size employs84 nozzles for a whopping 52.92 GPM (200.3 LPM) of waterdelivery.


Hub issue-20 [jan 2012] 17/1/12 14:20

When large industrial gearboxesbreak down and need to be repaireda variety of factors need to be takeninto consideration before a decisioncan be made to either repair orreplace. The decision was arelatively simple one forWienerberger, the world's largestproducer of bricks, when a largegearbox manufactured in 1967recently broke down.

The old Karl Handle gearbox was fittedto an eight tonne hopper feeding rawmaterial into the brickworks. Engineers atWienerberger contacted SEW Eurodriveto compare the cost of a repair, with acomplete turnkey project to replace theold gearbox with a new unit. This wouldinvolve the removal of panels from theside of the building to facilitate

Materials Handling

New gearboxbetter thanrepair for brickmaker



installation, engineering the machine to accept thenew drive, the design of a new plumber blockbearing and support steelwork. Even the walkwayshad to be modified.

Despite this SEW Eurodrive's quotation to supply andinstall a new unit was 40 percent less thanWienerberger had been quoted for a repair. Notonly that but SEW Eurodrive was able to supply,install and commission the new drive in just fourweeks, considerably less time than Wienerbergerhad been quoted for a repair. This is perhaps notsurprising considering the fact that spare parts for theold Karl Handle gearbox were no longer availableand would have to be made from scratch, probablyinvolving the reverse engineering of some of thegearbox's components.

After successful installation and testing SEWEurodrive's engineers measured the energyconsumption on another Karl Handle gearbox drivingan identical application. This data was thencompared to the energy consumption of the newbevel helical gearbox and the current was found tobe down from 9.5 Amps to 1.6 Amps. So accordingto Ohm's Law the new drive is using 3.28Kw lessenergy than the original unit, equating to a saving ofover £1,300 a year.

Hub issue-20 [jan 2012] 17/1/12 14:20

As part of Euroby's specialist sludgedewatering portfolio, Eurobysupplies, installs and maintains filterpress units to meet customer'sindividual needs.

Our filter presses are supplied to arange of process industries includingmunicipal, waste water, chemical,minerals, quarry, aggregates, recyclingand industrial applications.

Euroby Filter press units are available ina range of sizes to suit the customer'sspecific requirement from small manuallyoperated 500mm units to large fullyautomated 2mtr x 2mtr systems.

A range of plate types are availablewith standard recessed or membraneinflation and can be supplied with clothwash and cake discharge systems.

Euroby is the exclusive distributor forKlinkau polypropylene filter plates andspecialises in providing upgrades toexisting filter press installations. Inparticular, by utilising existing filter pressframes we are able to providesignificant improvements to boththroughput and cake dry solids. Onmost applications we can also providevarying levels of automation.

Upgrading from cast iron plates topolypropylene provides benefits fromsignificantly improved filtration and dueto the lower weight of plates, areduction in the stresses being appliedto press closing equipment. Eurobyregularly carries out upgrades to filterpress installations which lead toextended working life of the equipmentby up to 25 years.

In addition to recessed plates, Eurobyare also able to retrofit membraneinflation technology into existing pressframes thereby allowing significantlyreduced cycle times, greater throughputand achievable dry solid production.

On many upgrades we are able toachieve up to 35% improvement onoverall press efficiency.

Many existing filter press installations donot comply with current health andsafety legislation. Euroby are able toprovide a range of modifications toprovide a safe working environment foroperators.

Filter Pressmaintenance &refurbishment

Cost efficient peak performance goes hand in hand with regularmaintenance.

Euroby's Service Division offers a comprehensive service,maintenance and breakdown facility.

Our highly qualified and experienced engineers and techniciansare always available to keep your press running at its best. Ourengineers are qualified to work on all filter press installations andtheir associated ancillary equipment including sludge feed pumps,control panels, hydraulics and polymer dosing systems.

Euroby are able to provide a comprehensive service for filter pressrefurbishment - maintenance and case studies of previousupgrades are available on request.

Visit: www.euroby.com www.hub-4.com/directory/14746

Quarrying


Filter press - before refurbishment

Filter press - following refurbishment

Hub issue-20 [jan 2012] 17/1/12 14:20

Asphalt Burner ServicesInstall Vulcan Burner atShap

Asphalt Burner Services Ltd, a nationwide provider of asphaltservicing and spare part products, has fitted a Vulcan Burner inCEMEX Shap, Cumbria. This is a relatively new plant, runningsince 2009; however a new burner installation was required oflate. The results since installation speak for themselves as fuelusage is reduced, emissions lowered and overall plantperformance increased substantially. The Vulcan burner rangecomes with innovated features which raises the standards forasphalt production for many quarry's to take advantage off.

