At a glance
Saint-Gobain aimed to significantly increase the supply of recycled gypsum boards to production. This capacity increase had to be realized within the existing infrastructure, without major structural modifications, while maintaining a stable and reliable material flow.
Lybover resolutely opted for customization, starting from a thorough analysis of the existing situation. In close collaboration with technology partners, a solution was developed that is both technically robust and financially feasible. By combining smartly—reusing where possible and investing where necessary—a concept was created that perfectly matched Saint-Gobain’s real needs.
At the core of the installation is a Samson feeder that converts batch input into a continuous material flow. Dust generation is addressed not only at this point but throughout the process at every discharge location. Tailor-made conveyor belts, real-time weighing, and effective removal of ferrometals ensure a stable and controlled process. Thanks to an accurate 3D scan and the reuse of existing platforms, the new installation could be seamlessly integrated into the existing facility. The result is an efficient, future-proof solution.
Saint-Gobain faced a clear challenge: significantly increase the capacity of feeding recycled gypsum boards into production, without completely overhauling the existing infrastructure.
Lybover addressed this challenge by strongly focusing on customization and close cooperation with technology partners. After a thorough analysis of the existing situation and an inspiring site visit with Aumund, an alternative approach was jointly explored that was both technically and financially viable. By intelligently reusing what was still suitable and investing selectively in new components, the project was optimally aligned with the client’s actual needs. “We had already explored several scenarios ourselves, but we were looking for a partner who could translate our ideas into a robust, workable solution within our budget,” recalls Jeroen van Soelen, Project Engineer at Saint-Gobain.
At the heart of the new installation is the Samson feeder. This component efficiently converts batch feeding into a continuous material flow. The Samson feeder is also equipped with a dust hood and an integrated dedusting unit, effectively addressing dust generation. In addition, decentralized dust extraction was implemented throughout the process at each discharge point. The existing conveyor belts were replaced with tailor-made versions, perfectly adapted to the higher throughput capacity. An advanced weighing unit provides real-time insight into the supplied material. Ferromagnetic contamination in the recyclate, such as nails and screws, is effectively removed by an overband magnet from technology partner Steinert—a solution that proved to be the most effective based on extensive testing.
“It was important for us that all process steps were seamlessly aligned,” explains Cowdy Samyn, Sales Engineer Projects at Lybover BULK. “By working closely with our partners from the start and actively involving the customer in the design process, we were able to act quickly and deliver a solution that is not only technically strong, but also practical and safe to use.”
The combination of an accurate 3D scan and the reuse of existing platforms ensured that the new installation could be perfectly integrated into the existing hall, with minimal modifications and maximum efficiency. The result is impressive: a reliable, future-proof line that enables Saint-Gobain to accelerate its sustainability objectives. The collaboration between all parties is valued highly on both sides. “Lybover understood our needs and translated them into a solution that works. The result speaks for itself,” the customer concludes with satisfaction.