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GLASSRECYCLING OPTIONS IN NEW ZEALAND
JOHN WEBBER – GLASS PACKAGING FORUM ANDREW SLACK – TBL SOLUTIONS PIP CHRYSTALL – TBL SOLUTIONS
AGENDAHow is glass currentlyrecycled in New Zealand?
What are the options for useof excess recycled glass?
What are the options for collection of recycled glass?
Palmerston North City Councilexperience.
CastleBin collection system.
PROJECTTEAMGlass Packaging Forum
Palmerston North City Council
TBL Solutions
the glass story
manufacture sell and consume recycle glass
CLOSE THE LOOPglass can be recycled over & over
but the quality must be good
sort & decontaminate glass
In theory glass can be recycled indefinitely by re-melting and forming into new products
in a “closed loop”
glass recycling - target - quality
TARGET QUALITY COLOUR SORTED
The recycled glass must be colour sorted and free of contamination for glass re-manufacture
amber recycled glass
green recycled glass
flint (clear) recycled glass
glass bottle manufacture
Key steps in manufacture are:
1. Batch Feeding 2. Glass Melting 3. Gob Forming
7. Warehousing 8. Distribution
4. Bottle Making 5. Quality control 6. Palletisation
glass bottle manufacture
The recycled glass must be colour sorted and free of contamination for glass re-manufacture
recycled glass specification
colour sorted
only container glass
no contamination
other glass – window glass, light bulbs etc
metal
other
There is a current rejection rate of about 2.5% at Visy Glass Recycling in Auckland
benefits of glass recycling
waste prevention
re-use
recycle / compost
energy recovery
disposal
There are significant economic and environmental benefits for recycling glass
The priority for glass is the maximising of recycling and minimising of disposal to landfill
benefits of glass recycling
CONSERVE RESOURCES
Every tonne of cullet replaces 1.2 tonnes of raw
materials and prevents more than ½ tonne of
CO²
CONSERVE ENERGY
Melting recycled glass
uses 10% less energy
GLASS RECYCLING Environmental
Benefits
REDUCE WASTE
Glass recycling reduces waste and valuable landfill space. It saves on waste
disposal costs
REDUCE GREEN HOUSE GAS
In 2005 glass recycling saved 350,000
tonnes of CO² in the UK. Overall recycling reduces CO²
emissions by over 50%
recycling packaging in NZ increasing
NZ Packaging Recycling
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8019
94
1995
1996
1997
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2005
2006
Year
% T
ota
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(b
y w
eig
ht)
Glass Paper Plastics Steel Aluminium
In 2006 53% glass, 76% paper and 62% aluminium was recycled in New Zealand
packaging accord targets achievable
Material Recovery (%) Accord Target
Aluminium 62% 65%
Glass 53% 55%
Paper 76% 70%
Plastics 22% 23%
Steel 57% 43%
Total 57%
Targets for paper and steel have been met and aluminium, glass and plastics recovery
are close to target
typical composition of kerbside recycling
Palmerston North Recycling 2006/2007 by Weight
Paper & Cardboard
Glass
Plastic
Metals
Paper & Cardboard
Glass
Plastic
Metals
After paper and cardboard, glass is the second most significant recycled material by weight at around 25%
recycled glass is supplied under regional quotas by 12 principal suppliers
There are 74 local authorities (18 city councils and 58 district councils) in New Zealand.
The Ministry for the Environment reports that 92% of rural residents and 97% of urban residents have access to recycling services.
a high proportion of recycled glass comes from Auckland and less from the South Island
Glass Recycling by Region
Population by Region - 2006
Auckland
Other N.I.
S.I.
Auckland
Other N.I.
S.I.
There are 22 countries recycling…..
England collects the same amount as New Zealand.
7 countries collect less than New Zealand.
13 countries collect more than New Zealand.
New Zealand has a higher glass recycling rate than Australia, UK and the USA but lower than most of Europe.
The topography of New Zealand and low population means that our task is much more difficult.
glass recycling issues…..
Excess recycled glass with glass “mountains” in the South Island and in isolated spots around New Zealand.
Increasing transport costs to Auckland for glass sorting and re-manufacture.
Increasing contamination of glass from increased uptake of fully compacted co-mingled kerbside collection. Decreasing net quality glass from the Auckland region.
glass recycling issues…..
Lack of accurate data on glass recycling (and other recycling) in New Zealand with no accurate and central data collection.
The Glass Packaging Forum commissioned TBL Solutions to provide a comprehensive and independent review of glass recycling.Key components included:
current glass recycling behaviour in NZincluding a nationwide questionnaire.
overview of alternative uses of recycled glass in NZ with case studies.
Analysis of glass collection options in NZ.
glass recycling issues…..
This was conducted in partnership with Palmerston North City Council who intend to collect glass as a separate stream.
