Blue Supply New £5 Million Recycling Plant

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London, United Kingdom
20th November 2019

Blue Supply New £5 Million Recycling Plant

Waste Systems

The MP for Leamington Spa and Warwick, Matt Western has formally opened Fortress Waste’s new state of the art, Dry Mixed Recyclables, (DMR) waste recycling plant, which was designed and supplied by Blue Southern. Most impressively, the plant, which cost in excess of £5 million, has been constructed within a building measuring just 730sq. metres and 6.5m high

Fortress were looking to reduce the amount of waste they were sending to landfill and recover more of the material for recycling from the DMR collected from the many commercial businesses they service. Current landfill charges were having a significant impact on the business due to the fact that Fortress are handling around 22,500 tonnes of DMR waste per annum.

The main objective of the plant was to reduce the amount going to landfill by around 50%, resulting in immediate, and considerable savings in landfill charges. Utilising the technology proposed by Design Engineer at Blue Southern, Tom Rutherford, the plant is already achieving 98% purity on cardboard and paper. At this level, the business is able to sell the 9,900 tonnes of paper and card they take in at a premium price, and therefore generate a significant income from the waste. Something they were not doing previously.

The process begins with a Fuchs MHL 250 material handler feeding a specifically chosen Untha XR3000 shredder, processing at 30tph. The shredder has a defined cutting action, taking the material down to a very precise particle size and making it ideal for the optical sorters incorporated within the plant. Although the capacity of the plant can increase, initially Fortress are looking to run the plant at around 9 tonnes per hour, 10 hours per day and for 5 days per week. This means the shredder must initially feed a 80m3 dosing bunker via one of the many Westeria conveyors which make up the backbone of the plant. This allows the shredder to only operate at certain times, maximising running efficiency and permitting for maintenance on the shredder without effecting the running of the plant.

From the dosing bunker the material is fed into a Hartner Ballistic Separator, which separates the 2D and 3D material whilst also extracting the <50mm files from the waste steam via perforations in paddles. all ferrous is removed this <50mm, before it deposited into one of seven moving floor bunkers within plant. 3d material falls back ballistic separator with any and non-ferrous extracted an overband magnet eddy current separator. particular stream then moves to three tomra optical sorters integrated plant, which extracts plastic bottles for recycling leave a remaining rdf material. 4,750 tonnes makes up around 21% total amount processed will equate cost saving £30 per tonne compared landfill charges, following its separation rest waste. 2d taken directly discspreader® distribution system made by westeria®. patented ensures perfect, reliable across 2800mm wide acceleration belt further sorter. due requirement 98% purity paper card, sorter positively sort stream, even though card 70% feeding component overall other two 16,000 litres air be required plant function effectively, pressure manifold bar being between 8.5br 10br at times. cardboard forward specific 50m3 bunker, while through second separate film residual each materials separated, paper/card, ferrous, film, non-ferrous, as well fines are quality checked enters respective bunker. because final critical achieving plant’s objectives set fortress. another key aim was include high level automation, freeing labour alternative tasks site. such example can found bunkers, have built weigh cells. once cells indicate there sufficient bale, bunker automatically opens, taking precisely enough marathon 2r250 baler, turn feeds cross wrap direct steel tie. alternatively, should not require baling, westeria conveyor baler bi-directional meaning they bypass go lorry. looking produce 80 bales various day. commenting on blue group’s tom rutherford said, ‘after listening customers we knew going challenge meet those aims compact space. our experience however has allowed us create highly automated utilising almost every inch site recover numerous very level.’ fortress managing director david pass, also highlighted, ‘we invested heavily incorporates latest technologies ensure forefront uk. only reduce costs but generate significant income recovered materials, recuperated short period time”. matt western, local mp, commented “it’s terrific news see positive investment warwick leamington i welcome contribution make area. investing future vital environmental economic aims. look circular economy where recycle reuse generate, exceptionally pleasing private companies invest technology that help achieve objectives.”


After listening to the customers objectives we knew it was going to be a challenge to meet those aims in such a compact space. Our experience however has allowed us to create a highly automated plant, utilising almost every inch of the site which will recover numerous materials to a very high purity level.

Tom Rutherford, Blue Group