CASSWELL ECO GREEN COMPOST TARGETS GROWTH WITH NEW INDUSTRIAL PLANT
A pioneering company developing a new peat-free compost is set for growth after completing a six-figure investment.
Lincolnshire farmer, James Casswell, diversified into producing peat-free compost in 2022 and last month made a substantial investment in a new packing line at his Louth farm to meet demand.
In just four years, James has seen demand for his Casswell Eco Green Compost brand increase from fewer than a hundred bags per week to over 17,000!
The popularity of the natural fertiliser among gardeners across the UK looking for alternatives to peat-based composts caught the eye of several national retailers, including British Garden Centres, leading to a rapid and significant increase in demand. As a result, James needed to invest in a new packing facility to keep up.
Having outsourced his packing to a local contractor who used a bespoke packing line developed by Haith Group, it made sense to approach the Doncaster-based manufacturer for help.
“The guys at Haith really know their stuff, and it was clear from day one that they could design and install a packing line that would be up and running quickly,” says James. “This was critical as we were talking to British Garden Centres at the time about an extremely large order with a very short delivery time.
“Despite not having a signed agreement in place, I decided to invest in the new plant and Haith, along with its partner GIC, which make the vertical form fill and seal packing machine that puts the compost in the bag the compost in the bag. The installation was completed in January this year and the order from British Garden Centres was placed in February, perfect timing you might say!”
Based on the mobile bagging line developed by Haith’s material handling team with GIC in 2010, James’ new packing line features a receiving hopper onto which compost is placed. It then moves along specially designed conveyors with vibratory side panels to loosen the compost before it arrives at an overhead weigher, which deposits 20kg into the GIC5100 vertical form fill and seal packaging machine.
The latest version of the GIC5100 incorporates Allen-Bradley servo drives and controllers, SMC pneumatic components, and an improved design for greater mechanical robustness. GIC has also redesigned the jaw motion and added twin servo transport belts for improved jaw and film control.
The GIC5100 is equipped with a thermal printer, so bags ranging from 5 to 60kg can be date-stamped or barcoded as needed.
The packed bags of compost are transferred from the GIC to the palletising area, where James’ team handle the final stage of production.
“Having the new packing line has made a massive difference,” says James. “There are only five of us on the farm, one of whom is full-time on the compost side of our business. The rest of us split our time between Casswell Eco Green Compost and running the farm, which, as well as growing the raw materials for the compost, grows cereals, oilseed rape, beans, peas and barley on 1,300 acres of Lincolnshire land near Louth.
“My family are relatively new to farming, with my dad and grandad buying the farm in 1979 and things have changed a lot since then and especially in the years since the war in Ukraine started, which was when the price of fertiliser went through the roof, and I started to investigate how I could save some money by cooking my own compost.
“That was the start of two years of research and development, in which time we added beekeeping, green crops and sheep to the farm, and it is the by-products of these developments that fuel the compost side of the business, which is now a completely closed loop, which is important to me.”
Paul Ramplin, technical sales manager at Haith, oversaw the design and installation of the new packing line and can see similarities between the two companies. Haith has a reputation for innovation and was established 80 years ago by Mr George Haith, who had a passion for mending and improving machines as well as designing and manufacturing new ways of doing things. James is from a similar mould and has developed an innovative product that helps protect traditional peat supplies while delivering the same, or even better, nutrition for plants without harming the environment.
“We wish James and Casswell Eco Green Compost all the best for the future, and we know that the packing plant we’ve designed and installed will keep up with demand for many years to come.”