'ABS have spent years on this new range researching on the optimumperformance features include excess air control, combustion chamberoptimization and air pressure compensation are unique to the Vulcanrange. The difference is instantly recognizable in comparison to someof the current burners being used in sites across UK at present'.Asphalt Burner Services Ltd introduces a new range which includesmaintenance features having a major impact on the overall efficiency.The design concepts deliver energy savings in excess of 20 %. Thehigh efficiency burner design is extremely compact and easilyaccessible for servicing which is a major benefit for any serviceengineer.

Carbon Monoxide (CO) emissions at the dryer exhaust duct havebeen recorded averaging across three test points at unprecedentedlow levels of 45ppm with the burner set at 30% output, this is indeedexceptional as the target levels normally experienced on goodasphalt plant burners are anything between 200 and 400ppm.Carbon Monoxide in flue gases are an indicator of the efficiency ofthe burning process, the higher concentration of Carbon Monoxide(CO) present equates to unburnt fuel in the process. The undilutedCarbon Monoxide (uCO), was averaging at 150ppm, again levelsof the uCO are normally recorded on other asphalt plant burners atlevels of 400 to 900. The Vulcan burner is successfully burning100% on Nexgen 3 fuel oil; which has been fitted on a four year oldMarini 200-280tph asphalt plant at Shap Cumbria for Cemex UKLtd. Initial tests indicate the fuel costs have been significantly reducedfrom 9 Litres per ton to just over 6.5 to 7 Litres per ton with anadditional saving in carbon tax due to the overall performance of thenew burner.

Asphalt Burner Services Ltd headquartered in Northern Ireland andalso having another base in Leicester provides many burner relatedproducts such as spare parts. The company's success can becontributed to the high quality team of engineers employed andtogether with the backend office staff we have changed the wayburners are now serviced within the industry. The new Vulcan burnerrange is simply an added bonus feature for the company- to benefitthe industry economically.

Weir Minerals has secured a two-yearcontract to supply and service threeheavy-duty slurry pumps to Meichle undMohr - a sand, gravel and concreteproducer based in Immenstaad,southern Germany.Meichle und Mohr operates in numerouslocations in the region between the northshore of Lake Constance and the BlackForest, extracting sand and gravel andproducing ready-mix concrete and otherrelated products. The units - all from Weir Minerals' Warmanslurry pumps range - will drive wetprocessing and transportation of gravel.The win is the first agreement with aGerman business secured since the launchin September of a new service centre inEssen, providing customers in Germany witha permanent servicing and supply base toenhance service and after-sales support.Mr. Hansbert Hellstern, technical plantManager at Meichel und Mohr said: “Weselected Weir Minerals based on theproven track record Warman pumps havefor product lifespan and ease ofmaintenance.“The launch of the new service centre in Essenalso gave us complete confidence in theavailability of spare parts and maintenancesupport.”

Marcus Hessling, service manager at WeirMinerals' Essen service centre said:“Meichle und Mohr is a well-known supplierwithin the German construction industry andthis win adds a strong name to our portfolio ofGermany-based customers.

“We are continuing to expand our businessrapidly in the aggregates production marketwithin the region, and the recent opening ofthe permanent service base is playing a keyrole in this.”

Meichle und Mohr supplies aggregates,ready-mix concrete and a range of productsincluding paving stones, slotted channelsand concrete pipes to the constructionsector across southern Germany. The business was established in 1924when two family-owned firms merged.Today it is managed by a fourth generationof both families and the company nowemploys more than 300 people.


Weir MineralsWins Meichle undMohr SlurryPump Deal


Quarrying


Hub issue-20 [jan 2012] 17/1/12 14:20

Quarrying



Frank Johnson of Hanson AggregatesNeedingworth Quarry is highly satisfiedwith the design, build, installation andperformance of the twin screenssupplied by CMB International Ltd.Hanson Needingworth is a highefficiency, modern sand and gravelplant demanding highly effectiveequipment throughout, CMB successfullydelivered on all levels and providedscreens that are proving to be a realasset to the continued successfulproduction of high quality material.

In December 2010 CMB International Ltdwere commissioned by Hanson AggregatesLtd to provide Needingworth Quarry withtwo CMB VB40 2.4x6.0 Double DeckScreens and during April of this year thescreens were successfully installed and arenow running smoothly as an asset to thebusy production line at Needingworth.

