The Thorntons Dunboyne facility is designed around a fully integrated waste processing system, beginning with primary shredding followed by advanced screening, magnetic separation, and material classification.

Material flows through a series of mechanical and automated processes including a Hexact screen, double drum separation, and windshifting to effectively segregate light, mid-heavy, and heavy fractions. Ferrous metals are recovered through multiple magnetic separation stages, while optical sorting technology further refines outputs such as wood and non-ferrous materials.

Additional processes including flip-flop screening, single drum separation, and quality control stations ensure consistent output streams, with dedicated handling for fines, aggregates, and residual materials. Light fractions are compacted for efficient handling, delivering a streamlined, high-efficiency system focused on maximising recovery and material value.