Mobile screening equipment is playing an increasingly important role in Australia’s waste and recycling sector, particularly as operators seek flexible solutions that can process a range of materials. The latest example is the Ecostar Nhexa mobile screener, which is now being demonstrated across the country by CSS Recycling in partnership with equipment distributor Onetrak.
Designed as a compact and robust screening solution, the Nhexa combines established disc-screening technology with a mobile platform. The unit is mounted on tracks and built as a self-contained diesel hydraulic machine, allowing it to be easily deployed on different sites without the need for fixed infrastructure. This mobility is a key consideration for operators working across multiple waste streams or locations. Then there is the hardiness of the machine.
“The Nhexa is a five-metre screen deck with hexagonal Hardox steel discs working like other Ecostar screens and similar star screen technology,” said Neil Coyle, business manager for CSS Recycling. “Because those discs are made from Hardox steel, they have a much higher wear life.”
Unlike some traditional star screen systems that use plastic or rubber components, the steel discs on the Nhexa are intended to provide a longer operational life. This reduces the frequency of replacement and helps keep maintenance requirements manageable over time. The result is a machine that emphasises ruggedness and reliability while maintaining consistent screening performance.
Another key feature is the integration of Ecostar’s anti-wrap system. This proprietary design is built into the screening module and allows the machine to handle materials that would typically cause problems for conventional screening equipment. Items such as rope, plastic bags, and strapping can often wrap around screening components and reduce efficiency, but the anti-wrap manifold is designed to minimise this issue and keep the machine operating smoothly.
The overall layout of the screening deck works in a similar way to a conveyor. Material is fed onto the deck and moves across the rotating discs at a steady speed. As the material travels, smaller particles fall between the discs according to the selected screening size, while larger material continues along the deck to the oversize discharge. The Nhexa is configured to produce two fractions, allowing operators to separate fines from oversize material in a single pass.
Designed for organic processing
While the Nhexa is capable of processing a variety of materials, its current demonstration program in Australia is focusing heavily on organics. The machine being used on the demonstration tour is fitted with discs that include a specialised compost cleaning tooth, which is particularly useful when screening wet or sticky materials.
Organics processing can present challenges for traditional screening systems. Wet compost, mulch, and soil often bind together and block screening holes, reducing efficiency and forcing operators to stop work until conditions improve. The cleaning tooth system on the Nhexa is designed to address this issue by actively clearing material from the discs during operation. Coyle explained that the cleaning tooth works as a self-cleaning mechanism within the screening deck.
“The cleaning tooth works by scraping the disc next to it as it rotates,” he said. “That tooth cleans the next disc of any material sticking to it, and that disc then helps keep the next one clean as well.”
This approach allows the screening deck to remain open and functional even when handling damp or sticky material. As a result, the machine can continue working in conditions that would often slow down or stop other screening technologies.
Although organics are a key focus for the current demonstrations, the machine has been designed with versatility in mind. The aforementioned anti-wrap system allows it to handle materials beyond compost and green waste, including municipal solid waste and other mixed waste streams. This flexibility means operators can adapt the machine to different applications depending on their operational needs. For facilities that deal with several waste streams, the ability to switch between materials without major adjustments can be an advantage.
High throughput and practical operation
Performance is another area where the Nhexa is intended to stand out. During demonstration trials, the machine has been used to process shredded green waste and other organic materials, delivering high throughput under real operating conditions.
“The throughput always depends on the material you are putting through,” Coyle said. “When we were shredding green waste and feeding it straight into the screen, we were processing about 50 tonnes an hour. In general terms, it was pushing out around a tonne a minute. When we tested soil mixed with compost, we were getting closer to 180 tonnes an hour because that material is denser than shredded green waste.”
Like most mobile processing equipment, maintenance requirements are influenced by the type of material being handled. The diesel engine requires regular servicing at standard intervals, while other components such as chains and drive systems are inspected as part of routine maintenance.
The wear characteristics of the steel discs play an important role in overall service life. Compared with softer materials used in some screening systems, the Hardox steel discs are designed to last longer before replacement is required.
“Star screens often use plastic or rubber stars, so those components wear out much faster,” Coyle said. “With the Hardox steel discs you can get a longer life.”
For operators considering mobile screening solutions, the Nhexa represents a balance between durability, throughput, and operational flexibility. Its mobile design allows it to be moved between sites, while the screening technology can handle both organics and mixed waste streams.
As Australia’s recycling and resource recovery sector continues to evolve, equipment that combines rugged construction with adaptable performance is likely to play an increasingly important role. With its steel disc system, anti-wrap technology, and self-cleaning features, the Ecostar Nhexa has been developed to meet those demands while supporting efficient material separation across a range of waste processing environments.