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Challenges Facing MRFs: Material Flow Study
Resa DiminoDirector of Public Policy
26th Annual NYS Recycling ConferenceNovember 6, 2015
Promoting and Protecting the PET Package
Introduction to NAPCOR
• NAPCOR is the trade association for the PETpackaging industry in the United States and Canada
• 50 members encompass all parts of the PET value chain from resin production to end of life/recycling
• NAPCOR’s priorities are to:– Promote the introduction and use of PET packaging– Overcome hurdles to introduction, use and recycling of
PET packaging– Communicate the attributes of the PET container
as an environmentally sustainable package
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Promoting and Protecting the PET Package 3
PET Container Manufacturers
PET Resin Manufacturers
DAK Americas LLCIndorama Ventures USA IncNan Ya Plastics Corporation
PET Sheet / Thermoformers
Dart Container Corporation Direct Pack, Inc.Earthbound Farm
Genpak LLC Nu-B, Inc.
Octal Extrusion Corporation Polar-Pak, Ltd.
Peninsula Packaging CompanyPlastic Ingenuity, Inc.
PET Industry Suppliers
Amcor Rigid PlasticsPlastipak Packaging, Inc.
Yoshino America Corporation
NAPCOR Membership 2015
American Starlinger-Sahm, Inc.AMUT North America, Inc.
BMP RecyclingBP
Buhler Inc.CarbonLite Industries, LLCClear Path Recycling, LLC
ColorMatrix Custom Polymers PET
Erema North AmericaEvergreen Plastics
Husky Injection Molding Systems Krones Inc.
MHT USAMarglen Industries
Midwest Exchange EnterprisesMohawk Industries Inc.
Muehlstein
National Recovery TechnologiesNissei ASB CompanyParallel ProductsPeninsula Plastics RecyclingPenn ColorPerpetual Recycling SolutionsPlastic Reclamation Partners LLCPlastic Technologies, Inc.Plastrec, Inc.Polyquest, IncREPIReterraSidel Inc.SignodeSorema Plastic Recycling SystemsSukano Polymers CorporationUltrePet LLC
Promoting and Protecting the PET Package
The Problem: PET Recycling & Utilization Rates Illustrate Declining Quality
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Promoting and Protecting the PET Package
Reclamation Capacity 2014 – Major Assets USA
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*Includes bottles currently exported
COMMISSIONED BY PREPARED BY
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Goals
Why?
• The material mix at the MRF is constantly changing• Understanding how categories of materials flow will
help the industry improve recovery
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Methodology
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MRFs Tested (5)
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Paper Materials Plastic Materials
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Gable-top and aseptic cartons
Beverage cups (hot/cold)
Ice cream containers
Clamshells
Trays
Bottles & Jars
Small/Large plastic containers
Small/Large plastic lids
Clamshells/Domes/Trays
Beverage Cups
Two Types of AnalysisWhere did study materials end up?
100 PET cups
What was in each of thetarget bales?
nHDPE Bottles
cHDPE Bottles
TrashOther
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PET Bale (80)
Mixed Plastic (6)Mixed Paper (7)Residue (7)
nHDPE Bale
Product Characterizations were Calculated for:
Mixed Paper
Mixed PaperNewspaper
cHDPE
Newspaper PET nHDPE
Cartons Mixed Plastics
Residue
121. Some facilities only marketed one grade of paper2. Also included a HDPE/PP Tubs and Lids grade
1
2
What Did We Learn?
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Screen maintenance is key to consistent performance
• Clean screens of material that are wrapped around the shafts
• Replace worn and damaged discs
More screens produced better separation
• Large facilities both had 1 extra screen than medium facilities and had lower loss rates of plastics to the paper stream
Likely reasons for high loss:• 8% loss at large facility had unusually
compacted and wet material due to equipment failures and snowstorms
• 12% loss at both medium facilities likely had worn disc screen discs
Material preparation had a strong effect
• Minimize compaction of material by residents and collection trucks
• Keep material dry
Avoid overloading screens past their design throughput
Overall loss rates of plastic materials varied from 3% to 12%
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No material is perfect• Even plastic bottles had on average 5% loss to the paper stream
Rounder materials like cups, containers and bottles had lower average loss rates than square materials like clamshells and cartons
Materials that held their shape had a higher tendency to flow to the container line than those that flattened
• Lightweight water bottles had a loss rate of 15%
Loss rates above are to the paper stream only, each type also had losses to other commodities and to the residue15
Loss rate of packaging materials to the paper streams
Increasing benefits as stream evolves into being more diverse and lightweight
Manual sorters can be overwhelmed by number of individual pieces and confused by similar looking resins or packages (i.e. clear PET and clear PP)
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Factors Improving a Package’s Recovery
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Example Results
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Where Did the Material End Up
PET Bottles – Small (< 1L), regular weightSize – not too small
Holds 3D shape relatively wellVery common material in the MRF
cHDPE Bottles - AllSize – noted numerous small single
serving type bottlesHolds 3D shape relatively well
Very common material in the MRF
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Small, regular weight PET beverage bottles All CHDPE bottles
Size – many small containersMore likely to flatten due to open top
Very common material in the MRF
Size – noted numerous small single serving type containers
More likely to flatten due to open topVery common material in the MRF, but
easily confused with PP containers
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Where Did the Material End UpSmall PET Containers All CHDPE Containers
Size – not many small school milk cartons observedHolds 3D shape relatively well
Smaller percentage of overall stream
Size – not too smallMore likely to flatten due to open
topNot currently accepted by any of the
test MRFs 21
Where Did the Material End UpCartons Paper beverage cups
ConclusionsEach player in the recycling value chain has a role to play to improve recovery
Packaging Designers Design with recovery in mind
Municipalities Work with MRFs to add new materials and educate residents on proper material preparation
MRF Operators Adequate separation equipment and continual maintenanceimproves separations 22
MRF Equipment Designers Research designs to improve separation of new materials
COMMISSIONED BY PREPARED BY
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Thank you
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