Closing the Loop

First published in the October 2025 issue of Quarry Management

McLanahan, one of the world’s most trusted wash plant OEMs, alongside construction materials specialist SunEnviro, recently hosted a customer open day to showcase the latest advances in waste-washing technology. Visitors saw first-hand how construction and demolition (C&D) waste can be transformed into high-quality recycled aggregates, demonstrating the potential for operators to embrace circular economy principles while unlocking valuable new revenue streams

This year, McLanahan proudly celebrate their 190th anniversary – a remarkable milestone that reflects nearly two centuries of continuous innovation, trusted reliability, and dedicated support for customers/partners worldwide.

From pioneering solutions in aggregates and mining to advancing technologies in construction and demolition (C&D) recycling applications, the sixth-generation family-owned company has remained a driving force in helping industries evolve, operate more efficiently, and build a more sustainable future.

From humble beginnings in Hollidaysburg, Pennsylvania, McLanahan have grown into a global OEM leader in wet processing, setting industry standards in the design and supply of advanced recycling equipment, solutions, and technologies for the quarrying, construction, and mineral processing sectors.

Last month [September], the company and aggregates producer SunEnviro welcomed more than 100 visitors to an open day in Thetford, Norfolk. The successful event attracted customers, dealer partners, industry specialists, and trade press, all keen to see a new McLanahan C&D waste-recycling plant in action.

Guided tours gave attendees a close-up view of the Thetford facility at full capacity, whilst a series of technical presentations highlighted the system’s innovative design, performance, and sustainability credentials. Importantly, the open day underlined McLanahan’s and SunEnviro’s commitment to innovation and their role in driving the transition towards a more circular, resource-efficient construction sector.

Commissioned at the start of the year, the state-of-the-art aggregate washing plant is the latest addition to SunEnviro’s expanding network of recycling sites across the East of England.  The recycling facility can process up to 100,000 tonnes of construction, demolition, and excavation waste annually, delivering a consistent output of premium recycled aggregates and sand products.

All materials meet the requirements of British Standards (BSE 9321), ensuring suitability for a wide range of construction applications and providing a dependable, sustainable alternative to primary quarried resources. Mat Stewart, managing director of SunEnviro, described the launch of the bespoke McLanahan C&D waste processing system as a major milestone in the company’s sustainability journey and a clear statement of intent for the future.

‘By diverting significant volumes of waste from landfill and reintroducing them into the supply chain, the facility not only supports the circular economy but also helps reduce the environmental footprint of construction projects throughout the region,’ said Mr Stewart.

‘We aim to support customers in transforming waste into a resource by delivering high-quality recycled sand and aggregates that local and regional construction markets rely on. By investing in McLanahan’s innovative technology, we demonstrate a firm commitment to a more sustainable future. The open day was an excellent opportunity to showcase this partnership and exhibit the capabilities of our latest recycling solutions.’

From waste to worth

The customer showcase gave visitors a clear look at how to strengthen their recycling processes, from high-efficiency waste processing and water recycling to live demonstrations tackling trommel fines and other challenging waste streams.

With a focus on high-quality output and sustainability, SunEnviro’s new Thetford facility has been built to divert 40,000–50,000 tonnes of C&D waste from landfill each year, driving the circular economy and cutting the environmental impact of conventional aggregate production.

At the core of the operation are several highly engineered processing units. A McLanahan UltraSCRUB system offers robust, high-efficiency washing, ensuring the removal of fines and contaminants while maintaining aggregate quality. Complementing this, an UltraSAND unit provides precise sand recovery with minimal water use, enabling resource-efficient aggregate production. An HRT10 thickener integrates smoothly into the process, facilitating optimal water recycling and sludge management, which supports full site circularity.

The C&D washing plant’s environmental performance is further enhanced by a state-of-the-art filter press, which can convert up to 40 tonnes of liquid silt slurry into dry, pressed cake in 90min – reducing waste handling, reclaiming valuable water, and supporting a circular economy across East Anglia.

The high-capacity silt press uses advanced filter press technology to separate solids and liquids from slurry waste generated during the aggregate washing process. The resulting pressed silt cakes are repurposed in applications such as road sub-base layers and pond lining, converting what was once a waste stream into a valuable, reusable material.

‘The plant investment goes beyond operational efficiency; it’s about taking responsibility for how we manage resources,’ remarked Mr Stewart. ‘By rapidly transforming silt into a high-quality, sustainable product, we’re making significant progress in water conservation while playing a key role in the circular economy across the East of England.’

One of the biggest challenges in commissioning the McLanahan plant setup on site was the limited space. The Thetford site’s compact footprint posed a significant planning challenge for McLanahan’s engineers, requiring precise layout and co-ordination.

To optimize both workflow and space, the waste-washing plant has been configured in an ‘L’-shaped arrangement, with the various processing units strategically positioned along two sides of the site. This design allows ample room for feed material while simultaneously providing clear zones for clean, sorted end-products, thereby maximizing throughput and efficiency.

With the ability to recover up to 100,000 tonnes of material annually from C&D waste, excavation spoil, and trommel fines, SunEnviro’s new Thetford plant is playing a vital role in unlocking feedstock value by producing a wide range of washed and graded recycled sand and aggregate products for local construction, infrastructure, and landscaping markets under the company’s SunAggregates brand.

Around half of the plant’s feedstock is made up of crushed rubble, with the other half comprising trommel fines. These inputs are processed into a consistent range of end-products, including 0–4mm recycled sand, as well as 4–10mm, 10–20mm, and 20mm+ recycled aggregates.