CMB International takes pride in its abilityto provide bespoke engineering for allcustomers and the CMB screens designedfor the Needingworth site are no exception.The screens were designed to pick upNeedingworth's existing screen footprintand maintain the existing structural integrityby using finite element analysis, to ensurethe maximum life of the screen within itsstructure, providing the best possible returnon the clients investment.

The unique design of a CMB screenmechanism maintains that the centre line ofthe bearing is in direct alignment with thatof the screen sideplate, thus ensuring that allof the exciter forces are sent directly wherethey should be.

All CMB mechanisms are selected on thebasis of providing an L10 bearing life of20,000 hrs, most of CMB's competitorsonly work on 10,000 hrs; from experiencedoubling the potential life of the bearingshas proven to be invaluable to customers,who appreciate the extra life and benefitfrom the increase of production timebetween bearing changes due to the CMBmechanisms. The installation was completedwith auto greasers to ensure optimalbearing lubrication.

CMB deliver onall levels andhelp HansonAggregates atturn key siteNeedingworth

CMB are always looking at their manufacturing methods and designs,refusing to be bound by old conventions, currently looking at 3Dprinting as a way of producing CMB's castings. This is an incredibletechnology, which comes straight out of the science fiction books intoscience fact, CMB is striving and achieving improvements in productsand services to customers and take pride in using British suppliers forthe majority of components.

Hub issue-20 [jan 2012] 17/1/12 14:20

Following the demise of a competitorand as part of an overall companyexpansion CMS Cepcor haveextended their product range andincreased their stock holding ofreplacement asphalt plant wear partsand spare parts.

Offering a genuine alternative to theoriginal equipment manufacturers CMSCepcor can supply compatiblereplacement parts to suit all popularasphalt plants. As well as the usual mixerwear parts, CMS Cepcor have anextensive range of quality replacementspare parts to suit asphalt plants includinga range of dryer, elevator and screensection spares.

All CMS Cepcor compatible spare partsto suit asphalt plants are fully UKmanufactured and quality assured to beinterchangeable with the original parts.The company specialises in supportingasphalt plant, especially in cases wherethe original equipment manufacturer is nolonger able to support the plant; forexample ACP Titan, Braham Millar,Bristow's, Gencor, Stothert & Pitt and ViaNova.

A comprehensive solution:

This was recently demonstrated by CMSCepcor with support for a bespokeStothert & Pitt asphalt plant operated byAggregate Industries on the south coast.As no alternative supply was availablefollowing the demise of their previoussupplier CMS Cepcor and their UKfoundry partner acquired the originalpatterns and manufactured a set ofreplacement parts to facilitate the annualoverhaul of the paddle mixer. Withoutthis comprehensive support the only viablesolution would have been to install a newmodern retro-fit paddle mixer at greatcapital expense.

Quarrying

CMS Cepcorprovides fullsupport for theasphalt plantspares market.


A large investment:

David Gregory-Sales Director commented; “CMS Cepcor are now theonly aftermarket supplier that is committed to offering a genuine alternativeto the original equipment manufacturers. Our expertise, stock inventory,manufacturing facilities and technical support ensures downtime is minimisedfor asphalt plant worldwide”.

CMS Cepcor has also recently heavily invested in new CNC machinetooling to enhance their UK manufacturing facilities along with state-of-the-art measuring technology including FARO portable measuring armswhich make measuring complex parts and component assemblies easy.This technology is used by CMS Cepcor engineers to completealignment, calibration, inspection, product development and reverseengineering tasks within their material testing facilities.

A Faro co-ordinate measuring arm being used to measure a complex paddle arm


Hub issue-20 [jan 2012] 17/1/12 14:20

A leading independentsupplier of aggregates, wasteand recycling services in theMidlands has taken deliveryof three new Terex Finlaymachines from Finlay Centralat its new site in the region.

WCL Quarries has recently openedKetley Quarry, a 55 acre quarry,based in Kingswinford.

This new site is the second locationnow run by WCL Quarries, whoalready operate Cranebrook Quarryin Staffordshire. The company is alsodue to open another site in theMidlands later this year.

The expansion at Ketley Quarry hasseen WCL Quarries take on elevennew employees from across the localarea, to support operations on thesite.

This growth has created a greaterbusiness capacity, supported byinvestment in new equipment,infrastructure and ultimately the localarea by creating opportunities forpeople and businesses to work withWCL Quarries.

In the long term, the company hasalso announced plans to rehabilitatethe site, a move that will benefit thelocal community for generations tocome.

Quarrying

WCL Quarries ContinueExpansion Drive WithDelivery of Three NewMachines From FinlayCentral

Already a valued customer with Finlay Central - part of the FinlayGroup of companies - WCL Quarries already use Terex Finlaymachines at Cranebrook Quarry.

