Mill Farm Recycling

Three Years On: HAAS Static Wood Recycling Plant Continues to Deliver for Mill Farm Recycling

In April 2019, CRJ Services, in partnership with HAAS Recycling Systems GmbH, commissioned a fully integrated, turnkey static wood recycling plant at Mill Farm Recycling. Three years on, the plant continues to play a central role in Mill Farm’s operation, delivering increased throughput, improved product flexibility and reduced operating costs.

Following several years of processing biomass products using a combination of mobile shredders and screeners, Mill Farm Recycling identified the need for a static solution capable of handling increased volumes while producing consistent, high-quality outputs across multiple specifications.

Designing a Bespoke Static Solution

Working closely with CRJ Services, and following an extensive planning and development process, HAAS designed and installed a bespoke wood recycling plant tailored to Mill Farm’s requirements.

The plant incorporates a star screen, hammermill, eddy current separator and oscillating deck screen, linked by a series of chain conveyors that transfer and discharge finished products into dedicated storage bays. This integrated layout allows material to be processed efficiently through each stage, while enabling the production of multiple product sizes within a single workflow.

The plant currently processes approximately 8,000 tonnes of Grade A wood per year, achieving throughput rates of around 30 tonnes per hour, depending on material moisture content.

Performance Improvements Over Mobile Processing

Since commissioning, the static plant has delivered a significant uplift in production when compared to Mill Farm’s previous mobile setup.

“The plant has performed well with good throughput. The plant is delivering a 120% increase in production compared to our mobile setup,” explained Will Ainsworth, Partner at Mill Farm Recycling.

In addition to improved throughput, the move away from mobile machinery has also reduced daily downtime. The mobile system previously required daily blow-downs and refuelling, often removing over an hour of productive time per day. In contrast, the static plant now requires a weekly blow-down, typically taking only a couple of hours.

Greater Flexibility in Product Specifications

Producing different product specifications with mobile equipment previously involved time-consuming changes to trommel drums and screening baskets. The static HAAS plant has simplified this process significantly.

Access to key wear components is designed for speed and ease, with hammermill hammers and screens quickly accessible. Changes to the oscillating deck screen can be completed in under five minutes per section, allowing Mill Farm to produce three product sizes while simultaneously screening oversize material.

Reduced Maintenance and Improved Longevity

Maintenance requirements have also been reduced, with the plant proving both robust and durable in day-to-day operation. The most frequently replaced components are the dust seals around the chip screen, typically changed every nine months.

Beyond this, wear part replacement has been minimal, with only one full set of hammermill hammers and a single row of milling plates replaced to date. These plates have since been hard-faced and returned to service, further extending component life. Hard-facing of the milling bed and screen is carried out approximately every two months as part of routine maintenance.

By purchasing a stock of spare parts at the time of installation, Mill Farm has been able to minimise downtime, ensuring critical components are always readily available on site.

Improved Working Conditions and Energy Efficiency

The plant is also fitted with a dust extraction system, removing dust from key areas of the process and significantly improving both working conditions and fire safety within the building.

Alongside production gains, the electrically driven plant has reduced overall energy consumption compared to the previous diesel-powered mobile setup. The shift away from diesel has become increasingly beneficial in light of rising fuel costs, delivering long-term operational savings.

A Long-Term Investment in Performance

Three years after commissioning, the HAAS static wood recycling plant continues to deliver measurable improvements in productivity, efficiency and reliability for Mill Farm Recycling. The project highlights the benefits of bespoke static processing solutions, developed through close collaboration between operator, supplier and manufacturer, and designed to support long-term operational growth.