The core team was Andrew Slack, Anne Billing and Pip Crystall from TBL Solutionswww.tblsolutions.co.nz
glass questionnaire
A glass recycling questionnaire was issued to all 74 local authorities and covered:
Glass collection
Glass sorting
Glass transport
Glass issues
Glass stockpiles
Glass alternative uses
Available from the Glass Forum’s website www.glassforum.org.nz
glass questionnaire
34 or 45% of local authorities participated in the trial
67% participants have a kerbside collection for glass – 23% have a shopping bag collection system – 26% have a crate based system – 8% have a wheelie bin based recycling collection – 47% separate glass in the collection – 53% have a co-mingled collection
73% participants have drop off collection for glass
29% participating local authorities subsidised the collection of glass specifically
70% of recycling is funded by rates, 5% have a “user pays” funded system and 1 participant funded the recycling from landfill revenue
glass questionnaire
17% participants have specialist bottlebank systems for glass
23% participants have glass stockpiles amounting to an estimated 8,300 tonnes
29% participants have used recycled glass for another purpose
17% participants have crushed glass and 12% have used in aggregate.
options for excess recycled glass
StockpileHigh Volume
Low Cost
Options for Excess Glass
LandfillLow Volume
High Cost
options for excess recycled glass
High volume – low value
Base course and sub base
Glassphalt
Glasscrete
Backfill
Landfill cover
Drainage
High value – low volume
Insulation
Golf bunkers
Sand blasting
Filtration
Paint pigment
Tiles and bricks
Mulch
case study – PNCC – 5% recycled glass aggregate
In partnership with Higgins Aggregates and Fullcircle, Palmerston North City Council has bee using all excess recycled glass from PN in a 5% crushed glass aggregate mix during 2006/07.
Being cost effective compared to long term landfill charges this is a sustainable use of excess recycled glass for the region.
From 1 July 2007 the Council has paid Higgins Aggregates $30/tonne to generate the 5% glass aggregate. This is less than the local landfill charge - $95/tonne.
case study – Higgins Aggregate Preparation
Phase 1 : Pre-crush to 40mm
Process is as follows:
Pre crush glass to 40mm using only jaw crusher
Allows easy blending. Product more
homogonous and gives opportunity to hand pick
out rubbish.
Blend crushed glass with feedstock e.g. p-metal in a 50/50 ratio and crush down
to 10mm.
Back to normal production cycle of M4 base course,
blend 10% of 10mm crushed glass feedstock
into product during manufacture giving final
product with 5% crushed glass.
All blending is done by weight and uses on board weighing that is accurate to within 2%
Phase 3 : Blend to 5% Phase 2 : Blend/10mm Crush
case study – PNCC – 5% recycled glass aggregate
1,200 tonnes per annum of glass is recycled in Palmerston North.
Glass is collected as a separate stream in Palmerston North into a split truck.
This unique process was developed by Higgins Aggregates and is a relatively cost effective process compared to other crushing processes.
Contamination is removed before the crushing process.
case study – PNCC – 5% recycled glass aggregate
excess recycled glass 5% crushed glass aggregate
cycle track building foundation road
results – roading project – Brooklyn Heights 2007
A long term test of 5% recycled glass aggregate is being undertaken in Palmerston North in a new subdivision.
Half the road has a glass aggregate base course and the other half has no glass. The roading team will undertake long term monitoring to test road performance.
compaction testing 5% glass aggregate road
case study – mobile crusher
case study – mobile crusher
Modified Transit New Zealand spec and successful foundations trials provide opportunities for local use of crushed cullet.
There are not crushing facilities readily available at all collection locations.
The Forum determined at the end of 2006 that a mobile crusher would provide additional opportunities. With significant (part) sponsorship from Lion Nathan an appropriate machine was purchased.
The operation of the machine is to be undertaken by Silaca Crushers with administration from the Forum.
case study – mobile crusher
The machine was successfully launched at Parliament by the Minister for the Environment, David Parker and the Environmental spokesperson for the Green Party, Nandor Tanczos.
Initial trials very successful and itinerary for the South Island planned.
options for collecting recycled glass
Glass Collection Options
Co-mingled Glass
Collection
kerbside sorting
drop-off bottle banks
separate collection
multi compartment
bin
co-mingled bin
split bin waste & recycling
Single Stream Glass Collection
trends in glass collection
95% to 100% fully co-mingled in Australia- ease of use- increased volumes- improved health and safetyAustralia (44%) has a lower glass recovery than New Zealand (53%).
Auckland and Christchurch moving to fully co-mingled.
