Case Study

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Quarry Conveyor Spillage Reduction

How Hoverdale reduced clearing up by 75% and save the costs of three members of staff clearing up back spillage & maintaining an inefficient conveyor system

The Situation

The quarry is one of the largest in Europe and was suffering from excessive carry back spillage which was causing belt damage and using up excessive man hours in clearing up.

Before

Conveyor Spillage Reduction

The Client’s Objectives

To find a way to reinvent carry back spillage and reduce ‘wasted’ man hours and generally improve material flow through the plant.

Our Solution

We started with a site survey to assess the magnitude of the problem followed by a report and recommendations. We offered to demonstrate to effectiveness of our recommendations by selecting the worst transfer point at ground level.

We were given a free hand to do the best job we could.

We installed:

A primary scraper ‘T’
A secondary scraper ‘D’
A snub drum scraper
A lining in UHMPE to prevent material hanging up in the transfer point

The results were excellent.

Their Measures for Success

A dramatic reduction in spillage and a corresponding reduction in man hours clearing up plus all other associated benefits – less belt damage, less blockades.

Our Work

We completed our demonstration transfer point in three weeks. After a further four weeks the improvements were so dramatic that we were given the go ahead to upgrade the complete plant.

After the upgrade we only had to visit the site four times a year to carry our minor adjustments. After 18 months we started to replace the scraper blades.

After

Conveyor Spillage Reduction

The Timing

The first demonstration units were installed in three weeks. The balance of 38 conveyors were fitted out over a three month period working to a programme in conjunction with our customer.

Value to the Customer

Clearing up reduced from 4 times per week to 1 per month

Savings of two men on clearing up and one man on maintenance

Increase in belt and roller life

Rolls can be refurbished ad infinitum

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MATT BEVERLEY

A time served Mechanical engineer Matt’s background includes many high-profile projects within the Automotive Industry: The Rolls Royce Phantom, Rolls Royce Cullinan, Spyker Le-Mans racing teams, Bentley, Aston Martin, and Airbus A380. This history and knowledge of complex manufacturing and engineering projects have been transferred and further developed into the bulk material handling sector. Matt has work in Europe, North America, Indonesia, and China

He joined the bulk solids and bulk handling industry in 2019 as Managing Director of Hoverdale UK Ltd and subsequently completed a Management buyout in July 2020. The business has grown yearly, increased employment, its customer base, and worldwide reputation, and disrupted the market with groundbreaking innovative technology. Since Matt took over Hoverdale, the company has filed four patents for innovation; one was granted in 2023 for a design to improve bulk handling. The success had been driven by delivering tailored solutions to the waste recycling sectors that keep material flowing out and money flowing in.

Awards Include

  • 2024 – Shapa company of the Year
  • 2024- Shapa Innovation in Technology
  • 2024- MHEA Engineer of the year
  • 2021 – MHEA Innovation of the year
  • 2021- IMechE Innovation award

Current Positions Include.

  • Group Chairman Hoverdale UK Ltd
  • President (MHEA) Material Handling Engineers Association
  • Vice Chairman: IMechE Bulk Material Handling Committee
  • Council Member: (SHAPA) Solids Handling & Particle Association
  • Member: Chartered Management Institute

Matt has been happily married to Julie for 22 years and has 4 children, 3 of which are involved within the Hoverdale group of companies. He is an RFU level 2 qualified coach and referee having been in several head coaching roles at various age groups from under 6’s to adults for his local team Nuneaton RFC. He believes in the core values that rugby teaches of Teamwork, Respect, Enjoyment, Discipline, Sportsmanship and try’s to carry this through in his day to day business activities. He is passionate at brining the next generation of young, diverse engineers into the sector through promotion of apprenticeship scheme and further education routes.

DAVID BARTER

David is an experienced leader, with a background covering Operations, eCommerce, Finance, Compliance, HR and IT. His career spans Banking, Retail and Engineering, spending the majority of his career working for ALDI as they grew to become 4th largest supermarket in the UK, including seven years on their UK board as Managing Director of IT and eCommerce.

David joined Hoverdale’s Senior Management Team in 2023 to seek a fresh challenge in a completely different industry sector. He has applied his approach to Process Improvement, Efficiency, Customer Service and Teamwork to great effect during Hoverdale’s sustained growth.

Married to Jane, with three adult sons between them, David volunteers on the board of the Nottingham Playhouse theatre as well as his local rugby and football clubs. Any spare time he spends enjoying walks with their Golden Retriever, Buzz, who is also regularly seen in the Hoverdale office.

BEN DUCHESNE

Ben is a time serviced field service engineer in the busy waste and recycling sector, who’s career moved into to managing service teams and beyond. Originally beginning his career with a HGV repair and maintenance apprenticeship with IVECO, from there travelling and working in multiple countries moving towards waste processing shredders.

Ben joined the Hoverdale team in September 2024 seeking to apply his extensive knowledge to a new area. His values and ethics fit perfectly within the Hoverdale ethos.

He is happily married to Kristina, with 4 wonderful young children; 14, 11, 8 and 5. We the children he doesn’t get much spare time. He is a family man, who enjoys spending as much time with them as possible.