This article was originally published in Australian Waste Management Review, issue August 2025. Please see the original article here.
In local government waste management, a single piece of equipment rarely sparks a revolution. However, for Liverpool City Council, the acquisition of a TANA Shark shredder became a turning point. According to Tim Pasley, the council’s Resource Recovery Manager, it was “pretty much the stepping stone” toward a circular economy.
This initiative wasn’t driven solely by environmental goals. Instead, it began with a practical look at costs. Tim, who started as a procurement specialist, saw that outsourcing mattress disposal was expensive. Investing in infrastructure to manage waste internally made financial sense. Previously, the council collected and landfilled thousands of illegally dumped mattresses each year. This method was costly – up to $137 per mattress – and unsustainable. Landfill space in the Sydney basin is expected to run out by 2032. Recycling through private contractors cost the council nearly $800,000 annually.
What began as an investment in a shredder, quickly evolved into a vision to close the loop on mattress waste.
Expert insights
Mattresses are usually considered a nightmare in the waste management industry. Mattresses cannot be easily compacted in the landfill, and springs are difficult for most shredders. For low-revving and high-torque TANA Shark shredders, however, mattresses are an easy task.
“TANA Shark’s high torque, among the best in the market, allows it to tear through tough materials like spring mattresses in a single pass. That’s something most machines can’t handle,” says Eetu Tuovinen, Product Manager of Recycling, Tana Oy.
Thanks to TANA’s rotor design, metal wires from mattresses don’t wrap around the shaft. This means the process runs continuously without clogging or interruptions.
From mattress waste to Green Ceramics
After securing a grant from the Environment Protection Authority, the council quietly developed a local waste strategy over four years. On November 16, 2023, it unveiled the TANA Shark shredder – its newest tool for landfill diversion. Nicknamed “the Croc,” the shredder processes mattresses and separates the flock, a mix of textiles and foam, that was previously unusable. This material now feeds a new micro-factory at the Cowpasture Road facility, which is set to become the region’s Circular Economy Centre.
Through a partnership with the University of New South Wales (UNSW), the council transforms mattress flock into high-value products. Using UNSW’s technology, the flock is embedded into Green Ceramics. The team is also working on new methods to increase the percentage of mattress content in these products.
The goal is to integrate circular economy principles into council operations. For example, Green Ceramic tiles made from recycled mattresses will be used in capital works projects. The first application is an education centre at 600 Cowpasture Road, where 160 square metres of tiles will be installed.
“Visitors to the centre will be literally walking on the product,” Tim says. “It’s a tangible example of the council’s commitment.”
From waste to value
Mattresses are a difficult waste to process due to their complex mixture of materials, such as textiles, latex, foam, springs, and wood. The TANA shredder’s overband magnet efficiently separates steel wire, enabling metal recycling and turning problematic waste into a valuable resource.
“By enabling the recovery of difficult materials and supporting revenue streams, like selling separated metals, we help our customers turn waste into opportunity,” Eetu says.
Regional impact and community engagement
The success of the shredder and micro-factory has gained attention across the region. Although Liverpool City Council isn’t a business, its innovative approach has attracted interest from other councils and companies.
“We’ve got Wollondilly, Penrith, and Campbelltown signed up,” Tim says. “Several private companies are also sending mattresses to us for processing.”
By using Liverpool’s recycling facility, these partners contribute to the circular economy. This supports the state government’s goal of 80% landfill diversion by 2030. The council also engages the community. School groups and families are invited to visit the facility and learn where their mattresses go. Tim hopes this hands-on experience builds pride and helps people understand the circular economy in action.
Scaling up for the future
Looking ahead, the council’s vision is bold. The current facility processes up to 78,000 mattresses each year. With two more TANA shredders, the goal is to reach one million mattresses annually. To achieve this, the council is working to lift development restrictions and expand capacity.
The collaboration goes beyond recycling. Liverpool Council is co-funding research and offering learning opportunities for UNSW PhD students and local trainees. The aim is to create future jobs and drive innovation.
“We’re trying to do things a little bit differently here,” Tim says.
“The TANA Shark unlocked all of this. We started with just the shredder, and then new opportunities kept emerging.”
He adds, “The Croc is the bridge in the recycling process. We collect the waste, we process it, and then the Croc connects us to the manufacturing hub we’ve built.”
Tana Australia
Tana Australia is a leading provider of waste processing and recycling equipment in Australia. As a subsidiary of Tana Oy, one of the world’s leading developers of solid waste management equipment, Tana Australia combines global innovation with local expertise to better serve the Australian waste and recycling industry.
With over 25 years of experience serving the Australian market under the name GCM Enviro, they have built a strong reputation for reliability, expertise, and customer-focused solutions as an authorized Tana distributor. In May 2025, GCM Enviro was acquired by Tana Oy and became Tana Australia, marking the beginning of a new chapter in a partnership that has thrived for over two decades.
Key takeaways
1. One machine, big impact
The TANA Shark shredder was the catalyst for Liverpool City Council’s shift toward a circular economy. What started as a cost-saving investment evolved into a full-scale recycling and manufacturing initiative.
2. Mattress waste turned into valuable products
Through a partnership with UNSW, shredded mattress materials are transformed into Green Ceramics –used in tiles, furniture, and infrastructure – demonstrating how difficult waste can become a resource.
3. Regional collaboration and future growth
Liverpool’s model has attracted other councils and companies. With plans to scale up to one million mattresses annually, the initiative is creating jobs, supporting research, and driving long-term sustainability.