Client Background

A leading waste processing facility specializing in the pre-treatment of municipal solid waste (MSW) and compost feedstock sought to optimize its material separation process. The plant produces high-quality refuse-derived fuel (RDF), biomass, and compost for energy and agricultural markets, where efficiency and material quality are critical to both operational performance and downstream processing.

Operational Challenge

Prior to upgrading, the facility operated an 8-meter traditional disc screen but faced persistent issues that limited productivity and increased operating costs:

Frequent disc wear and clogging caused by stringy and irregular materials like branches, sticks, and packaging tapes.

High energy demand at ~40.5 kW/h due to the machine’s struggle to move material consistently.

Poor separation quality, with oversize material carrying excess organics, and undersize fractions contaminated with plastics increasing wear on secondary shredders and reducing throughput.

Ongoing downtime and maintenance, which hindered continuous operation and throughput capacity.

Solution Overview: Hexact 8000 with DDS & HDDS

The facility installed the Ecostar Hexact 8000 stationary dynamic disc screen equipped with Dynamic Disc Screening (DDS) and Hyper Dynamic Disc Screening (HDDS) technologies.

ECOSTAR case study showing eFACTOR3’s Dynamic Disc Screening equipment in recycling/waste processing application

Key machine features included

  • Hardox wear-resistant disc construction for durability in abrasive waste streams.

  • Anti-wrapping design significantly reducing material entanglement.

  • Adjustable screening section (±30%) enabled real-time optimization of separation sizes.

  • Compact modular design to fit within the existing production line and reduce installation costs.

  • Energy-efficient powertrain: only two 7.5 kW motors (15 kW total) for the 8 m screen.

Results & Impact

BenefitHEXACT 8000Traditional Disc ScreenResult
Annual Maintenance Hours60600-90%
Annual Maintenance Cost€1,500€15,000-90%
Installed Power (kW/h)1540.5-63%
Production Efficiency+15%Baseline+15%

The transition to the Hexact 8000 delivered measurable improvements across operations:

Operational Efficiency

  • 90% reduction in maintenance hours — the annual maintenance requirement dropped from ~600 hours to just 60 hours.

  • Continuous operation with fewer stoppages thanks to anti-wrapping design and robust components.

  • Cleaner material fractions, with the fine output showing ~15% less contamination from plastics, improving throughput and feedstock quality for downstream equipment.

Energy & Cost Savings

  • 63% reduction in energy consumption, achieved through streamlined screening dynamics and reduced traction force needs.

  • Lower operating costs and reduced wear on secondary shredders due to cleaner, consistent material flow.

Process Quality & Productivity

  • Enhanced separation precision supported the facility’s goals of producing higher-value RDF, biomass, and compost.
  • Reduced downtime and optimized screening improved overall plant cycle times and processing capacity.
Ecostar HEXACT 8000 stationary disc screen for waste and recycling separation

Conclusion

Replacing a conventional disc screen with the Hexact 8000 dynamic disc screen significantly improved the plant’s operational performance, sustainability, and bottom line. With lower energy use, less maintenance, and higher-quality outputs, this upgrade exemplifies how advanced screening technology can modernize waste handling and recycling operations — aligning with eFactor3’s mission to deliver innovative, cost-effective material processing solutions.