Case Study

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Screw Feeder Liners

How replacement liners saved one waste management client £38,700 in replacement parts & 598 man-hours in maintenance.

The Situation

Plant & equipment supplied by a German OEM was beginning to wear out after a waste management plant had been in operation for 18 months.

Hoverdale were called in to help reduce maintenance costs in this plant, especially in relation to a screw feeder which fed material up a slope into the next part of the process.

Trough liners, supplied by the OEM, were rigid & fixed in place. In addition, because the OEM had gone out of business, the client was having to keep volumes of the troughs in stock because they didn’t know where to find an alternative.

The client was using types of trough liner:

400 BHN wear strips for the harsher end of the process before materials were separated out

Hard plastic: Polypropylene which was pre-formed

Screw Feeder Liners
Screw Feeder Liners

The Client’s Objectives

The client’s main objective was:

To find a supplier that could provide a better outcome with longer life thus reducing the maintenance costs and reducing the need to carry stocks of parts.

With the OEM going out of business, the client didn’t have anyone to consult with on reducing maintenance costs of the plant.

Our Solution

Hoverdale’s solution was to:

Replace the Polypropylene liners with Polyurethane liners in the dry section

Replace 400 BHN RQ&T liners with Ultraclad 800 liners which would bring about an increase in life of 7 times

Hoverdale’s PU troughs were as hard as the OEMs troughs but were more flexible making for easier storage. The Ultraclad liners would bring about a 7 times increase in life for a similar cost.

Their Measures for Success

The client had 2 main measures for success.

Correct fitting of liners (in changing from a formed to a flexible liner)

Lifetime of liners (old v new)

Hoverdale aimed to provide an increase in the lifetime of the liners in excess of three times

The Timing

A simple change over to new materials when the original material had worn out.

Value to the Customer

The value for the customer was significant:

PU liners lasted 3 times longer life saving the company £30,000 per annum

512 man-hours saved maintenance on the PU liners which needed to be replaced less frequently

Parts were made available on a 10-day delivery basis leaving the client with no need to carry stocks

The Ultraclad liners lasted 7 times longer saving the customers £8,700 per annum

86 man-hours per annum saved maintenance on Ultraclad liners which needed to be replaced less frequently

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BEN DUCHESNE

Ben is a time serviced field service engineer in the busy waste and recycling sector, who’s career moved into to managing service teams and beyond. Originally beginning his career with a HGV repair and maintenance apprenticeship with IVECO, from there travelling and working in multiple countries moving towards waste processing shredders.

Ben joined the Hoverdale team in September 2024 seeking to apply his extensive knowledge to a new area. His values and ethics fit perfectly within the Hoverdale ethos.

He is happily married to Kristina, with 4 wonderful young children; 14, 11, 8 and 5. We the children he doesn’t get much spare time. He is a family man, who enjoys spending as much time with them as possible.

DAVID BARTER

David is an experienced leader, with a background covering Operations, eCommerce, Finance, Compliance, HR and IT. His career spans Banking, Retail and Engineering, spending the majority of his career working for ALDI as they grew to become 4th largest supermarket in the UK, including seven years on their UK board as Managing Director of IT and eCommerce.

David joined Hoverdale’s Senior Management Team in 2023 to seek a fresh challenge in a completely different industry sector. He has applied his approach to Process Improvement, Efficiency, Customer Service and Teamwork to great effect during Hoverdale’s sustained growth.

Married to Jane, with three adult sons between them, David volunteers on the board of the Nottingham Playhouse theatre as well as his local rugby and football clubs. Any spare time he spends enjoying walks with their Golden Retriever, Buzz, who is also regularly seen in the Hoverdale office.

MATT BEVERLEY

A time served Mechanical engineer Matt’s background includes many high-profile projects within the Automotive Industry: The Rolls Royce Phantom, Rolls Royce Cullinan, Spyker Le-Mans racing teams, Bentley, Aston Martin, and Airbus A380. This history and knowledge of complex manufacturing and engineering projects have been transferred and further developed into the bulk material handling sector. Matt has work in Europe, North America, Indonesia, and China

He joined the bulk solids and bulk handling industry in 2019 as Managing Director of Hoverdale UK Ltd and subsequently completed a Management buyout in July 2020. The business has grown yearly, increased employment, its customer base, and worldwide reputation, and disrupted the market with groundbreaking innovative technology. Since Matt took over Hoverdale, the company has filed four patents for innovation; one was granted in 2023 for a design to improve bulk handling. The success had been driven by delivering tailored solutions to the waste recycling sectors that keep material flowing out and money flowing in.

Awards Include

  • 2024 – Shapa company of the Year
  • 2024- Shapa Innovation in Technology
  • 2024- MHEA Engineer of the year
  • 2021 – MHEA Innovation of the year
  • 2021- IMechE Innovation award

Current Positions Include.

  • Group Chairman Hoverdale UK Ltd
  • President (MHEA) Material Handling Engineers Association
  • Vice Chairman: IMechE Bulk Material Handling Committee
  • Council Member: (SHAPA) Solids Handling & Particle Association
  • Member: Chartered Management Institute

Matt has been happily married to Julie for 22 years and has 4 children, 3 of which are involved within the Hoverdale group of companies. He is an RFU level 2 qualified coach and referee having been in several head coaching roles at various age groups from under 6’s to adults for his local team Nuneaton RFC. He believes in the core values that rugby teaches of Teamwork, Respect, Enjoyment, Discipline, Sportsmanship and try’s to carry this through in his day to day business activities. He is passionate at brining the next generation of young, diverse engineers into the sector through promotion of apprenticeship scheme and further education routes.