Tasmanian Topturn: CEA

As Dulverton Waste Management embarks on a three-stage facility upgrade, Project Manager Matthew Layton details stage one: the purchase of a Komptech Topturn.

In February this year, Kentish Council in north-west Tasmania approved a Development Permit Application from Dulverton Waste Management.

The permit allows the company to upgrade its existing compost facility and provide best practice leachate and odour control.

Development plans include the construction of an industrial compost cover and associated mechanical equipment to better manage aeration and moisture of existing compost windrow operations.

According to Matthew Layton, Dulverton Waste Management Project Manager, the improvements will control the effect of rain on organic input material, which includes council green waste and industry input stock from across Tasmania.

“We get 1000 millimetres of rain a year down here, which is very different to a lot of facilities on the mainland,” he says.

Dulverton, which in addition to its organics facility operates an award-winning landfill, collectively processes upwards of 100,000 tonnes of material annually – with 40 per cent processed through an open windrow composting system.

“We’re a regional facility, so unlike many mainland composters, we need to accept everything in our region,” Layton says.

“That includes product residues from food manufacturing and green and municipal waste.”

He explains that the industrial compost cover is just one development in a three-stage facility upgrade plan.

Stage one, he adds, was the purchase of a specialised windrow turner with irrigation, which began operating on Dulverton’s existing open-air compost piles in January.

The Komptech Topturn X63 compost turner, purchased through Australian distributor CEA, has a throughput of up to 4500 cubic meters per hour.

The combination of a large drum with thrower blades and powerful drive ensures the turner leaves a well-mixed windrow in its wake.

Before acquiring the Topturn, Layton says Dulverton used a traditional excavator to turn its compost piles.

With a view of consolidating cost and making its processes as efficient as possible, Dulverton went to market to look for a suitable turner to replace its excavators.

“In the lead up to our facility expansion, we wanted to ensure our operations were more cost effective and efficient,” he says.

“There are a number of turners on the market that could achieve that, but we went with the Topturn primarily because of the service support in regional Tasmania.

“There was also the added benefit of a commonality of parts, especially with the engine.”

The Topturn’s engine meets all relevant emissions standards, with a new cooling system keeping the system running under heavy loads and high outside temperatures.

Komptech’s X63 features a large-dimensioned turning drum for high throughput and complete mixing, with easy maintenance access via ladders and platforms integrated into the body.

Furthermore, CEA offer the turner either wheeled or tracked, with engine power converted efficiently into forward movement.

Since operating the Topturn, Layton says Dulverton has seen a dramatic increase in turning efficiency.

“We’ve seen changes in our processes for the operators working with the machine, but also the biology of the compost,” he explains.

“Not only is the Topturn process faster, but it also creates a better composting environment by introducing air right throughout each compost windrow.

“We are achieving exceptional material shrinkage rates.”

The Topturn purchase, Layton says, was Dulverton’s first commercial dealing with CEA.

“They’ve been really good from a client support perspective, particularly in terms of information sharing and guiding us along the track to where we needed to be,” he adds.

“They also offer significant after sales assistance, which really supports the way we’re trying to modernise our facility.”

A key feature of Dulverton’s Komptech Topturn is the ability to add a lateral displacement device at a later stage, Layton says. He adds that in the future, this will give operators the ability to turn and move more compost at once.

When coupled with the turner, CEA’s lateral displacement device minimises transport distance and improves viability and monitoring. By collapsing two windrows, the decomposition shrinkage is smoothed out, making full use of the space.

“We expect this equipment will continue to deliver environmental benefits by providing full aeration and moisture-balance of the compost to assist the natural decomposition process,” Layton says.

“The windrow turner will continue to be used throughout our upgrade program.”

For more information click here

Related stories: 

Two drums with teeth: ELB Equipment

ELB Equipment’s Komptech Crambo shredders are working over-time at Van Schaik’s Bio Gro’s Melbourne organics facility to keep up with a steady influx of material.

Landscaping and permaculture suppliers have reported unprecedented demand for their products in recent months, with an increasing number of Australians looking to become self-sufficient in light of COVID-19.

According to a recent article published in The Canberra Times, the surge prompted Australia’s largest online gardening club, Victoria’s Diggers Club, to advise that it was no longer accepting new product orders.

While the new wave of home gardeners is challenging supply and demand for some, it’s welcome news to waste management and horticulture specialists Bio Gro.

Operating out of South Australia and Victoria, Van Schaik’s Bio Gro (Bio Gro) produces nutrient rich products tailored for a wide range of horticultural and agricultural applications.

According to Sage Hahn, Operations Manager of Bio Gro’s Victorian Operations and Melbourne facility, the application of Bio Gro products to soil results in a range of environmental benefits.

