International Electronics Recycling Conference

October 1st & 2nd Los Angeles, CA

SDR Plastics created in 1988 ◦ Initial operation toll compounder◦ Custom compounder of styrenics & engineering

polymers

Star Plastics created in 1998 ◦ Subsidiary of SDR Plastics ◦ Processes and provides feedstock materials

Post Industrial Post Consumer materials

History & History & BackgroundBackground

Star Plastics-Millwood, Star Plastics-Millwood, WVWV

SDR Plastics-Ravenswood, WVSDR Plastics-Ravenswood, WV

History & History & BackgroundBackground

Recycling of E-Waste Plastics◦ Project Started in 2000◦ Researched & Reviewed “Best Equipment

Technologies”◦ Facility Design and Equipment Selection in 2007◦ Operational 2008◦ Continue to modify and enhance our system

History & History & BackgroundBackground

Project GoalProject Goal Closed Loop RecyclingClosed Loop Recycling

End of Life Electronics

Electronics De-manufacturing

Consolidation of Scrap Plastics

Polymer Separation & Purity Enhancement

Formulation, Compounding,Pelletizing, & Packaging

Molding of New Parts

Plastic Content – Plastics are not plastics. Plastics within Plastics – Plastics are not what they

appear. Contamination – A little goes a long way. Regulations – What we need to meet? Conversion – What effects cost? What has been accomplished?

Keys to Recycling Keys to Recycling E-Waste Plastics E-Waste Plastics

Separation & Composition◦ Plastics bundled in 1 of 3 forms◦ Bale, Shredded, & Nested

Plastics ContentPlastics Content

De-Manufactured E-Waste Plastics Composition1

◦ 50 – 60% ABS◦ 10 – 20% HIPS◦ 10 – 20% PCABS◦ 2 - 8% PC◦ 12 – 20% Various Plastics

PVC, PE, PP, Actetal, PPO, Nylon, ABS/PVC, & Acrylic 1 – Internal study performed by Star Plastics

Plastics ContentPlastics Content

Plastics Difficult to Recycle ◦ Bio-Based Plastics

Polylactic Acid (PLA) or any PLA/Co-Polymer blends◦ Exotic Alloy Blends

PP/Nylon, ABS/Nylon, ABS/PET, PC/Acrylic◦ Heavily Mineral Filled Plastics

Carbon Black, Talc, Calcium Carbonate

Plastics ContentPlastics Content

Plastics are not what they appear◦ Flame Retardants Plastics & Non-Flame Retardant

Inhibit the spread of fire Used in specific components

Potential for high heat Monitors TV’s

65% E-waste plasticsflame retardants

Plastics within Plastics within PlasticsPlastics

Various- FR

Various- GP

PC- FR

PC- GP

PCABS- FR

PCABS- GP

HIPS- FRHIPS- GP

ABS- FR

ABS- GP

PCABS

◦ Blend of PC, SAN & Butadiene rubber at various %

◦ Manufacture’s proprietary formulation ◦ Compatibility issues – very sensitive to the ratios◦ Difficult to separate from both PC and ABS

PC – acceptable ABS – not acceptable

Plastics within Plastics within PlasticsPlastics PC

(Plastic)

Butadiene Rubber

SAN (Plastic)

Non-Plastics Metals – Wood – Foam - Rubber – Glass – Paper & Foil labels -

Contamination Contamination

Fasteners, Springs, Clips, Wire

Pallets, Manufactured press wood

Acoustical light weight foam

Variety of materials, diff. to separate, cause greatest problems

Clear float glass, little CRT leaded glass

Metal foils reduce plastic recovery, paper easily removed

Plastics◦ Black Plastics -

◦ Coatings -

◦ Glass Filled Plastics -

Contamination Contamination

Difficult to separate, Carbon Black loadings

Paints and metalized coating

Req. special handling, molded part surface imperfections

ContaminationContamination

GlassBlack & Glass Filed Plastics

Metals

Wood

Coated & Labeled Plastics

Foam

Rubber

Misc Contam

Contamination Removal◦ All Contamination has to be REMOVED◦ Compounding

Higher scrap rates Irregular/inconsistent pellet size

◦ Reduce Quality Surface imperfection Customer rejection rates

ContaminationContamination

What needs to be met.

