Application: Waste Insulation Recycling System

Our customer who operates in the insulation industry had been awarded a job on which they needed to recycle dust waste and rejected insulation slabs back into the production line. DRB worked with the customer to develop the concept for both systems and once the contract was awarded DRB carried out a 3D scan of the area to make the most of the available space whilst avoiding clashes with the existing systems.

They also approached us for work with their sustainable production targets in mind. Our customer wanted their recycling approach to waste in their operations to be improved and therefore asked DRB to design and produce a from-scratch brand new recycling system that would accept, feedback and recycle off-cut excess materials into their production line for other uses.

We wanted to invest our time to make sure the reliability and accuracy of this recycling system were as best as they could be for producing effective environmental results to fight waste pollution, we made sure that the variables in this operation were being controlled using an automated process.

The DRB team designed and developed a 2-in-1 machine that contained two separate feeding systems. The shredder system accepts compressed blocks of small fibres and shreds this sparse material back onto the conveyer for customer line use. The second system we inputted was a bulk bag system that collects the crushed materials into a lead bag using a crane and drops it into the collection hopper.

To allow for the waste concentration to be accurately measured, we input weight sensors onto the lead bag to correctly weigh out the by-products evenly. When it comes to minimising waste pollution on the production line, it’s important that we made a system for our customers that measured the rate of wastage distribution to accurately calculate the amount that was being shredded and collected per cycle.

The key advantage to this system for our customers would be that it increases their recycling habits and reduces unwanted wastage by processing it for other uses. Not to mention that it improves the company’s environmentally sustainable practices and values.

This machine is customizable within reason and therefore can be designed for a range of manufacturing sectors. We can make it bespoke to suit the requirements and needs of your manufacturing operations.

  • Can recycle up to 700 tons of insulation waste per year to enable customers to achieve sustainability targets.
  • Process removes the compacted waste from either 0.5 ton bulk bags (FIBC’s) or stacked slabs and delivers shredded material back to the main plant at a controlled, steady rate.
  • Fully guarded safe operator access is provided for untying the bulk bags and inspection/maintenance purposes.
  • The dust waste recycling system comprises of 2 lifting beams and electric lifting trolley to suspend.
  • FIBC’s above the two hoppers. Once above the hoppers the dust was emptied into the loading screw conveyors below.
  • Pneumatic actuators would massage the FIBCs to dislodge any remaining material.
  • The dust waste is transported through the loading screw conveyors into the dust waste weigh screw conveyor to monitor the mass flow rate of the waste back into the production line.


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