Background

Solutions for the biomass industry have become a core focus of our business, though this is far from a new development. In 2019, we were commissioned to develop an attachment specifically for harvesting two-year hedge growth to serve as fuel for a biomass heating system. The customer sought to determine if this material could be a viable and sustainable energy source for their setup.

While hedge-cutting attachments were already available on the market, they lacked the capability to both harvest the material and cut it to a uniform size. This necessitated the creation of a bespoke solution.

The project was commissioned by a private client in Southwest England, with development funding provided by a government renewable energy grant.

Design and Development

This unique project had no comparable products on the market at the time, requiring our R&D team to start from scratch. After detailed discussions with the client to understand their objectives and requirements, our team quickly developed an initial concept. This design was refined over several stages to produce the final product.

The Product

The hedge harvester system was designed to be mounted to a tractor, with the cutting head fitted to the front loader arm and the collection system at the rear. Steel stars rotated at high speed, removing material from the hedge and pulling it into a collection system. This simultaneously cut the material down into uniform 25mm pieces, ready for the biomass system.

Just like our Gyru-Star screening buckets, the cutting head was hydraulicly driven, from the tractor’s auxiliary circuit, with carbon belts connecting the motors to the shafts. Unlike our screenings, however, the stars were made from steel, with each finger individually replaceable.

As this project was completely experimental, our R&D wanted a way to quickly replace the stars should they be damaged.

A bespoke Kustom Konnect arm was also fabricated for the product, providing the lateral adjustment and extended reach for the cutting head.

The collection system at the rear of the tractor used a vacuum system, powered by a small petrol engine. This was connected to an adjustable hopper, allowing the material to be loaded directly into a trailer.

Manufacturing

As with all Wheatway Solutions products, the hedge harvester was designed and manufactured entirely in-house at our Gloucestershire facilities. This included all fabrication, machining, and assembly, ensuring total control over quality and precision.

Compliance and Technical Documentation

Before delivery, the hedge harvester required UKCA and CE certification to confirm compliance with all relevant safety and regulatory standards. CE certification was also essential for potential export to Europe.

Our in-house team managed every aspect of the certification process, including creating all necessary technical documentation. This capability allowed us to deliver a bespoke, market-ready solution without delay.

Real-World Testing and Design Evaluation

Our team was onsite during the initial testing phase, guiding the customer through setup and operation. These initial tests were highly successful, with the hedge harvester functioning as designed and meeting all project requirements.

Do You Need a Bespoke Industrial Solution?

Sometimes, you face challenges that don’t have an ‘off-the-shelf’ solution — and these are the problems we specialise in solving. We collaborate closely with customers across a variety of global industries to design, manufacture, and deliver innovative solutions to their most pressing challenges.

If you’d like to discuss a project, please contact our team at sales@wheatway.com. If you’d like to discuss a project, please contact our team at sales@wheatway.com.