Case study: Kealshore powers the future with Tyrone International wash plant

When Kealshore wanted to go to the next level with its wash plant it knew where to turn.

About the project

Kealshore Ltd., a leading quality construction aggregates supplier in Merseyside, had a problem, and it came to Tyrone International to solve it. Founded by Ian Pickavance and his father, Kealshore is a major supplier of aggregates to the construction sector, specialising in recycling products coming on and off site. As such, high throughput and total reliability are the top of its list when it comes to equipment.

Kealshore turned to Tyrone International to revitalise operations with a new wash plant. Tyrone International’s response was to demonstrate how it could increase efficiency: faster, more reliable and more flexible.

The challenge

Faced with an ageing wash plant that was proving increasingly unreliable, requiring regular maintenance that often ground work to a halt resulting in costly interruptions, Kealshore needed change. In addition, Kealshore had also outgrown the tons per hour (TPH) throughput of its existing plant, so an upgrade was needed in order to allow the company increase its productivity across the board.

Kealshore’s Merseyside site

the solution

Tyrone International first performed a complete site survey in order to understand Kealshore’s processes and the problems it was dealing with. From here, Tyrone International proposed options for helping Kealshore to move forward. As processing recycled aggregate is the heart of Kealshore’s work, the solution had to not only increase throughput as a form of future proofing, but also handle extremely variable material with the end result being consistently clean product.

“This new wash plant that we’re supplying to Kealshore is what we’d regard as the next generation wash plant,”

said Fintan McKeever, director of Tyrone International.

The Result

The result was clear: Kealshore’s previous wash plant had a throughput of 100 TPH. Installing a wash plant from Tyrone International saw a 50% boost, with throughput raised to 150TPH – a significant increase in overall processing capacity, meaning both a boost to profits and the ability to better support customer needs.

More than just increasing output, though, the new plant also broadens Kealshore’s range, said Pickavance.

“It does an extra 40 mm, so we now do a 10 mm  pipe bedding, a 20 mm  pipe bedding and a 40 mm  pipe bedding, which is a real feather in Kealshore’s cap,”

Pickavance said.

Reliability was also improved through Tyrone International’s use of high quality components and materials based on years of on-site experience. Indeed, Tyrone International’s designs keep continuity at the top of the list of demands, with easy maintenance access a key factor.

Hour-long shutdowns required in order to unblock the plant are now a thing of the past, as Tyrone International’s wash plant is designed from the get go for rapid access: panels can be simply unlocked and opened, providing instant access.

“The new plant is so much more efficient,”

said Pickavance .

Working together to deliver to Kealshore’s precise needs, Tyrone International is more a partner than just a supplier. For Kealshore these improvements all add up to one thing: better business.

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