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

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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

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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

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Thank you