Lindner Micromat 2500: High-Performance Carpet Recycling for Equestrian Surfaces
When your shredding machine is holding back production, choosing the right replacement can transform your entire operation.
That was exactly the challenge faced by Equestrian Surfaces Ltd, a specialist manufacturer of synthetic riding surfaces based in Burnley, Lancashire.
The company required a reliable industrial shredder capable of processing full-size pieces of carpet down to approximately 30 mm, while delivering the throughput needed to support its production operation.
After extensive trials and consultation with Mach Tech Services, Equestrian Surfaces selected the Lindner Micromat 2500.
The results demonstrated the difference that selecting the right shredding technology can make.
The machine was producing approximately 2 tonnes of shredded carpet per hour, significantly improving on the performance of the company’s previous shredder.
The Challenge: Increasing Carpet Shredding Throughput
Equestrian Surfaces manufactures synthetic riding surfaces used in equestrian arenas and ménages.
As part of its manufacturing process, the company processes carpet material and reduces it to a controlled fibre that can be incorporated into its riding surfaces.
The required output was approximately:
30 mm and below
However, the company’s previous shredder wasn’t delivering the required throughput.
The machine had been supplied with a promised throughput of approximately 3.2 tonnes per hour, but actual performance was considerably lower.
According to Production Manager David Jolliffe, the previous machine averaged around:
800 kg per hour
Even under particularly favourable conditions, it achieved only around 1.3 tonnes per hour.
For a growing manufacturing operation, this created a significant bottleneck.
Finding a Better Carpet Recycling Shredder
With the existing machine unable to deliver the required production rate, Equestrian Surfaces began looking for an alternative.
The company investigated different shredding technologies and spoke to blade and machinery suppliers to determine what would provide the best performance.
Lindner was repeatedly recommended as a leading manufacturer of industrial shredders.
This led Equestrian Surfaces to Mach Tech Services, Lindner’s UK partner.
However, following the disappointing experience with the previous machine, the company was understandably cautious.
The team didn’t want another machine based purely on promised specifications.
They wanted to see the performance for themselves.
Extensive Trials Before Investment
Mach Tech took a different approach.
Rather than simply making claims about what the Micromat 2500 could achieve, the team carried out extensive trials and compared the results against the existing equipment.
This allowed Equestrian Surfaces to assess the machine’s actual performance before committing to the investment.
The results were compelling.
Mach Tech was confident enough in the Lindner Micromat 2500 to offer a performance guarantee: if the machine failed to achieve the agreed tonnage, Mach Tech would take it back.
That level of confidence helped give Equestrian Surfaces the reassurance it needed to proceed.
The Lindner Micromat 2500
The Lindner Micromat 2500 is a single-shaft industrial shredder designed for demanding recycling and waste-processing applications.
The Micromat range is designed around flexibility, allowing machines to be configured according to the material being processed and the required output.
Applications can include:
- Carpet
- Textiles
- Plastics
- Paper
- Cardboard
- Film
- Waste wood
- Production waste
- Secure document destruction
Mach Tech’s current Micromat range includes the Micromat 1500, 2000 and 2500, alongside HP versions of the machines.
For Equestrian Surfaces, the Micromat 2500 provided the combination of throughput, reliability and controlled particle sizing the business required.
Processing Carpet Down to 30 mm
The primary requirement for Equestrian Surfaces was straightforward:
Take full-size pieces of carpet and reduce them to approximately 30 mm.
The shredded material is then used as part of the manufacturing process for synthetic riding surfaces.
The Micromat’s cutting and screening configuration allows the machine to produce a controlled output fraction suited to the application.
This is particularly important when shredded material becomes part of another manufactured product.
The size and consistency of the recycled material need to be predictable.
2 Tonnes Per Hour of Carpet
The most important measure for Equestrian Surfaces was throughput.
The Lindner Micromat 2500 was achieving approximately:
2 tonnes per hour
In a typical 12-hour shift, this equates to approximately:
20 tonnes of material
The machine could also operate for extended periods, with the original case study reporting occasions where it ran for up to 24 hours continuously.
Compared with the previous machine’s average of approximately 800 kg/hour, the improvement represented a substantial increase in usable production capacity.
