A leading Dublin-based manufacturing and wholesale company successfully transformed their waste management operations using Gradeall’s integrated compaction solutions. The implementation of G140 Pre-Crush and G90 compactor systems reduced wood waste collections from 3-4 times weekly to monthly, delivering substantial cost savings and operational efficiency improvements.
Sanbra Fyffe, a manufacturer and wholesaler of plumbing supplies based in Dublin, exemplifies the waste management challenges facing modern manufacturing operations. Supplying to most builders merchants across the UK and Ireland, their extensive distribution network generates substantial packaging waste.
Like any manufacturing business, stock arrives on pallets and wooden crates, creating persistent waste management challenges. These materials were initially disposed of in open-topped skips, creating multiple operational issues:
Inefficient Space Utilisation: Bulky pallets and crates created air gaps in containers, requiring frequent collections Rising Collection Costs: Multiple skip collections per week created escalating disposal expenses Operational Disruption: Frequent collection schedules disrupted manufacturing and distribution operations Storage Problems: Accumulated wood waste required significant storage space
The pandemic brought unprecedented challenges as home renovation demand surged. “With the pandemic came an increase in people renovating their homes and thus an increase in orders for the company, wood waste became a significant problem with multiple open top skip collections per week.”
This business growth, whilst positive, exacerbated existing waste management issues and highlighted the need for more efficient processing solutions.
Sanbra Fyffe’s approach to equipment selection demonstrated strategic thinking based on long-term experience with Gradeall equipment.
The company contacted Gradeall based on extensive positive experience: “having a GV500 and G-eco 150 Baler for over 20 years they knew the equipment was reliable and built to last.
This 20-year operational history provided confidence in:
After reviewing successful municipal implementations, “after seeing the case study for the G140 Pre Crush at Carrickfergus they felt that it would significantly reduce the amount of skip collections needed for wood waste.
The comprehensive solution included:
The G140 Pre-Crush system incorporates specialised features for manufacturing applications:
Wide Hopper Design: The wide hopper makes loading pallets very easy, accommodating standard pallet sizes and irregular wood waste shapes.
Forklift Compatibility: Both machines were fitted with open top hoppers to allow for quick and easy loading of material either by hand or by forklift.
Pre-Crushing Technology: Wood waste is crushed with ease, significantly increasing the tonnage that the container can be filled with.
Safety Features: An access panel is provided to inspect the inside of the hopper and to clear any blockages. An electronic interlock prevents the machine from operating when this door is open.
The complementary G90 system addresses cardboard waste from packaging operations:
The implementation delivered measurable operational improvements:
“With the increase in business we found there was much more wood waste, we required frequent skip collections about 3-4 times per week. With the G140 pre crush not only is it easier to load but also with much more waste in the skip collections are required much less frequently.” – Manager, Sanbra Fyffe Dublin
Collection Frequency: Reduced from 3-4 times weekly to significantly less frequent collections Loading Efficiency: Easier material loading through forklift-compatible hoppers Container Utilisation: Much more waste fits in each container through effective pre-crushing Operational Simplicity: Streamlined waste management processes
Reduced Collection Costs: Fewer collection schedules translate directly to lower waste management expenses Improved Space Utilisation: Enhanced container fill rates reduce storage requirements Labour Efficiency: Forklift loading reduces manual handling and labour costs Operational Flexibility: Integrated systems accommodate varying waste volumes
Modern manufacturing operations generate diverse waste types requiring tailored management approaches:
Packaging Materials: Pallets, crates, cardboard packaging, and protective materials Production Waste: Off-cuts, defective products, and processing by-products Maintenance Waste: Equipment packaging, spare part containers, and maintenance materials Administrative Waste: Office waste, documentation, and general facility waste
Effective manufacturing waste management requires comprehensive equipment solutions:
Wood Waste Processing: Specialised compaction for pallets, crates, and timber waste Cardboard Compaction: Dedicated systems for packaging materials Baling Systems: Processing recyclable materials for revenue generation Material Handling: Forklift-compatible loading systems for operational efficiency
The Sanbra Fyffe installation demonstrates effectiveness across various manufacturing applications:
Plumbing and Building Supplies: Managing packaging waste from distribution operations Electronics Manufacturing: Processing component packaging and protective materials Food Processing: Handling packaging materials and organic waste streams Automotive Manufacturing: Managing diverse waste from production and assembly operations