To support the sustained growth of the Ketley Quarry site, thenew additions to WCL Quarries' fleet now include a Terex Finlay883 Heavy Duty Screener, a 683 Supertrak three way splitmobile screen and a J-1160 Jaw Crusher. All three machineshave been supplied by Finlay Central.

The plant is being used to process ironstone and engineeringclay, which is quarried on-site. The machines are also handlinginert waste, of which 70 per cent is recycled to deliver productsincluding single sized recycled aggregates and recycled Type 1MOT material.

The introduction of the plant has enabled Ketley Quarry to reachoutput rates of 300 tonnes an hour.

The versatility of the machines also means Ketley Quarry caneasily adapt their use from the recycling process to includenormal quarrying activities as well.

First fed through the tracked 883 Reclaimer, stockpiles of 75mm,40mm down and oversize product are created.

The oversized and middle grade materials are then sent forcrushing to the J-1160, which incorporates a high performance1000mm x 600mm Jaques jaw chamber and an advanced PLCcontrol monitoring system, which facilitates an automatic start-upsequence, making the machine more user-friendly.

This material is reduced to 75mm down and fed through theTerex Finlay 683 inclined screen, which creates three stockpilesof crushed 75mm, 40mm and dust.

With a strong focus on service delivery and quality, WCLQuarries need the best plant on site to ensure they continue tomeet their high standards.


Hub issue-20 [jan 2012] 17/1/12 14:20

Simon Winner, managing director ofWCL Quarries, said: “We have a goodrelationship with Finlay Central and nowhave eight of their machines locatedacross our two sites.

“WCL Quarries' expansion to KetleyQuarry has been a successful set-up andwe are very satisfied with the productionof all three of the new Terex Finlaymachines.

“A Finlay Central representative is alsoalways on hand if needed with adviceand support.

“Customers come to WCL Quarriesbecause we know the industry they workin, and it's this experience andpartnership they value.

“The larger capacity and coverage we now have as abusiness means it is more important than ever for us tomaintain and even improve the levels of service and expertisewe provide to the people and businesses we work with on adaily basis.”

Key to WCL Quarries' successful expansion has been thecareful selection of plant and machinery equipment.

In the last few years, WCL Quarries has taken delivery of atotal of three Terex Finlay 883 Reclaimers, two Terex Finlay683 Supertracks, two Terex Finlay jaw crushers and a TerexFinlay 390 Hydrascreen.

Working closely with Neil Bailey of Finlay Central, WCLQuarries has built up a fleet that has provided a platform forgrowth and flexibility across the business's operations.

This has included some machines being purchased secondhand and sometimes hired first to weigh up long termfeasibility and sales of the material processed - a policy thatmirrors the company's desire to expand into new marketsunder a carefully controlled cost programme in the presentclimate.

Neil Bailey, sales engineer of Finlay Central, said: “We havefocused on delivering the most competitive and economicalprocessing solutions for WCL Quarries.

“We are delighted they have built up their fleet through ourcompany and that they enjoy the reassurance of ourcomprehensive service and spares offering.

“We've worked closely to ensure every piece of machineryintroduced delivers excellent value. For example, the threenew machines at Ketley have been brought in under a set upthat enables them to work separately, or together, formaximum productivity.

“It's also important that the machines are flexible in theiroutput.

“This means, that at Ketley, as well as Cranebrook, apart fromaiding in the recycling processes, the machines can be usedfor normal quarrying too in exactly the same way, ensuring adouble duty at the sites.”

Quarrying



Hub issue-20 [jan 2012] 17/1/12 14:20

Quarrying


Hewitt Robins have recentlysupplied a 3.0m wide x 9.6m longtriple deck washing Screen toNorstone's biggest plant situated inNorway.

Norstone is part of the HeidelbergCement Northern Europe and theyrecently completed phase 2, upgradeproject for a new screen/rinse system atTau. Tau quarry currently produces2.3million tons per year of aggregateand with the new upgrades they look toincrease production by 500,000 tonsof additional railroad ballast.

The new Hewitt Robins 2QV-14 3.0mwide x 9.6m long Triple Deck WashingScreen allows them to do this. Theheavy duty screen was installed byAgdermaskin - Hewitt Robins partner inNorway who also designed andinstalled the stand alone washing plantwhich is beside Tau's ship loadingfacility in order to be able to rinse therailroad aggregates or other productsbefore being transferred into the shiploading system.