◦ EPEAT◦ RoHS◦ Supplier Requirements

RegulationsRegulations

EPEAT Overview◦ Environmental Assessment Tool◦ 8 performance categories◦ 23 criteria are required to be met

28 optional criteria◦ Products are ranked:

Bronze Meet all 23 criteria

Silver Meet all 23criteria + 50% of the optional criteria

Gold Meet all 23criteria + 75% of the optional criteria

RegulationsRegulations

RoHS Directive – Restriction of Hazardous Substance◦ 5 regulated substances

Cadmium (Cd) Lead (Pb) Mercury (Hg) Hexavalent Chromium (Cr VI) Polybrominated Biphenyls (PPB) & Polybrominated Diphenyl

Ethers (PBDE)

RegulationsRegulations

RoHS Requirements◦ PPB & PBDE <1,000 ppm

No on-line production test Qualitative screening

X-Ray Fluorescence spectrometric analysis Measures only total Bromine

Quantitative screening Independent 3rd party testing Wet Chemistry Analysis

Gas Chromatography/Mass Spectrometry (GC/MS)

RegulationsRegulations

Various- FR

Various- GP

PC- FR

PC- GP

PCABS- FR

PCABS- GP

HIPS- FRHIPS- GP

ABS- FR

ABS- GP

RegulationsRegulations

40,000 lbs. of E.o.L.E. Plastic contains 14,400 lbs. of ABS-FR

Bromine FR Levels◦ ABS-FR Monitor – 12% Bromine(Monitor meet a UL burn spec V0 @ 0.060”)◦ 12% = 120,000ppm

◦ Our maximum is 300ppm or 0.25%

◦ 1 T/L of EOLE plastics creates 5MM lbs of RoHS Compliant ABS-FR

RegulationsRegulations

40,000 lbs. of E.o.L.E. Plastic contains 14,400 lbs. of ABS-FR

Supplier Regulation and Guidelines

◦ Environmental Audits◦ No Land Fill Policy◦ No Overseas Shipping ◦ ISO Certification◦ Downstream Vender Verification

RegulationsRegulations

How Star Plastics is helping OEM’s meet EPEAT ◦ Producing plastics w/ 33% post consumer content

◦ In development to produce plastics 65% Post consumer content

◦ Plastics materials that are environmentally safe ◦ RoHS Compliant

RegulationsRegulations

What effects pricing?◦ Shipping cost◦ High material loss◦ Quality of plastic properties◦ Levels of contamination◦ Competition

CostingCosting

Our Competition

CostingCosting

What effect the cost of finished products?◦ Multiple automated processes required

Size reduction, dry separations, wet separations, & final purification

◦ Packaging◦ Shipping to final molding destination

CostingCosting

Closing the Recycling Loop ◦ Domestic Solution◦ Integrated Automated Processes◦ Providing Certified Post Consumer Content

plastics ABS PCABS HIPS

◦ Traceability – Transparent system

AccomplishmentAccomplishmentss

Product Line

◦ International Sales

AccomplishmentAccomplishmentss

◦ Domestics Sales

AccomplishmentAccomplishmentss

What does this mean?◦ Reduction Landfill Waste◦ Exporting of finished good materials◦ Products meeting OEM’s specification◦ A domestic e-waste plastics recycling solution◦ Relationships that Close the Loop in preparation

of potential future regulations.

Broader Impact Broader Impact AccomplishmentAccomplishment

ss

Concludes Presentation

Thank you for your time

For more information please visit www.starplastics.com

or www.postconsumerplastic.com

Questions?