Hub-4 MRF Equipment Focus

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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

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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

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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.

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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


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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

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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



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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.



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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.

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Axion Consulting launchesnew analysis service forMRFs

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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.

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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.



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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,

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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





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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".

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


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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

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A fast andEfficient Way toRecycle




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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.





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






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.





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.





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