CRJ Services Supply New Haas Wood Recycling Plant to Mill Farm Recycling Ltd.
Mill Farm Recycling Ltd is a family run business with roots in the agricultural industry. In 2004 the company diversified and started a small, on farm, composting site, with the sole aim of producing compost as a fertiliser to use in their own organic farming system. In 2010, further diversification saw them enter the biomass industry, supplying their local power station with fuel.
Since then, Mill Farm Recycling have started supplying other biomass customers who have more specific fuel requirements. They now produce various grades of biomass fuel, depending on customer and seasonal demand.
Mill Farm Recycling required a new static wood recycling plant, capable of producing consistent wood chip products, at a high specification with flexibility to process other products. They already operated a pre-shredder, which shreds the raw feed stock down to be further processed through the plant. Therefore, the new plant had to take this pre-shredded material, shed it down to -55mm, remove all metallic content and then screen the material into various fractions.
The new static plant needed to be proven, robust, flexible and able to consistently process 35 tonnes per hour to meet the ever-changing demands of their clients. To future proof the plant, they also required the ability to easily change the gradings of the fractions, by exchanging the size of the hammermill basket, and screening decks.
Mill Farm Recycling, a long-standing customer of CRJ Services, made an approach for a solution to their new plant requirements. CRJ representatives met with Mill Farm Recycling to discuss in-depth, their challenges and requirements for the project, in order to best propose a tailormade solution.
As the exclusive UK dealer for HAAS Recycling, a German manufacturer of recycling machinery, CRJ collaborated with HAAS to design a solution for Mill Farm Recycling. Following several meetings between the three parties, visits to reference plants in Belfast and Germany, a plan was developed, and plant drawings and specifications agreed.
A purpose-built building was erected to house the new processing plant, protecting the equipment and end products from the elements. Mill Farm Recycling supplied a large exterior 30m3 hopper which received the pre-shred down material to be further processed by the HAAS plant thereafter.
The material leaves the hopper and travels under an inline magnet, which removes any larger pieces of metal from the stream. The remaining material is fed into the building where it enters a HAAS Star Screen, which separates the sub-fraction material from the oversize, allowing it to bypass the Hammermill. The oversized material then enters the HAAS HSV 1600 Hammermill, fitted with 50mm baskets, to be further shredded. The Hammermill is equipped with a ballistic chute, which automatically expels any foreign objects which cannot be shredded, thereby protecting the Hammermill.
All material is then fed onto a Wagner Eddy Current Separator which removes both ferrous and non-ferrous metals from the product stream. The removed ferrous and non-ferrous material is conveyed outside the building.
The clean wood material is then fed across a HAAS HPS 125 – 3 deck oscillating screen which splits the material into 4 fractions. The bottom deck screens out the fine material, the 2nd screen removes the lower mid-sized product, and the third screen layer removes the upper mid-sized material. Any oversize material is then circulated back to the beginning of the plant to be reprocessed.
The final products are then transported via chain conveyors over to the adjacent side of the building and dispensed into the product bays. These conveyors can be electrically controlled to determine which product bay to fill. There are two control panels, one in the control cabinet, and another in the processing building, allowing Mill Farm Recycling to view the plant when adjusting settings.
The system comes equipped with a dust extraction system, fitted throughout the plant. This extracts dust at critical areas and has a dust filtration system which is situated outside of the building.