From 800 kg/hour to 2 tonnes/hour
The difference in performance is particularly significant when comparing the two machines.
| Previous Shredder | Lindner Micromat 2500 | |
| Typical throughput | ~800 kg/hour | ~2 tonnes/hour |
| Best reported throughput | ~1.3 tonnes/hour | ~2 tonnes/hour |
| Required output | ~30 mm | ~30 mm |
| Continuous operation | Limited by maintenance | 12-hour shifts / extended operation |
| Application | Carpet processing | Carpet processing |
The key point isn’t simply that the Micromat produced more tonnes per hour.
It delivered the required output while allowing Equestrian Surfaces to streamline its production process and reduce the time spent operating and maintaining the shredder.
Reduced Maintenance Requirements
Throughput was only part of the problem with the previous machine.
Equestrian Surfaces also experienced significant maintenance demands.
The previous shredder required blade checks at the beginning of every shift because blades could become loose.
It also required a full maintenance routine every week.
The Lindner machine introduced a considerably more straightforward maintenance regime.
The customer reported that blade checks were carried out every 24 hours according to the machine’s monitoring system, while lubrication requirements were monitored by the shredder itself.
This meant maintenance staff could monitor the machine more efficiently.
More Production with Fewer Shifts
The improved throughput and easier maintenance also changed how Equestrian Surfaces could operate its production process.
Previously, the company had been operating its competitor’s machine 24 hours a day, six days a week, with one person per shift.
The Lindner machine allowed the company to achieve the same level of production with a much more streamlined operating schedule.
The original customer case study reported that the business was able to operate the shredder for 12 hours a day, five days a week, while producing the same amount of product.
This is a good example of why shredder performance should be measured by more than simply the machine’s headline throughput.
Energy, labour, maintenance and machine availability all contribute to the real cost per tonne.
Why Shredder Efficiency Matters
For manufacturers using recycled material as part of their production process, the shredder can become a critical part of the production line.
If the shredder doesn’t produce enough material, the rest of the manufacturing process can be affected.
Poor shredding performance can lead to:
- Production bottlenecks
- Increased labour requirements
- Longer operating hours
- Higher energy consumption
- Increased maintenance
- Reduced output
- Unplanned downtime
By selecting a machine that can comfortably meet the required throughput, businesses can create additional production capacity.
A Future-Proof Shredding Solution
Equestrian Surfaces also wanted a machine that could accommodate future requirements.
The Lindner Micromat 2500 was configured with the ability to accommodate future upgrades.
This gave the company flexibility to increase or modify its shredding capabilities as its production requirements developed.
For a significant capital investment, having the ability to adapt the machine over its working life can be an important consideration.
Installation Without Major Disruption
Installing an industrial shredder can potentially cause significant disruption to an operating site.
Equestrian Surfaces initially expected to shut down around 50% of its yard for a week to accommodate the installation.
However, Mach Tech’s installation team was able to work around the company’s existing operations.
The installation was completed within the planned one-week timeframe, with cranes and lifting equipment arranged by Mach Tech.
The company was able to begin shredding with the new machine on the Monday morning following installation.
This demonstrates the importance of having an experienced engineering team behind the machine.
Installation Is Only the Beginning
Buying a shredder is a major investment.
The support provided after the machine arrives is equally important.
Mach Tech supports customers throughout the machine’s working life with:
- Installation
- Commissioning
- Operator training
- Preventative maintenance
- Breakdown support
- Knife replacement
- Knife gapping
- Wear-part replacement
- Engineering support
- Precision engineering
- Welding
- Hardfacing
- Shredder rebuilds
For Equestrian Surfaces, the ongoing support from Mach Tech formed an important part of the overall package.
The customer reported that Mach Tech engineers continued to make adjustments and optimise the machine based on operational feedback.
Why Choose the Lindner Micromat 2500 for Carpet Recycling?
The Equestrian Surfaces case study highlights several advantages of using the Lindner Micromat 2500 for carpet recycling.
High throughput
Approximately 2 tonnes per hour in the application described.
Controlled output
The machine processes carpet down to approximately 30 mm.
Reliable operation
Designed for demanding industrial applications and extended operating periods.
Easier maintenance
Machine monitoring and accessible components can simplify routine maintenance.
Flexible configuration
Rotor, knife and screen configurations can be selected according to the application.
Engineering support
Mach Tech provides installation, maintenance and ongoing technical support.
Carpet Recycling with Lindner Shredders
The Equestrian Surfaces installation is one example of how Lindner shredders can be used for carpet recycling.
Mach Tech has supplied Lindner Micromat shredders to a number of customers operating in the equestrian surfacing industry.
