Mill Farm Recycling Ltd

Mill Farm Recycling Ltd Optimises Biomass Production with Bespoke HAAS Recycling Plant

Mill Farm Recycling Ltd is a family-run business with deep roots in agriculture. In 2004, the company diversified into composting, producing organic fertiliser for its own farm. By 2010, Mill Farm Recycling had entered the biomass sector, supplying fuel to local power stations. Today, the company produces various grades of biomass fuel, tailored to customer specifications and seasonal demand.

The Need for a High-Spec, Flexible Recycling Plant

As their biomass business grew, Mill Farm Recycling required a new static wood recycling plant capable of consistently producing high-quality wood chip products. Their pre-shredded raw material needed to be further reduced to -55mm, have all metallic content removed, and be screened into multiple fractions. The plant also had to be robust, flexible, and capable of processing up to 35 tonnes per hour, with future-proofing for adjusting product gradings.

Tailor-Made Solution with CRJ Services and HAAS Recycling

CRJ Services, the exclusive UK dealer for German manufacturer HAAS Recycling, collaborated with Mill Farm Recycling to design a bespoke solution. After extensive discussions and visits to reference plants in Belfast and Germany, a plan was developed and approved, including detailed plant drawings and specifications.

A purpose-built building was erected to house the processing plant, protecting both the equipment and the finished product. A 30m³ external hopper receives the pre-shredded material, which passes under an inline magnet to remove larger metal pieces before entering the building.

Advanced Material Processing

The material is first separated by a HAAS Star Screen, isolating the sub-fraction from the oversize material. Oversized material is processed in a HAAS HSV 1600 Hammermill fitted with 50mm baskets. A ballistic chute automatically ejects any foreign objects, protecting the Hammermill from damage.

Next, a Wagner Eddy Current Separator removes both ferrous and non-ferrous metals, which are conveyed outside the building. The clean wood then passes over a HAAS HPS 125 3-deck oscillating screen, separating it into four fractions. Fines exit via the bottom deck, the two mid-sized fractions are collected from the middle decks, and oversize material is recirculated for further processing.

Control, Automation, and Dust Management

Material is transported via chain conveyors to product bays, with electrical controls allowing operators to direct the flow. Two control panels—one in the main cabinet, and one inside the building—enable Mill Farm Recycling to monitor and adjust settings throughout the process. The plant is also fitted with a dust extraction system, filtering dust at critical points to improve safety and working conditions.

Flexibility for the Future

The new plant allows for easy modification of fraction sizes by swapping hammermill baskets and screening decks, ensuring Mill Farm Recycling can adapt to changing client requirements while maintaining consistent product quality.

Mill Farm Recycling, a long-standing customer of CRJ Services, approached the team to deliver a turnkey, tailor-made solution. CRJ representatives worked closely with the business to understand their operational challenges and requirements, resulting in a plant that is robust, flexible, and capable of supporting the company’s growth in biomass fuel production.