Normally separate (bottle bank) collection and CDL in Europe to achieve 70 – 90% glass recovery.
kerbside recycling equation
RecyclingCost
CollectionCost
ProcessingCost
TransportCost
RecoveredRevenue+ + -Other
Cost+
All recycling in New Zealand is subsidised by local authorities
As landfill costs rise it makes recycling more economically viable
There are other community and environmental benefits of recycling (other than dollars)
An analysis of recycling must include the product life cycle. The recycled material must be of required quality for its end use (re-manufacture of glass containers)
-
multi criteria analysis
Recycling CollectionMulti-Criteria Analysis
1. Environmental Factors2. Community Factors3. Economic Factors
Community Factors1. Convenience and ease of
handling2. Litter control3. Health and safety
(collection & household)
Economic Factors1. Overall capital investment2. On-going operating costs3. Relative collection cost4. Relative sorting/processing cost5. Glass cross contamination6. System wear and tear
EnvironmentalFactor1. Recycling volumes2. Glass recovery rates3. Pest & wind control
Palmerston North City Council has used a multi-criteria analysis to determine that a separate glass collection using bottle banks and / or bins is the best long term solutions for glass collection.
co-mingled glass - kerbside
Normally fortnightly collection in 240litre MWB
Higher volumes
Improved health and safety
Ease of use and proven
High glass breakage in compactions above 120 kg/m³
Higher cross and waste contamination
Around $100/hh/year
240 litre MWB
Mixed glass (waste) fines
from co-
mingled MRF
colour sorted glass45 to 70 litre recycling crate
shopping bags
separate glass - kerbside
clean colour sorted bags
separate glass – drop off
Wanganui Gisborne
separate glass – bottlebanks
United Kingdom Switzerland
MOLOK - Switzerland France
bottlebanks
Increasing the density of bottle banks to around one per 1,500 people significantly increased the glass recovery.
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ITASPA
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No of Inhabitants per Collection Point
castlebin – separate glass
Glass in bottom compartment
Other material (paper, cardboard, metals and plastics) mixed in top
Automatic side armed truck separates into two compartments.
Glass in bottom (non-compacted tray)
Other material compacted to over 200kg/m³)
CastleBin – separate glass
No cross contamination
Greater glass recovery
Greater compaction of other material
Flexibility of MWB system
H & S of MWB systems
Estimated that some overall cost of existing fully co-mingled system
Suspect long term savings- Lower MRF capital- Lower MRF wear and tear
case study – Palmerston North CastleBin
GROUP 1
GROUP 2
GROUP 3
3 WEEKS
RC
RC
RC
WB
WB
WBCB
CB
CB
SHOPPING BAGS
3 WEEKS 3 WEEKS 3 WEEKS
The sample size was 350 households from a population of 27,500.
This sample size is predicted to provide around a 5% margin of error.
Each trial area was split into 3.
Each trial was run fro 12 weeks – 3 weeks on shopping bags (control period) and 3 weeks on each of the 3 new methods.
case study – Palmerston North CastleBin
Kerbside Recycling Yield
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1.0
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7.0
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1Recycling Method
Kg
Shopping Bags
Recycling Crates
Standard MWB
Castle Bin
(kg/household/week)
Greatly increased overall recycling yield from MWB systems compared to shopping bags.
case study – Palmerston North CastleBin
Total Recycling Trial Preferences
Shopping Bags
Recycling Crates
Wheelie Bins
Multi Bins
90% of trial participants preferred a MWB system. 60% of trial participants preferred the CastleBin.
case study – Palmerston North CastleBin
Sort Time
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60.0
70.0
80.0
Total P&C Plastic Glass Metals
Minutes
Mat
eria
l
Shopping Bags
Recycling Crates
Standard MWB
Castle Bin
The relative sort time for the CastleBin was half the standard MWB
case study – Palmerston North CastleBin
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150
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300
350
400
Waste Recycling Method
kgTotal Residual Waste
Shopping Bags
Recycling Crates
Standard MWB
Castle Bin
The residual waste for the CastleBin was less than half the standard MWB.
case study – Palmerston North CastleBin
Dedicated Recyclers (30%)
Possible Recyclers (40%)
Unlikely & Never (30%)
Shopping BagsNew Recycling Collection System
The east of use of MWB systems allows the recovery from the 40% possible recyclers to increase.
Palmerston North has a goal to increase recycling to around 50% (compared to waste by weight) by 2012.
CastleBin – next steps
Partnership to develop commercial CastleBin and collection truck.
- Palmerston North City Council (phase in over 2-3 years) - Andrew Slack – Project Manager - Glen Castle – inventor – Design - Craig Dias – Project Worxs – Plastic Injection Moulding - Noel Burgess – IPSC) – Design / Truck
The Bin has an international patent.
It is expected to get a commercial truck on road in 2 years after 3 versions with the initial side arm loader in the workshop, an initial truck prototype.
further information
John Webber Glass Packaging Forum Email [email protected] Mobile
021 949 215 Website www.glassforum.org.nz
Andrew Slack TBL Solutions Email [email protected] Mobile
021 267 1788 [email protected]
