East Cramlington recycled aggregates
C&D WASTE RECYCLING & WATER TREATMENT PLANT
Northumberland, UK
MATERIALS
Processing mixed inert aggregate waste streams, construction and demolition waste.
OUTPUT
0-2mm & 0-4mm recycled sand | 10mm, 20mm & 40mm high-quality recycled aggregates
USAGE
Construction aggregates, infrastructure projects and sustainable development projects.
Project Overview
East Cramlington Recycled Aggregates (ECRA) is a leading recycling and haulage business serving the North-East of England, specialising in the collection, processing and supply of recycled aggregates to the construction sector.
Operating from a compact one-acre site, ECRA had already established a successful recycling operation processing mixed inert waste streams. As demand for sustainable construction materials continued to grow, the business identified an opportunity to recover greater value from incoming material through aggregate washing technology.
To achieve this goal, ECRA partnered with Tyrone International to design, manufacture and install a bespoke wash plant and water treatment solution capable of increasing material recovery, reducing landfill volumes, and producing high-quality recycled aggregates for the local construction market.
The result is a highly efficient recycling facility that delivers exceptional washing performance, maximises resource recovery and recycles up to 95% of process water, all within the constraints of an existing operational site.
The Challenge
ECRA’s existing recycling operation successfully processed mixed inert aggregate waste streams, however a significant proportion of fine material and contaminants limited the amount of reusable product that could be recovered.
The customer recognised that washing would allow them to recover a greater percentage of marketable material while supporting their long-term sustainability objectives by diverting more waste from landfill.
Working within an active site of approximately one acre created additional challenges. Any new installation needed to fit within a restricted footprint, work alongside existing crushing and screening operations, and provide sufficient capacity for both current production requirements and future business growth.
ECRA specified a target processing capacity of 50 tonnes per hour while minimising disruption to existing site operations.
The Solution
Following detailed consultations, site surveys and feed material analysis, Tyrone International developed a bespoke aggregate washing and water treatment solution specifically tailored to ECRA’s operational requirements.
The wash plant was strategically designed to fit within an unused corner of the site, transforming previously underutilised space into a high-value recycling operation without impacting existing crushing and screening activities.
At the heart of the installation is the Tyrone T-Scrub 1100 Log Washer, an advanced washing system engineered to process difficult recycled aggregates and remove contaminants efficiently. The system is capable of processing up to 70 tonnes per hour and producing three clean aggregate products.
Material is then transferred to the T-Sand 60 classification system, where the sand fraction undergoes secondary washing through hydrocyclones to remove unwanted silts and lightweight contaminants before being separated into fine and coarse sand products.
The complete solution incorporates a full water treatment plant with filter press technology, enabling the site to recycle up to 95% of process water while producing a dry filter cake for easy handling and disposal.
Designed with operator safety and maintenance efficiency in mind, the installation also features extensive walkways and service access throughout the system, ensuring maximum plant uptime and ease of operation.
The Results
The new Tyrone International wash plant immediately delivered measurable improvements to ECRA’s recycling operation.
The facility now processes a wide range of inert recycled aggregates while producing multiple high-quality end products including fine sand, coarse sand, and washed 10mm, 20mm and 40mm aggregates suitable for reuse in construction applications.
Key project outcomes included:
- Increased recovery of valuable materials from waste streams.
- Significant reduction in landfill disposal volumes.
- Production of multiple high-quality recycled aggregate products.
- Up to 95% process water recycling through integrated water treatment technology.
- Creation of a compact, high-capacity wash plant within an existing operational site.
- Future-proofed production capacity capable of supporting business growth.
- Improved sustainability performance and resource efficiency.
- Enhanced operational efficiency through purpose-built maintenance access and servicing walkways.
By recovering a greater percentage of reusable materials and reducing waste disposal requirements, ECRA has strengthened its position as a leading supplier of sustainable recycled aggregates across the North-East of England.
