Transforming Plastics Recovery at ENVA, Bourne with the Next-Gen Air Drum Separator

Client Overview

ENVA, a prominent environmental solutions provider in the UK and Ireland, operates a diverse network of recycling and resource recovery facilities. Their site in Bourne, Lincolnshire, focuses on plastics recovery from mixed waste streams, aiming to maximise recyclable yield while supporting ENVA’s overarching goal of achieving zero waste to landfill.

The Challenge

With increasing regulatory pressures and growing demands for higher-purity output materials, ENVA needed a solution that could:

• Consistently remove light contaminants from heavy plastics
• Handle variable and complex waste streams
• Deliver high throughput with minimal downtime
• Enhance the quality and marketability of recovered plastic materials

Traditional separation technologies were falling short—particularly in terms of flexibility, maintenance demands, and separation precision.

The Solution: Impact’s Next-Generation Air Drum Separator (ADS)

ENVA partnered with Impact Air Systems to install their next-gen Air Drum Separator (ADS)—a key part of Impact’s smart air separation technology.

Refined for Performance

The next-gen ADS offers a leap forward in separation precision, system reliability, and ease of operation. At the Bourne facility, it was deployed to handle complex mixed plastics streams including contaminated mixed material from existing MRF’s and other production processes.

ADS Capabilities at ENVA:

• Precise separation of light and heavy fractions (e.g., films, foils, and paper, rigid plastics from aggregates, wood & metal)
• Consistent throughput performance up to 250m³/hr
• Low energy consumption, thanks to energy-efficient frequency-controlled fan
• ATEX-compliant integrated dust control
• Self-cleaning system components, minimising downtime

Implementation and Integration

Working closely with ENVA’s operations and engineering teams, Impact conducted detailed site surveys and performance modeling to tailor the ADS to ENVA’s specific needs. The compact system was easily integrated into the existing line with minimal disruption, leveraging Impact’s collaborative, design-led approach.

Real-World Results – See gallery

The results were immediate and impactful.

“Impact’s ADS has been a fantastic addition to our process,” says Bernard McCulloch, Engineering Services Manager at ENVA.
“It’s significantly improved the purity of our plastic streams and runs consistently with minimal intervention. The results have been nothing short of spectacular.”

Quantifiable Benefits:

• Significant improvement in output quality, leading to higher market value for recovered plastics
• Improved recovery rates and lower volumes sent to landfill
• Reduced manual intervention and maintenance
• Fast return on investment through operational savings and improved material resale

Beyond the Install: Ongoing Partnership

ENVA benefits not only from a high-performance separation system, but from Impact’s full-service support through its sister company, Impact Technical Services. The partnership includes:

• Tailored maintenance contract
• On-call service response
• Rapid spare parts availability

This ensures maximum uptime and performance continuity in a mission-critical environment.

Conclusion: A Game-Changer for Recycling Operations

The installation of the next-generation Air Drum Separator at ENVA’s Bourne site exemplifies how smart engineering, and collaboration can elevate recycling operations. With the ADS, ENVA is better equipped to meet sustainability targets, reduce operational costs, and deliver cleaner, higher-value materials to market.