DRS Screening Shafts Improving Plant Efficiencies and Carbon Impact at a UK MRFs
Biffa Seaham

Improving Plant Efficiencies and Carbon Impact at a UK MRF Facility: A Hoverdale Case Study on DRS Screening Shafts

 

The Challenge:

A UK-based recycling plant was reliant on OEM parts for their DRS Screen Shafts sourced from the USA, encountering substantial lead times of up to six months. This reliance severely hindered production efficiency due to delays in obtaining spare parts. The need to maintain a costly inventory of spare parts to mitigate the risk of downtime and the extended wait for new parts added financial strain. Additionally, frequent failures in the stub end shafts led to regular breakdowns, impacting production and profitability. This approach also contradicted the plantā€™s carbon reduction goals, as it involved significant carbon emissions associated with transatlantic shipping.

Customer Objectives:

– Decrease operational costs
– Shorten lead times for parts replacement
– Enhance part quality and reliability
– Minimise environmental impact
– Reduce dependency on large inventory holdings

The Hoverdale Solution:

Hoverdale conducted a thorough investigation to understand the high failure rate and rapid wear of the parts. Utilising insights from this analysis, Hoverdale re-engineered the shafts using a superior material designed to extend durability and prevent failures. The redesign process included designing and testing the new parts using Catia V6 3D CAD & Finite Element Analysis software.

The newly developed parts were field-tested, leading to significant improvements in performance and durability, greatly surpassing the original specifications. This innovation not only fulfilled the customer’s operational and environmental objectives but also set a new standard in parts sustainability and efficiency.

Manufacturing and supply of DRS Screening Shafts DRS Screen Shafts DRS Screening Shafts Trilobes

Results:

  • 40% reduction in costs
  • Lead-time reduction from 24 to 4 weeks
  • Quality improvement increases service life and removes the design flaws causing catastrophic failures.
  • Parts are manufactured in Warwickshire at Hoverdale Head Office, resulting in parts being within 30 minutes of the customer site.
  • Hoverdale has sites located across the UK.
  • Significant reduction in customer carbon footprint
  • Customer no longer needs to hold large stock levels due to lead-time reduction.

DOWNLOAD THE FULL DRS SCREENING CASE STUDY HERE

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MATT BEVERLEY

A time served Mechanical engineer Mattā€™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 ā€“ Shapa company of the Year
  • 2024- Shapa Innovation in Technology
  • 2024- MHEA Engineer of the year
  • 2021 ā€“ 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 6ā€™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 tryā€™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 Hoverdaleā€™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 Hoverdaleā€™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, whoā€™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 doesnā€™t get much spare time. He is a family man, who enjoys spending as much time with them as possible.