Hidden away in the Cheshire countryside is a robotic waste revolution, quietly being led by Waste Wave. This revolution was not running at full capacity until the introduction of a new slow-speed primary Eggersmann Forus F38 shredder from Molson Green. The F38’s ability to process material down to the right piece size for the ZenRobotics automated pickers has increased material recovery rates and reduced waste to landfill.
When founded by Mike White in 2016, Waste Wave was an asbestos removal company. Built on a reputation for quality services, they moved into general waste, continuously looking for ways to boost growth by upgrading their processes. Most recently, this included adding an Eggersmann Forus F38 to their production line.
Tooling Up For A Growing Business
Father and son team Mike and Josh White had already built a strong customer base by delivering five-star specialist care from their Warrington site. So, when their Sales Manager Lee Galloway joined the team and suggested moving into general waste, maintaining this quality at scale was a priority.
“We knew the original process, which involved manual picking, wouldn’t handle the increase in volume,” Josh explains. “It wasn’t efficient or reliable, which is why we adopted the ZenRobotics system.”
An AI-based waste sorting system, ZenRobotics has the ability to pick through more than 500 waste fractions, helping to output high-quality recyclables. For Waste Wave, introducing this technology meant they could deal with the higher waste volumes and run processing all day, maintaining a low head count without sacrificing output purity.
However, despite all these benefits, the team still had a problem; they struggled to achieve the correct fraction. This meant the material could not be picked through as efficiently by the ZenRobotics system, meaning far too much of it ended up in landfill.
This wasn’t just a problem for maintaining the company’s reputation, it also challenged their sustainability goals.
Josh says, “With recycling becoming the go-to, finding space for waste material is a challenge for the industry, not just for us. It can leave you paying a massive landfill tax bill if you are not careful. Introducing the Eggersmann Forus F38 means we send less to landfill and more can be recycled.”
Eggersman Was The Obvious Choice
When they purchased their first machine purchased from Molson Group the Waste Wave team had already done their research. Adam Waldron, Molson Green Sales Manager explains, “In some ways, it was an easy sell, because Mike and Josh had looked into the details of the Forus F38 and knew it could deal with higher intake while achieving the desired final fraction.”
Josh added, “We wanted the Eggersmann because it felt like the investment in the ZenRobotics system had not reached its full potential. We could not get the right fraction from the original trommel screen, and the Forus F38 seemed like the best replacement. With Molson becoming the new Eggersmann dealer in the UK, we reached out to their team.”
Versatile Power And Performance
A 2m twin shaft shredder, the Eggersmann Forus F38 is suitable for almost every application and is available in both tracked and hook lift styles. The electro-hydraulic and diesel-hydraulic engines can output between 200kW and 280kW of power. Combined with the optimal infeed achieved by the hydraulically lifting and lowering hopper, it is possible to reach a throughput of up to 80 tonnes per hour.
Both the direction of the rotation and the speed of the shafts can be set independently. This makes them self-cleaning and protects against material wrapping. As Josh explained, “The fact that they are independently driven provides full protection against anything unshreddable. That is a big plus. These shafts can also be equipped with 40 multifunctional rotor tools, making them adaptable to multiple applications.”
Instant Improvement in Productivity
The efficiency and reliability of the machine have quickly made an impact on the Waste Wave operation, asJosh explained, “Alongside the ZenRobotics system, the Eggersmann Forus F38 has streamlined the workflow. It can continue to shred without interruption thanks to its hydrostatic shafts, which means we can maintain productivity with a smaller workforce.
“The machine can maintain production without feeling overstrained. Our site is quite tight, so the Forus F38 works well with its compact footprint and manoeuvrability allowing it to navigate the site easily. This means that the machine can be moved quickly, maintaining efficient production and helping us keep up with the incoming waste stream.
“We chose the Eggersmann because of its build quality and how easy it is for the operator to use, from the shafts to the breaker bar, and it’s not disappointed us so far.”
Breaker Bars Boost Accuracy
The quick-change breaker bar in the Eggersmann Forus F38 was a key feature for the Waste Wave team. With five different bars to choose from, it allows operators to determine the piece size more accurately.
The A1 breaker bar is used to process general waste into a 300mm product that the ZenRobotics system can pick through effectively. Switching to an A3 bar allows them to reprocess waste wood materials down to a smaller, marketable size. The hydraulic mounting and locking mechanism mean the breaker bar can be changed in as little as 10 minutes, which has been a game changer for the team.
Josh commented, “They told us we could complete the change that fast, but you don’t really believe it until you see how easy and quick it is. It is amazing in terms of productivity, and is also much safer for our operators, which means we can now process general waste more efficiently and create a sellable wood product.”
Straightforward Servicing
The machine is built with maximum uptime in mind. With large, ground-level maintenance doors operators can access key compartments easily and safely. Plus, the intuitive controls mean the Forus F38 can be easily programmed via the Eggersmann One-Logic interface or a 10-channel radio remote control.
These features, alongside the reliable servicing support of Molson aftersales, means the Waste Wave team can operate their new Eggersmann machine with complete confidence.
As Josh further stated, “Molson has been great to deal with, particularly Adam. He is a great guy and a good laugh, so it doesn’t just feel like a commercial transaction when you work with him. You feel like the team genuinely cares.Between that and the versatility of the machine, we’re set up to make real progress and continue to grow.”
