Local conveyor manufacturer goes global with mobile trommel screen
Metberg Enviro stays ahead of the competition with compact, versatile unit from Dark Red Design
Client’s Main Objective
A small, Northern Ireland-based manufacturer of material handling conveyor systems for the mining, quarrying and recycling industries had identified the need for a new compact, mobile machine to add to their existing product portfolio. Enlisting the help of Dark Red Design, they were able to launch the Metberg Enviro 3000, a multipurpose, adaptable solution with market leading features.
With an ever more stringent focus on environmental sustainability, the need to recycle an increasing amount of the waste going to landfill sites has been an issue in industry for some time. A significant rise in landfill tax has prompted recycling firms to try and reduce the volume of waste being sent by recovering as much of value as possible.
For some companies, this has meant a heavy investment in costly processes to separate and salvage qualifying materials to avoid paying higher rates. The client recognised the demand for a highly efficient mobile Trommel screen that could process large capacities, was versatile and robust enough to be used in any location and was simple to use and maintain. The unit would have to be flexible enough to also appeal to their current client base in the mining and quarrying sectors, as well as attracting potential new customers.
Because of the company’s limited size and budget, the ambitious project had an extremely tight timescale and would require high quality rendered imagery of the machine to be used as marketing material prior to completion.
We undertook extensive research of a variety of the existing Trommel screens in production and identified a number of ways in which we could improve their design in regards to flexibility, set up time, maintenance and efficiency. Once the most appropriate design solution had been chosen from the multiple concepts we produced, we were able to advise the client on the range of different funding opportunities available to help finance the project.
Our long experience of engaging with development agencies that exist to support business growth was instrumental in securing backing from Invest NI. We were able to assist with the complex paperwork, as well as setting up meetings with investors that successfully gained Research and Development capital for the Trommel.
Before completing the manufactured prototype, we generated detailed photo-realistic imagery, along with Finite Element Analysis (FEA) data, to showcase the machine to existing and prospective customers. The final design was based around a modular construction to ensure components could be removed independently for quick and easy maintenance and the change out time for the screening drum and the interchangeable screen mesh were kept to a minimum.
Large hinged doors on both sides gave an unprecedented amount of access for cleaning and the highly efficient CAT 2.2 Turbo engine was designed to run at low RPM to reduce emission levels while still maintaining maximum production throughput. The 3000 series Trommel screens are highly mobile and come in a wheeled version for flat ground or can be fitted with tracks for uneven, difficult terrain.
Its broad range of applications, along with its unique, intelligently designed features, has made the Metberg Enviro 3000 series Trommel an unqualified success for the company. Dark Red Design’s holistic approach to the design process meant a fast and efficient route from concept to manufacture, and our CAD renderings of the finished product ensured customer orders were received much earlier than would have been otherwise possible. The machinery is currently being exported internationally to firms in the construction, demolition and waste recycling sectors, doubling Metberg Enviro’s net worth since it was included into their product line-up.