Some 47,300 homeowners in the region between Bognor and Littlehampton were told to keep their windows and doors shut amid fears the harmful smoke could enter their properties.
Emergency services even had to close two miles of one of the busiest roads in Sussex due to the mammoth firefighting effort, which is expected to continue into the weekend.
At its peak, more than ten fire engines and several ladder trucks and water carriers were involved in the battle to bring the blaze under control at the Arun Waste Services facility in the Bairds Business Park near Littlehampton.
Motorists were diverted onto the A27 resulting in huge delays after the A259 between Littlehampton and Flansham, near Bognor, was shut so fire engines could access the scene quickly.
The affected unit, estimated to be around 1,645 square metres, contained recycling waste and machinery making the inferno hard to contain.
Fire investigators say it is too early to say what caused the fire, but will start making inquiries once the flames are fully put out.
The alarm was first raised at around 10.20am when the 999 call centre received several reports of the blaze in the village of Climping, just outside Littlehampton.
Soon after, firefighters from as far as Preston Circus in Brighton joined in the effort to extinguish the flames.
Pictures show a range of techniques being used from using ladder trucks to hosing down areas outside the building to try contain it. The flames took around seven hours to bring under control.
Aerial footage shows thick black plumes of smoke forming clouds hundreds of feet high above the site.
A spokeswoman for West Sussex Fire and Rescue Service issued an update just before 5pm on Friday. No casualties were reported and everyone is accounted for.
“Firefighters are still dealing with the significant fire at a waste services site in Grevatts Lane, Climping.
“However, the number of resources we have at the site has been scaled back.
“One large building full of recycling and plant machinery was fully involved in the fire. Fire crews have now surrounded the fire and contained it to one location.
“Firefighters will remain at the scene overnight and into the weekend.
“The smoke plume is now dissipating, but if residents can see or smell smoke, they must stay inside and keep their doors and windows shut.
“The A259 at Grevatts Lane remains closed at this time, so please avoid the area and use alternative routes.
“Residents can be assured that we are working hard to re-open this major A-road, and this remains a priority for our teams dealing with the incident.
“The cause of the fire will be investigated when it is safe to do so.”
Road traffic was severely impacted by the A259 closure which links Littlehampton to Bognor Regis.
It meant Stagecoach’s 700 bus route was cut short and passengers were told to get on separate services and change in Chichester – potentially adding hours to a journey.
It was not much easier for drivers in their own cars, either, who had to contend with more than 30 minutes of delays on the A27 with much of the traffic being funnelled to the single-lane section through Arundel.
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