Project

Sawgrass Substrates

Custom composting installation in Northern Ireland
Composting
Klant
Sawgrass Substrates
Locatie
Northern Ireland
Periode
2014-2019
Projecttype
Composting Installation
5 bunkers
for phase 1 composting
21 tunnels
for phases 2 and 3 composting
1000 tons
of matured compost per week
200 truckloads
from Venlo to Northern Ireland

The Challenge

Sawgrass Substrates wanted to increase control over their supply chain by producing compost in-house for their mushroom cultivation. The Ballygawley site, however, presented several technical challenges that required a creative approach.

Specific challenges:

  • Topography: Significant elevation differences required earthworks
  • Space limitations: Available plot allowed only a limited building length
  • Indoor requirement: The entire composting facility had to be installed indoors
  • Logistical needs: Direct loading from tunnels onto trucks without intermediate storage
  • Material logistics: Optimal balance between locally available and imported components

The GTL Approach

GTL’s solution-oriented approach made the difference. Where others proposed standard solutions, we designed a fully customized system.

Innovative design choices:

  • Custom filling cassette: A narrower fill-entrance required a cassette with 5 belts instead of the standard 4, enabling direct loading
  • Site-optimized layout: Minimal earthworks using natural elevation differences
  • Future-proof planning: Expansion capability incorporated despite space limitations
  • Local integration: Careful selection of materials based on local availability
"Thanks to our approach, we realized a system perfectly aligned with Sawgrass Substrates’ requirements despite the complex constraints. The result is a highly productive compost facility that serves as a reference for the entire sector."
Jack Lemmen
CEO

The Project Timeline

Timeline: 2014 – 2019 (5 years from first contact to start-up)

  • 2014: Initial contact and concept development
  • 2014–2016: Pre-project phase including permitting procedures
  • 2017–2019: Engineering and construction
  • Early Q2 2019: Successful start-up

The longer pre-project phase was mainly due to complex permitting procedures, in which we fully supported the client.

Immediate results

  • High-quality compost production from day one
  • Full control over quality and timing
  • Significant cost savings through in-house production

 

Partnership in Practice

GTL’s involvement extended beyond delivery and installation. We ensured a seamless transition to independent production:

  • Intensive guidance: GTL specialists on-site for months during start-up
  • Knowledge transfer: Extensive training of the local team
  • Continuous optimization: Weekly contact for process improvement

From Junior Project Leader to Expert: Learning on the Job

At GTL, we believe the best way to learn is by doing. Our junior project leader, Jip, gained hands-on experience during the construction phase at Sawgrass in Northern Ireland, working as both technician and foreman.

By working on-site for several months, he gained insight into the technical challenges and project execution – from foundations to fine-tuning. Back in the Netherlands, Jip could immediately apply his knowledge as a full-fledged project leader for new assignments. This is a prime example of how we develop junior talent by giving them responsibility in challenging projects.

Our Added Value

GTL added value at every stage of the project:

  • Concept Phase: Creative solutions for complex spatial challenges
  • Engineering: Customized design tailored to local conditions
  • Permits: Full process management
  • Execution: Professional project implementation, including 200 transports
  • Start-up: Intensive guidance to ensure optimal performance
  • Aftercare: Ongoing partnership for further optimization