A separate Mach Tech application example describes a Micromat 2000 processing carpets at approximately 2 tonnes per hour, producing a finished fraction below 50 mm, predominantly in a fluffy fibre form.
This demonstrates the versatility of the Micromat platform across different carpet-processing requirements.
More Than a Carpet Shredder
Although the Equestrian Surfaces project demonstrates the Micromat’s capabilities for carpet processing, the machine isn’t limited to one application.
The current Lindner Micromat range is designed for a broad range of materials and can be used in applications including:
Plastics Recycling
Processing plastic waste into controlled fractions for further recycling.
Waste Wood Processing
Reducing waste wood into a suitable size for downstream processing.
Paper & Product Destruction
Processing paper, confidential documents and other products requiring controlled size reduction.
Alternative Fuels
Preparing suitable waste streams for fuel production.
Metal Recycling
Supporting size reduction processes within wider metal recycling systems.
Genuine Parts and Rapid Engineering Support
Even the most reliable industrial shredder will eventually require maintenance and replacement wear parts.
That’s why Mach Tech maintains over £1 million worth of spare and wear parts in stock.
If you need parts quickly, many components can be dispatched the same day.
For recycling and manufacturing businesses, this can make a major difference when a machine is down.
The objective is simple:
Reduce downtime. Protect production. Keep your shredder working.
The Result: A Shredder That Delivered
Equestrian Surfaces’ experience demonstrates the importance of selecting shredding equipment based on real-world application requirements rather than headline specifications.
The company needed:
- Approximately 30 mm output
- Increased throughput
- Reliable operation
- Reduced maintenance
- Long operating periods
- Responsive engineering support
The Lindner Micromat 2500 delivered a solution that met those requirements.
The machine was producing approximately 2 tonnes per hour, allowing Equestrian Surfaces to significantly streamline its shredding operation.
As David Jolliffe, Production Manager at Equestrian Surfaces, concluded, the Micromat was an extremely powerful machine that met the company’s requirements.
Mach Tech Services, Lindner Shredders in the UK & Ireland
Mach Tech Services is the sole distributor of Lindner Recyclingtech shredders in the UK and Ireland.
We provide complete shredding solutions from initial application assessment and machine selection through to installation, commissioning, maintenance, repairs and spare-parts supply.
Whether you’re processing carpet, plastics, wood, paper, textiles or other difficult waste streams, our team can help identify the right shredding technology for your application.
With over £1 million of spare and wear parts held in stock, we can also provide rapid support when replacement components are required.
Need a better-performing shredder?
📞 01706 838246
✉️ sales@machtechservices.com
Frequently Asked Questions
What is the Lindner Micromat 2500?
The Lindner Micromat 2500 is a large single-shaft industrial shredder designed for demanding recycling and waste-processing applications. It can be configured for materials including carpet, plastics, paper, wood and textiles.
Can the Lindner Micromat 2500 shred carpet?
Yes. The Micromat 2500 has been used by Equestrian Surfaces to process full-size pieces of carpet for use in synthetic riding surface production.
How much carpet can the Micromat 2500 process?
In the Equestrian Surfaces application, the Micromat 2500 was producing approximately 2 tonnes per hour. The machine could operate during 12-hour shifts and, on occasions, for up to 24 hours continuously.
What size does the Micromat 2500 shred carpet to?
Equestrian Surfaces required material to be processed to approximately 30 mm and below for incorporation into its synthetic riding surfaces.
How did the Micromat 2500 compare with the previous shredder?
The previous machine averaged approximately 800 kg per hour, reaching around 1.3 tonnes per hour under particularly favourable conditions. The Micromat 2500 was producing approximately 2 tonnes per hour in the application described.
Is the Micromat 2500 suitable for continuous operation?
The machine is designed for demanding industrial applications. In the Equestrian Surfaces case study, it operated for 12-hour shifts and occasionally for up to 24 hours continuously.
What other materials can the Micromat shred?
Depending on configuration, the Micromat range can process plastics, paper, cardboard, film, textiles, carpet, wood and other industrial waste streams.
Does Mach Tech install Lindner shredders?
Yes. Mach Tech provides installation and commissioning services across the UK and Ireland.
Does Mach Tech provide shredder maintenance?
Yes. Services include preventative maintenance, knife gapping, wear-part replacement, repairs, engineering support and full shredder rebuilds.
Does Mach Tech stock Lindner spare parts?
Yes. Mach Tech holds over £1 million worth of spare and wear parts in stock, with many parts available for same-day dispatch.
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