The screen is currently handling1500tph of railway ballast plus over10,000 liters of water/minute in thefeed and from the sprays. The screen isrequired to wash the material prior tobeing loaded onto the ship and alsotake out -20mm waste. The top deckseparates at 45mm, 20mm middle deckand 4mm bottom deck using TemaIsenmann WS85 heavy duty modules.

The Hewitt Robins screen is constructedof 15mm thick side plates which includeadditional 15mm thick doubler platesaround the vibrator units. The heavyduty crossmembers are spaced at every600mm to be able to withstand thelarge amounts of aggregates and waterand the total weigh of the machine isover 30,000kgs.

The 2QV-14 vibrating unit is oillubricated and consists of 4 podsincorporating 2 off 140mm bearings ineach pod (8 bearings in total) givingthe customer increased bearing life. The

Hewitt Robinssupply 1500tphWashing Screento Norway


four Quad-V Pods are timed together using a timing belt on the no-drive side and the pods are coupled together through the centre of thescreen using 2 cardan shafts. The cardan shafts take up less spacethan conventional shafts and vibrator tubes which allow there to beadditional access between the decks for easier maintenance whenchanging modules.

Bjørn Ingvalstad - Technical Manager - Norstone commented: “Thenew stand alone washing plant incorporating the heavy duty 2QV-14Hewitt Robins 3.0m wide x 9.6m long 3 deck washing screen allows usincrease our production at Tau and supply a higher quality product. Theinstallation went well, on time and on budget. Operationally the screen ishandling the required capacities and gives us an exceptionally cleanproduct. We would like to thank Agdermaskin and Hewitt Robins for theircommitment and professionalism which allows us to meet our customersneeds.''

Hub issue-20 [jan 2012] 17/1/12 14:20

Market Place

www.hub-4.com

6100mm x 1830mm (20' x 6') inclined vibrating screen (new)Fully assembled-ready to run!!

This Inclined Vibrating Screen is a singledeck, “Ripl-Flo” screen (can be adapted totwin deck!), complete with full set ofsprings, inner, outer, side snubbers withfriction blocks, complete with upper andlower fabricated spring mounts.

It has a perforated top deck screening panel(40mm), 5-4 eccentric throw mechanismcomplete with bearings, housing gasketsand seals (fully assembled). Complete withdrive pulley (500mm diameter) includingbalance weight housings, with weights, toeach end of eccentric drive shaft.

Complete with fabricated feed pan andremovable lifting points.

HUCK bolted construction for rigidity.Heat treated after manufacture to eliminatematerial fracture during vibrating actionand motion.

If required, we offer a complete installationpackage with all our equipment.Suitable for use in recycling, mining,minerals and aggregates.

Price: offers in region of £40k

Green Screen Engineering Ltd offers a range of Inclined Vibrating Screens for Aggregate and Mining industry duties.Our range of screens are rugged in design and build, yet versatile in performance for a wide variety of applications.

Interested? Contact Green Screen Engineering Ltd on 01924 892180 or [email protected]

Proven fuel costs and emission reductionRaising the standard in asphalt productionThe new burner range from Asphalt Burner Services Ltd

Contact [email protected] or +44 028 7930 1237 for more information.

Brauer Limited. Dawson Road,Mount Farm,Milton Keynes, MK1 1JP.t: +44 (0)1908 374022 f: +44 (0)1908 641628 e: [email protected] w:www.brauer.co.uk

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For all your Filter Press needsincluding:

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T - 01903 69 44 00 www.euroby.co.uk

25 years experience of belt weighers,weigh feeders, batching and conveyor

blending systems

01484 400334www.hkprocess.co.uk

Rollers andDrives for allBulkHandlingapplications

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[email protected]

01536 748525

Customers world wide enjoying world class products

Screening…behind every passion there is a driving force – this is ours ..WS85

We aim to offer the most successful screens. Whilst constantly searching for new and better solutions we do not follow short-lived trends, but build on our experience.

TEMA Isenmann Ltd4 Great Central Way Woodford Halse Northamptonshire NN11 3PZTEL 01327 264227Email: [email protected]

InstantCrusherSpares

Leading supplierof quality crusherwear parts

T. 01352 732284www.instantcrusherspares.co.uk

If you would like to advertisein Market Place call

0845 6800024

162 Chiltern Drive, BerrylandsSurbiton, Surrey KT5 8LS

Tel: 0208 399 9991Fax: 0208 390 2004

email: [email protected]

Custom engineered air pollution control systems

Hub issue-20 [jan 2012] 17/1/12 14:20

Hub issue-20 [jan 2012] 17/1/12 14:20

Hub-4 Issue 20

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Transcript of Hub-4 Issue 20