Leading globally, delivering locally

While North America continues to serve as McLanahan’s home market, the company has been steadily extending its global reach in recent years. Europe, in particular, has emerged as a region of increasing importance, with the business making substantial investments and building a strong local presence to meet rising demand.

‘We are really excited about what’s happening in Europe and the momentum we are seeing in the market,’ said Sean McLanahan, chief executive officer of McLanahan Corporation. ‘In recent years, we’ve made a significant investment in the region, building up our infrastructure and our team, and today we employ more than 100 people across the UK and mainland Europe. That investment has given us a solid foundation to support customers locally and to grow in the areas that are most important for the future of our industry.’

Over the last three decades, McLanahan have come a long way in the quarrying and wider construction sector, and the family-owned company’s evolution is testament to its enduring vision and steady growth. The purchase of the equipment division of Linatex North America in 2001 marked a pivotal step for McLanahan.

Formerly known as LPT Group, the equipment line strengthened the foundation of the company’s aggregate processing capabilities, which today includes a full range of washing, classifying, crushing, and screening equipment, alongside cyclones, separators, and assembled slurry pumps.

In 2003, the business entered a new era with the opening of its first international offices in Newcastle and Brisbane, Australia, building on relationships forged in the 1960s. Today, these sites house corporate, engineering, and sales teams, supplying mineral and aggregate processing equipment, as well as bulk material sampling solutions for the wider Asia–Pacific market.

Looking to establish a presence in the UK and broader European markets, McLanahan’s first European office was later set up in south-east England, providing custom-engineered processing solutions and direct support to mineral and aggregate operators throughout the continent.

‘Expansion through acquisition has also played a central role in our growth,’ highlighted Mr McLanahan. ‘The purchase of Anaconda Equipment in Northern Ireland brought us a strong line of mobile tracked equipment – from scalping and screening to recycling and conveying.

‘Before that, we made several key strategic acquisitions, including Universal Engineering Corporation and Eagle Iron Works – a long-time competitor with a strong reputation for durable, high-quality washing and classifying equipment. With each acquisition, we’ve not only strengthened our product portfolio but also carried forward the legacy of durability, quality, and first-class support that customers expect from us.’

Providing market-leading customer support remains a pivotal part of the company’s business, and it is central to building long-term customer partnerships. McLanahan place as much emphasis on service and after-sales care as they do on equipment design and manufacturing, ensuring operators have access to the technical expertise, spare parts, and responsive back-up they need to keep plants running efficiently.

With strategically located offices across the Americas, Australia, and the Asia–Pacific region, McLanahan can deliver localized support on a truly global scale. In the UK, recent major investment in state-of-the-art production facilities at Ardboe, Co. Tyrone, underlines the company’s long-term commitment to the UK and European materials processing market.

‘Rising global demand for McLanahan’s aggregate systems equipment portfolio makes this investment particularly timely,’ said Mr McLanahan. ‘The expanded capacity in Northern Ireland – including our centre of excellence with Anaconda – will deliver higher quality, improved sustainability, faster lead times and greater productivity, all in line with McLanahan’s core commitment to customer satisfaction.

‘Coupled with the acquisitions of CMB International, RubbleCrusher, and Diefanbach, we can now deliver everything for the UK/European market from modular units to full plants – complete with washing, scrubbing, classifying, and tailings solutions, including water treatment and oversize crushing.’

Alongside its expanding global footprint, the company is continually broadening and diversifying its product portfolio. Cory Jenson, executive vice-president of sales and business development at McLanahan, told QM: ‘Research and development lie at the heart of our future. Central to this approach is a relentless commitment to innovation – driving us to further improve existing technologies, refine processes, and develop solutions that respond to the changing demands of the construction and mineral products sector.

‘For McLanahan, two market segments stand out as global growth drivers for the business – C&D waste recycling and water management/tailings. Both are becoming increasingly important for operators facing the twin pressures of meeting sustainability targets and tightening environmental regulations.’

McLanahan’s innovations and applications will no doubt unlock new opportunities across the quarrying sector, as operators increasingly recognize the value and versatility of the company’s wet-processing technologies and systems. Beyond traditional mining, McLanahan equipment is being applied in aggregates, industrial sands, environmental remediation, and C&D waste recycling.

‘We are very optimistic about the huge potential the UK market presents,’ remarked Mr McLanahan. ‘With the right infrastructure and expanded capacity now firmly in place, we are well-positioned to consolidate and grow our presence – not only domestically in North America – but also in key, growing export markets such as Britain and mainland Europe.

‘We are largely on track with what we set out to achieve in our UK growth strategy. The ultra-modern McLanahan-Anaconda manufacturing headquarters in Co. Tyrone provides an exceptional base from which to expand and further develop our business and workforce in the region.’

Mr Jenson added: ‘The expanded production capacity, paint shop, warehousing, and office facilities position us to respond effectively to a rapidly evolving aggregates market, where customers increasingly expect plant equipment that is bespoke, advanced, safe, and environmentally responsible.

‘Last year we achieved our highest-ever turnover in the UK market, and we expect sales across the McLanahan family of brands to grow even further in the years ahead. Our goal over here has always been to deliver a consistent, first-class service while developing innovative products and solutions that fuel future growth. With the resources, capacity, and comprehensive range of industry-leading equipment now in place, we’re ready to turn that ambition into reality.’

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