Several Lybover business units joined forces to produce a new sorting line for French metal recycling company Henault. This ensures better separation of waste fractions and thus higher sales value.

The project at a glance

The challenge

Henault Recyclage wanted a new sorting line in a newly built hall to sort and upgrade non-ferrous metals, which were already separated from iron fractions, even more precisely. The purer the different fractions are, the more residual value they yield. In turn, better recycling of plastic, wood and textile fractions would prevent them from going to landfill. In addition, Henault wanted to be able to treat shredder waste on site to reduce transport to distant sites. Finally, some already existing equipment needed to be reused.

The plan

While Henault originally wanted three separate sorting lines, it became clear to both parties during the engineering process that one integrated line would make more sense. To do so, Lybover would use an extensive arsenal of solutions from partners and the various business units.

A 3D scan of the existing site allowed the engineering teams to design based on accurate data. In doing so, they had to take into account the limited available interior space, possible extensions, operator ergonomics and energy efficiency. A 3D model allowed Lybover’s teams and the client to walk through the plant in VR.

The execution

An inspection scan of the hall took place before assembly started to map the real situation. The anchoring points for the installation were then plotted with a total station. Thanks to precise engineering, well-oiled cooperation between Lybover’s business units and the flexibility of the fitters, there was an answer to every unexpected challenge during the works. The new sorting line at Henault is ready to be commissioned.

The Lybover way

How do you get more and purer non-ferrous fractions from your sorting line?

The purer the fractions coming out of sorting lines, the more profit a recycling company makes. Henault Recyclage also knows this. This family company, with four sites in France, specialises in recycling metals from private individuals and companies. For its Oradour-sur-Glane site, Henault was looking for new sorting lines to better separate the different non-ferrous fractions from the shredder. Fractions of plastic, wood and textiles also needed to be better recycled to reduce waste. In addition, Henault wanted to treat the shredder waste on site to reduce transport to remote sites.

Through Steinert, a manufacturer of sorting systems and partner of Lybover, Henault came to Lybover. The beginning of a challenging project that the colleagues brought to a successful conclusion thanks to their flexibility and close cooperation.

Thinking beyond the question

Thinking along with the customer and proposing the solution that best suits its needs and budget: this is Lybover all over. Again, this approach was at the heart of the development of the sorting plant. ‘The customer originally wanted three separate sorting lines to be installed in a newly built hall. During discussions with our engineers, it became clear to both parties that one large line would make more sense. This is because in the initial plan, bulldozers would have to transport material from one line to another. With one line, those movements are not necessary,’ interjects Louis Schollier, Project Engineer at Lybover.

‘The customer also wanted to reuse some existing equipment in the new line or elsewhere in the plant. These included two conveyors, two top belt magnets and an eddy current or eddy current separator. These were still in good condition and so Henault avoided additional investments. So in engineering we had to take those existing devices into account. We also needed air treatment to reduce emissions and prevent dust from flying around,’ continues Katrien Vyvey, Project Engineer at Lybover.

Detailed scans for precise engineering

The sorting line would be located in a new building, alongside already existing facilities. The conveyor starts at an existing cyclone and under a vibrating table. Precise measurements were therefore needed to determine the position of the first belt. 3D scans were used to map both the current installations and the location of the new building. This way, Lybover’s engineers immediately had the necessary measurement data at their disposal and additional trips to France were unnecessary. The consultation with the customer was also able to take place smoothly by digital means.

Thinking ahead for a total solution

‘Our measurements and the architect’s plans made one thing clear: the available space was very tight. So it was quite a challenge to integrate all components smartly into the building and to ensure that the installation would be accessible for maintenance work. Moreover, we wanted to provide space to expand the line with an automatic sorting machine in the future. Operator ergonomics and energy-efficient climate control in the sorting and operator cabins were also a point of attention. We translated the principle diagrams for the sorting lines and dedusting into a 3D model where we could walk around in VR. That made it possible to explain our design to the customer from a distance,’ explains Louis Schollier.

Getting down to business

After the construction of the production hall, the actual assembly could begin. But not before a 3D scan for verification took place, notes Louis Schollier. ‘We work to the millimetre. So it is useful when we see and resolve any deviations from the plan before we start assembling.’ Next, all anchoring points for the installation were plotted with a total station, allowing Lybover’s mechanics to work efficiently.

Louis Schollier: ‘A large site like this always comes with specific challenges. There is a tight schedule for delivery of parts and assembly. At the same time, good coordination is needed with the other parties involved, such as the electrical engineers appointed by the customer. In terms of assembly and logistics, our INSTALLATION colleagues always showed flexibility in case of unexpected delays, for example in the concrete works. Internally, cooperation between the different business units ran very smoothly thanks to good contacts and open communication. This way, we quickly responded to customer requests.’