Wholesale operations face similar challenges:
The 20-year operational history of existing equipment demonstrates:
Industrial Construction: Robust design withstanding demanding manufacturing environments Consistent Performance: Reliable operation across diverse applications and conditions Maintenance Efficiency: Manageable service requirements supporting continuous operation Technology Evolution: Equipment updates and improvements over extended operational periods
Long-term equipment performance delivers:
Effective waste processing supports environmental goals:
Landfill Diversion: Reduced waste volumes decrease landfill requirements Transportation Efficiency: Fewer collection vehicles reduce carbon emissions Material Recovery: Enhanced processing enables better material separation and recycling Resource Conservation: Efficient processing supports circular economy principles
Modern waste management systems support:
Successful implementation requires comprehensive planning:
Space Requirements: Adequate area for equipment installation and operation Infrastructure Needs: Power supply, access routes, and utility connections Workflow Integration: Seamless integration with existing manufacturing processes Safety Considerations: Proper safety zones and operator protection measures
Expert Installation: Professional setup ensuring optimal performance and safety Operator Training: Comprehensive education on safe, efficient equipment operation Integration Support: Assistance with workflow and process integration Performance Optimisation: Fine-tuning for maximum efficiency and throughput
Equipment Costs: Initial investment in processing machinery and installation Operational Savings: Reduced collection frequencies and associated transportation costs Labour Efficiency: Automated processing reducing manual handling requirements Space Optimisation: Improved facility utilisation through efficient waste storage
Collection Cost Reduction: Immediate savings through fewer waste collections Operational Efficiency: Improved workflow and reduced labour requirements Environmental Compliance: Meeting regulatory requirements and sustainability goals Long-Term Value: Extended equipment life delivering sustained benefits
Gradeall International delivers comprehensive waste management solutions with demonstrated success across manufacturing applications:
Industry Expertise: Deep understanding of manufacturing waste management challenges Proven Solutions: Equipment designed specifically for industrial applications Long-Term Reliability: Track record of decades-long operational performance Comprehensive Support: Complete service from consultation through ongoing maintenance
Our customer-focused sales team combines over 100+ years in the recycling industry with specialised understanding of manufacturing waste management requirements.
Technical Expertise: Experienced engineers providing optimal solutions for specific challenges Application Knowledge: Understanding of diverse manufacturing processes and waste streams Integration Support: Assistance with workflow integration and process optimisation Ongoing Partnership: Long-term relationship supporting evolving operational needs
For comprehensive manufacturing waste management solutions that deliver measurable operational and financial benefits. Our experienced manufacturing waste management specialists can assess your facility’s requirements and recommend appropriate solutions to reduce costs, improve efficiency, and support environmental sustainability goals.
Transform your manufacturing waste management operations with proven compaction technology that delivers rapid return on investment and sustained operational benefits, backed by decades of proven reliability in demanding industrial environments.
Explore additional manufacturing case studies and technical information about waste management equipment applications across diverse industrial sectors and material types. Contact our technical team for detailed specifications and performance data for your specific processing requirements.
Pallets, crates and wood waste are easy to load into the hopper via forklift
Pallets loaded into the G140 pre crush
The wide hopper makes loading in pallets very easy
Wood waste is crushed with ease, significantly increasing the tonnage that the container can be filled with
An access panel is provided to inspect the inside of the hopper and to clear any blockages. An electronic interlock prevents the machine from operating when this door is open.
Cardboard waste being loaded into the G90 compactor
A GV500 and G-eco 150 which have provided reliable serivce for over 20 years.
More details on the G140 Pre Crush
More details on the G90 Static Compactor
"With the increase in business we found there was much more wood waste, we required frequent skip collections about 3-4 times per week. With the G140 pre crush not only is it easier to load but also with much more waste in the skip collections are required much less frequently."
Manager Sanbra Fyffe Dublin
Our customer focused sales team have a combined 100+ years in the recycling industry and have a deep understanding of the Tyre Recycling Industry and waste baling/compacting industry to ensure our customers are getting the best advice and products to improve recycling processes at their business.
Get in touch to see how we can help you today
+44 (0)28 8774 0484
[email protected]
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