From Idea to Impact: The Story of SortFlow OPS

We’re excited to announce the launch of SortFlow OPS, our new cloud-based application bringing downtime management and production reporting together in one seamless, easy-to-use system for waste processing facilities. This journey has been a truly collaborative effort, shaped by real operational needs and insights from industry partner Grundon.

The Challenge

At Grundon’s Colnbrook Material Recovery Facility (MRF), the team faced an all-too-common industry problem: daily operational issues—like breakdowns, delays, and blockages—were slipping through the cracks of traditional reporting systems. These undocumented setbacks made it difficult to understand their true impact, identify recurring patterns, or assign real costs, leaving teams in the dark about where improvements were needed most.

As Keith Knox, Plant Manager, notes:

“Before SortFlow OPS, it felt like we were always catching up—fixing problems after the fact instead of finding out why they kept happening. We were good at firefighting but not at finding out where the sparks were coming from.”

Discovery

The journey with SortFlow began as Grundon searched for a simple, flexible system to record sampling data in line with the MRF Code of Practice for EA compliance. SortFlow through their sampling application, SortFlow IO, ticked that box effortlessly—but it also opened the door to much more. Alec Powell, Grundon’s General Manager – Resource & Recovery, quickly saw potential beyond its original scope, imagining a solution that could shine a light on the everyday issues hidden from standard reporting.

Collaboration & Development

A collaborative partnership took shape as we worked closely with Alec and the Grundon team to co-develop SortFlow OPS—a tool built for the realities of busy waste processing plants. Together, we created a system that captures the full story: unplanned downtime, manual interventions, blockages, cost impacts, emergencies, and everything traditional systems tend to miss. The result is a digital platform designed not just to record data, but to uncover it.

Impact

Since introducing SortFlow OPS at Colnbrook, the change has been clear. The team was able to pinpoint a recurring fault in a key piece of equipment—an insight that wouldn’t have surfaced without this new approach. By identifying the trend early, they avoided extra costs and costly unplanned downtime. Now, tracking issues, assigning costs, and analysing trends is woven into everyday decision-making and maintenance planning.

As one of the shift supervisors shared:

“Now if a machine goes down, we log it straight away and it’s all there—what happened, how long, and what it cost us. It’s not just for the managers—everyone can see the bigger picture. It’s made us feel part of the solution.”

And in Alec Powell’s words:

“SortFlow OPS has given us something we’ve never had before—true visibility into the daily workings of our plant. It captures the things that traditional reporting systems miss: breakdowns, delays, and the real cost of downtime. Working with the SortFlow team to develop this tool has been a game-changer. It’s exciting to finally have a system that doesn’t just record data—it tells
the story behind it. SortFlow OPS is now central to how we manage, plan, and improve our operations.”

The Road Ahead

SortFlow OPS is only at the beginning of its journey. We’re actively working on new features, including the ability to log and track maintenance activities, more advanced production reporting, and a dedicated calendar to monitor everything happening across the plant. These enhancements—alongside automatic plant equipment data integration—ensure SortFlow OPS continues to evolve, supporting teams with clearer insights, smoother operations, and the tools they need for ongoing improvement.

SortFlow Limited, 06/10/2025