Screening Screens: McGill Environmental Auditions the Industry
5 /10/08
McGill Environmental Systems of N.C. is an international compost manufacturer
with facilities in the United States and Ireland. Specializing in composting
organic by-products from municipal, industrial and agricultural processing and
production, they have been involved in waste management projects globally, including
work in Europe and the Far East. With a range of clients spanning private companies,
local municipalities and the U.S. government, McGill has provided solutions
to biological waste treatment and remediation and has conducted research and
demonstrations of approved waste treatment procedures. “Compost is our
business,” said Bill Kish, operations manager for McGill Environmental
Systems. “We are concentrating on producing a totally clean, organic product.”
McGill Environmental Systems opened its first composting facility in North
Carolina in 1991 in Sampson County and its second in 2002 in Chatham County.
Through the years, they tried various combinations of equipment to produce the
product quality for which they are known.
McGill takes in municipal bio-solids, water treatment residue, food waste, clean
wood, agricultural waste, yard waste, untreated-unpainted pallets and lumber
as well as organic waste from supermarkets and food companies to produce their
products. The menu of results includes two soil mixes, a soil builder for use
with the customer’s own amendments, specially formulated landscape and
nursery blends, compost suitable for vegetable and fruit operations and a mix
specially formulated for certified organic crop producers.
“Our facilities are different from most compost operations,” Kish
stated, “because they are enclosed.” The creation of indoor composting
facilities has allowed optimum utilization of the McGill method for composting,
which is based on a scientific enhancement of the natural composting process
that creates and maintains an environment conducive to the proliferation of
specific microbial populations. These microbes are responsible for biodegradation
and, when provided with the right balance of moisture, temperature, and oxygen,
are able to produce a more rapid decay of organic material.
The use of the building allows the compost operation to process organic waste
in any weather, at any time, 365 days a year. This refinement on the usual open-air
composting facility allows McGill Environmental to produce high-quality compost
material in 14 days, which would otherwise take from four to seven months in
an open-air facility. The constant temperatures, regulated airflow, and moisture
maintenance enhance production.
In 2006, McGill Environmental recognized that their screening results would
benefit tremendously from a more efficient, productive solution that would not
only reduce processing time, but the associated costs as well. To ensure they
were getting the best option available, several companies were invited to conduct
a thorough demonstration of their product lines—DoppstadtUS brought the
SM 720 trommel. All of the machines were subjected to strenuous testing over
the course of two days. Different types of materials were processed to create
different blends of materials. Throughput was thoroughly tested and measured,
and each machine was subjected to challenging material scenarios.
“We involved our employees in this collaborative process as well,”
Kish noted. “We needed to make sure that the machines offered an ease
of operation and maintenance in addition to overall performance under tough
conditions.” Because the need was so critical, Kish wanted to be sure
each potential was reviewed as thoroughly as possible before making such a significant
investment.
When all the dust had settled, it was clear that the SM 720 offered the versatility
McGill Environmental was seeking. There were numerous benefits Kish recognized
in the SM 720, but the power and results delivered from the fuel-efficient100
hp engine was one of the biggest; fuel costs are always a big concern, and the
efficiency of the Doppstadt trommels was impressive.
Overall, the SM 720 was easy to move, easy to operate, and easy to maintain.
Kish was not surprised that the two SM 720s McGill Environmental ultimately
purchased have lived up to, and even surpassed the original demonstration trials.
“The trials were accurate,” he said, “and we have had no downtime
except for preventive maintenance, which is made so easy by the Doppstadt design.
We have been extremely happy with the low fuel consumption. On average, we burn
only two gallons of fuel per hour of operation!”
Maintenance is easily performed with the exclusive swing-out design that allows
the engine to be pulled out perpendicular to the chassis. A hydraulically tensioned
cleaning brush sweeps any lingering debris from the screen continuously, minimizing
spearing and allowing for maximum output of material. All SM trommels are also
engineered with a patented load-sensing device ensuring material is fed at a
proper rate, resulting in a higher screening efficiency. Multiple product production
is easily accommodated by the SM series trommels due to the ease of screening
changes. The drums are simply lifted off the urethane wheels with a forklift,
and replaced with another size drum. The entire change takes less than 15 minutes.
Once the material is processed inside the building, the now stable product is
moved outside and placed in windrows for curing. The SM 720s are then employed
for final screening of the cured compost. Because much of McGill’s product
is processed for use on sports turf, a 3/8” screen is the size of choice
to make a topsoil-like material that is perfect for that application. But McGill
makes a variety of other products as well, including custom mixes for agricultural
use, landscaping and municipal applications. “With the SM 720, we can
dial in the screening through one piece of equipment,” Kish elaborated.
All Doppstadt SM series trommels are also available in stationary configurations,
a benefit not missed on McGill. Their first stationary SM 720 is expected to
arrive in the summer, and the process of integrating them with his indoor operations
will commence.
The operation at their second facility is totally computerized. Room air is
changed nine times an hour, removing any odors associated with traditional composting.
This is ecologically sound as well as neighbor-friendly. As a result, McGill
Environmental can operate on smaller properties with this method, creating a
consistent product with the same quality every time, without such a large investment
in real estate.
Kish is particularly excited about McGill Environmental’s two new ventures.
McGill now has one under construction in Virginia (opening in May 2008) as well
as another under construction in Ireland (opening in July 2008). It will be
the largest indoor composting facility in the state of Virginia. “It is
hard to get permits for this type of facility these days,” Kish noted.
“But with careful planning, and our proven track record in North Carolina,
we will be opening our new facility in Sussex County, Virginia, about 40 miles
southeast of Richmond.” The building will be 400 feet long and 250 feet
wide, and Doppstadt equipment will be front and center, ready to make and finish
the product with continued efficiency.
According to Kish, Doppstadt equipment has made a huge difference in the productivity
and cost-effectiveness of McGill Environmental’s operations. And as they
continue to pursue new opportunities and expand their ever-growing operations,
the SM 720 trommels will continue to accompany McGill Environmental’s
success in the composting industry.
