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‘Spiroflow’ Bulk Handling Equipment at Dekura

11 November 2008

What was formerly Polypro Ltd, Dekura, in Telford, Shropshire, purchased two big bag dischargers, two rigid bin dischargers, three big bag fillers, a fountain blender and ten flexible screw conveyors. Here is what happened...

Spiroflow supplied two Big Bag Dischargers, two Rigid Bin Dischargers, three Big Bag Fillers, a Fountain Blender and ten Flexible Screw Conveyors to Dekura when they (Dekura - formerly Polypro Ltd) increased the capacity of their PVC-U re-cycling facility in Telford at the beginning of 2007. As their Environment and Development Manager, Sean Heath, comments, “We are pleased with the design of the equipment and the quality of the workmanship. Our operators like the plant - it looks after itself”.

All of the controls for this equipment were designed and manufactured by Spiroflow such that they could be integrated into the PLC systems that control the new Pulverising and Compounding lines - which make up the additional capacity. One of the Big Bag Dischargers is furnished with massagers so that it can deal with difficult bags that have become compacted during transportation or contain non-free flowing chopped material.

Collecting waste from more than 1,000 window and door fabricators nationwide and a fully accredited member of Recovinly, Dekura is the largest and the UK’s leading PVC-U recycler. Uniquely in the UK the company is not only able to recycle waste generated in the fabrication process but also post-consumer waste generated from old early generation PVC-U windows, doors, roofline and rainwater goods.

Waste is first processed in size reduction equipment, once broken down powerful magnets remove and separate out ferrous metals, other less magnetic materials for example stainless steel and non-ferrous materials. As part of the process all of these materials are sorted ready for shipment for recycling – no recyclable material collected by Dekura goes to landfill.

Following further manual inspection, shakers help to sort material sizes ready for shipment for reprocessing. This begins with more refined processing to remove any remaining debris, for example tiny fragments of metal or rubber. This is followed by colour sorting. The equipment used to do this is incredibly advanced and can be calibrated to pick out even the slightest variation between individual fragments. 

This completes the process and the material is ready to be compounded into pellets or pulverised ready for use in a new generation of advanced products

The original plant at Telford uses a combination of positive pressure pneumatic and vacuum conveying systems to move material. When asked why they chose Flexible Screw Conveyors for the new plant, Sean Heath advises, “The original plant is more expensive to run, it is fairly noisy and of course we have to have a filtration system to remove the dust from the exhaust air. I know of Flexible Screw Conveyors from a previous life; they are quiet in operation, have low running costs, do not require any filtration and have the added advantage that they continually re-mix as they convey – very important for blended materials”.

Asked why Spiroflow were the supplier of choice, Sean Heath confirms, “I already knew of Spiroflow by reputation and when I visited them at Clitheroe, I liked what I saw. The quality of the workmanship is good and if equipment looks good, it usually is.”

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