Building a Landmark Wash Plant for Thorncliffe Building Supplies

Established in 1987, Thorncliffe Building Supplies is one of the largest independent builders' merchants in North Wales and the North West of England. Alongside supplying building materials, plant hire and waste management services, the company operates its own recycling facilities, continually investing in modern processing technology to improve efficiency, sustainability and the quality of its recycled aggregate products.

For Thorncliffe Building Supplies, the investment in a new aggregate washing facility marked a significant step forward in expanding its processing capabilities. The aim was to create a modern, high-capacity operation capable of producing consistent, high-quality aggregates and sands, whilst exercising highly efficient wastewater management.

To deliver the project, Thorncliffe Building Supplies partnered with CRJ Services and their partners, Bruce Engineering and Tecnoidea to design, supply, install and commission a complete turnkey aggregate washing solution. Now fully operational, the site combines high-performance aggregate washing with advanced wastewater management technology, creating an integrated processing system built for reliability and long-term performance.

The completed installation represents one of the largest wash plant projects undertaken by CRJ Services in recent years, bringing together multiple processing stages, extensive conveyor infrastructure and a sophisticated wastewater treatment system.

Designed Around Efficient Aggregate Processing

At the heart of the installation is a Bruce Engineering wash plant, configured to maximise production while maintaining excellent material quality across a range of aggregate products.

Material first passes through the Bruce Electric Scalper, where oversized material is removed before the fines enter the washing circuit. The Bruce BWR wash plant and BWS sand plant then work together to wash, classify and recover valuable aggregates, producing cleaner, more consistent end products ready for stockpiling. The plant is capable of processing up to 80 tonnes of material per hour, producing up to 70 tonnes per hour of saleable products.

Supporting the washing circuit is an extensive network of conveyors, including a 38-metre lattice conveyor, radial stockpile conveyors and purpose-built transfer conveyors that efficiently move material throughout the process. The conveyor system has been designed to optimise material flow while reducing unnecessary handling, helping improve productivity and operational efficiency.

The installation also incorporates purpose-designed walkways, access platforms and a dedicated control cabin, providing safe access for maintenance alongside centralised control of the washing process.

Integrated Water Treatment for Sustainable Operation

A key feature of the project is the integration of a Tecnoidea water clarification system, ensuring wastewater management forms a core part of the overall washing process.

Aggregate washing relies heavily on water, making efficient recovery and reuse essential for operational efficiency. The Thorncliffe installation incorporates a complete Tecnoidea clarification plant, including a high-capacity clarifier, lime silo, vertical stocking tank, water drip tray and automated filter press.

As process water leaves the washing plant, suspended solids are removed through clarification before sludge is transferred to the filter press. Here, material is compressed into a dewatered filter cake, making handling and transportation easier. Meanwhile, recovered water is returned to the washing circuit for reuse.

Around 90% of process water is recovered and recycled, reducing the site's requirement for fresh water by approximately 90% and helping to minimise overall consumption.

The result is a closed-loop water management system that supports continuous production while improving resource efficiency.

Delivering a Project of Significant Scale

Installation took place over several phases, with equipment arriving on site in a carefully planned sequence. The Bruce Engineering wash plant components - including the BWR wash plant, BWS sand plant, pre-screen, conveyors, structural supports, walkways and control cabin - were delivered and assembled progressively as the build advanced.

Alongside the washing equipment, the Tecnoidea wastewater treatment system was installed, with the clarifier, lime silo, filter press, vertical stocking tank and associated pipework and control equipment positioned and connected as part of the overall process.

Several crane lifts were required throughout the installation, with equipment ranging from 70-tonne to 220-tonne capacity used to position the larger components. One of the most significant stages was installing the 38-metre lattice conveyor, which was lifted into place before the remaining conveyors, walkways and supporting infrastructure were completed.

Following the mechanical installation, electrical systems, hydraulics, process pipework and water treatment infrastructure were connected before the plant entered commissioning. Testing and final adjustments ensured each stage of the process was operating correctly before full production began.

From Installation to Production

Now fully operational, the Bruce Engineering wash plant and Tecnoidea water treatment system work together as one integrated process, producing washed aggregates while continuously recovering and recycling process water.

As a fully electric installation, the plant also complements Thorncliffe Building Supplies' investment in on-site solar generation, allowing renewable energy to contribute towards powering the operation and improving overall resource efficiency.

Material now flows through every stage of the Bruce washing circuit before being transferred to stockpiles via the integrated conveyor network, while the Tecnoidea clarification plant continuously recovers and recycles process water in the background.

The project demonstrates how modern washing technology and advanced water treatment can combine to deliver consistent product quality, efficient resource management and reliable day-to-day operation.