These include, she says, improved soil health, water savings, improved crop productivity and an enhanced ability to mitigate climate change by sequestering carbon within soils.

In addition to functioning as a distribution centre for premium potting mixes, Bio Gro’s Melbourne facility operates as an organics resource recovery centre.

“We manage green and timber waste for two councils out of the Eastern Organics Tender, with that material processed at our site and sent off for further composting,” Sage says.

“We deal with roughly 40-50,000 tonnes of organics per annum and produce between 35 and 40,000 cubic metres of premium product that goes out to production growers, landscapers and nurseries.”

To process its organic waste material, Bio Gro operate a Komptech Crambo dual-shaft shredder, purchased through Australia’s exclusive Komptech distributor ELB Equipment.

When material comes in, Sage says Bio Gro decontaminate it manually, before using the Crambo to break down material sizing and generate a more uniform stream.

“Particular sizing is extremely important as it allows us to get more material onto trucks, with the organic material tipped out at the other end ready for composting,” she says.

“Komptech equipment is the best we’ve seen for green waste. It’s extremely robust and the machinery is clever in the way it works through contamination. Machinery maintenance is also very easy, and the fuel efficiency is fantastic.”

Komptech Crambo dual-shaft shredders are designed for shredding all types of wood and green waste. The machines feature two slow-running drums with shredding tools to minimise fine particle and noise and dust emissions, while resisting contraries.

Simon Humphris, ELB Product Manager, says the Crambo enables easy adjustment of the output particle size, with operators able to exchange the screen basket to suit the specification.

“The Crambo is powered by a modern Caterpillar engine, with a complete muffling of the engine compartment keeping noise emissions to a minimum,” he says.

“Through load dependent rotation speed regulation, the hydraulic drum drive ensures that full advantage is taken of the engine output.”

When shredding waste wood, Simon says the shredder’s wear-resistant surface hardened teeth provides a high level of resistance to contraries.

“Counter rotating shafts, together with the special shape of the teeth, produce a perfect feed, even for fractions with high board content,” he says.

Similarly, Simon explains that the shredder facilitates a high throughput for bulky vegetation via a generously dimensioned feed area, folding hopper and counter rotating teeth.

“The teeth size the material and press it in a cutting and splitting action against the cutting edge and screen baskets located underneath,” he says.

“Slow turning results in a lumpy shred initially, however, the material does not exit the shredding area until the particle size matches the hole size of the screen basket. This enables the quantity of shredded material in the desired particle size to be maximised.”

The shredding drum, with rotation speeds up to 44 rotations per minute, has specially developed bearings to keep the drum in place even under extreme loads.

Strong planetary gears boost drive train life, Simon adds, providing dependable service through thousands of operating hours.

Bio Gro’s shredder has been performing above expectation, Sage says, maintaining consistent efficiency in the face of high capacity operations. She adds that the ELB team’s technical expertise and training is second to none.

“ELB come out to our facility and do on-site training with operators. There are not many businesses that do that level of training. And we find it to be absolutely integral to the performance we get out of the machine, because our operators actually understand how it works,” Sage explains.

Furthermore, Sage says ELB’s spare parts service works to maximise uptimes.

“With overseas equipment you can get caught out with spare parts, but because Komptech is so entrenched in the organics sector, ELB has a lot of spare parts in Australia, which means there’s much less downtime,” she says.

Related stories: 

Equipment distributor CEA acquires ELB Equipment

Agriculture and construction equipment distributor CEA is set to become the Australian distributor of Komptech shredders after acquiring ELB Equipment.

CEA CEO Hylton Taylor said as a leading distributor of world-renowned capital equipment brands, ELB is a natural fit for the CEA business.

“We see this as a great opportunity to further expand our product portfolio and build on our already strong suite of brands we represent in the marketplace today. Operating for almost 40 years, our business understands the market requirements, and how best to meet the evolving demands of our customer base,” Mr Taylor said.

“CEA will seek to capitalise on the extensive knowledge from within the ELB Equipment business, ensuring the high level of service customers have come to expect from ELB remains throughout the transition period.”

CEA will also become the distributor of Diamond Z, Screenpod and TrackStack, adding high speed grinders, stacking conveyers and modular wind sifters to its portfolio of products.

“The waste recycling business is a growth industry and Komptech occupies a unique position in that sector,” Mr Taylor said.

ELB Equipment Managing Director Christopher Malan said the company is excited about the opportunity to further expand and evolve its footprint across Australia and New Zealand.

“This is a great opportunity for our highly skilled staff who are passionate about the business to grow and evolve and join a business with a very strong and positive culture driven by its highly professional leadership team,” he said.

Related stories:

X