Processing Recyclables for Markets A One-Stop Commodity Guidebook

Southern States Waste Management Coalition 3URFHVVLQJ 5HF\FODEOHV IRU 0DUNHWV $ 2QH6WRS &RPPRGLW\ *XLGHERRN IRU /RFDO *RYHUQPHQWV April 1995 Southern States Energy Board 3091 Governors Lake Drive, Suite 400 Norcross, Georgia 30071 (404) 242-7712 Southern States Energy Board SSEB is a non-profit, interstate compact organization established in 1960. Sixteen states and two territories comprise SSEB, and each jurisdiction is represented by the governor and a legislator from the House and Senate. SSEB enhances the quality of life in the South through innovations in energy and environmental programs. Southern States Waste Management Coalition The Southern States Waste Management Coalition (SSWMC) operates under the auspices of the Southern States Energy Board. The Coalition is an issue-focused, problem-solving, interactive decision-making body of gubernatorial appointees, public and private sector representatives. The Coalition forms consensus on policy recommendations for the Southern Governors' Association to consider for adoption on a regional basis. Through this coordinated and cooperative effort, the Coalition can support the decision makers of the southern region in taking a balanced and responsible approach to policymaking on today's recycling and solid waste management issues. For more information, contact: Southern States Energy Board 3091 Governors Lake Drive Suite 400 Norcross, Georgia 30071 (404) 242-7712 Phone (404) 242-0421 Fax (404) 242-8324 BBS The Southern States Waste Management Coalition is pleased to present Processing Recyclables for Market: A One-Stop Commodity Guidebook for Local Governments. This guidebook has been produced in an effort to assist local leaders and other processors of recyclable commodities in developing processing and marketing systems that are appropriate, efficient and sustainable. $FNQRZOHGJHPHQW The Southern States Waste Management Coalition is pleased to present Processing Recyclables for Markets: A One-Stop Commodity Guidebook for Local Governments. The guidebook represents an expression of need for this type of resource by the gubernatorial appointees serving on the Coalition. The Southern States Waste Management Coalition and the Southern States Energy Board acknowledge the hard work and dedication of the following working group members who wrote the individual sections of the guidebook. Without their commitment, expertise and insight this project would not have been possible. Introduction: Jim Shirrell Barbara Davis Arkansas Department of Pollution Control & Arkansas Department of Pollution Ecology Control & Ecology Keith Tice Envirmark, Inc. Jeri Winkleblack Aseptic Packaging Council Patrick Hayes Proctor & Gamble Company Mary Anne Banich South Carolina Department of Health and Environmental Control Elizabeth Tarver Louisiana Department of Environmental Quality Suzette Miller Steel Can Recycling Institute Facility Design & Operation: Paper: Plastic: Stephanie Hubbard American Plastics Council Metal Robin Mitchell Mark Davis U.S. Environmental Protection Agency, Region IV David Baker Glass Recycling Institute Glass: Mike Forster Alabama Department of Environmental Management Yard Trimmings Mike Forster Alabama Department of Environmental and Other Management Organics: Automotive Materials: Steve Dale Kentucky Recycling Brokerage Authority Auburn University - Alabama Cooperative Extension Service Brad Jones American Petroleum Institute A special thanks is extended to Steve Dale who coordinated and led this project through much of the process. And finally, we wish to acknowledge the outstanding work and coordinating efforts of the staff members of the Southern States Energy Board. Their ability and persistence were crucial to the completion of this project. This document is funded through the Southern States Energy Board's annual state appropriations budget and contributions from the private sector. Thomas E. Whitten, Chairman Director, Division of Waste Minimization Mississippi Department of Environmental Quality Mike Forster, Working Group Leader Solid Waste Branch - Land Division Alabama Department of Environmental Management Kenneth J. Nemeth Executive Director Southern States Energy Board )RUHZRUG As more communities initiate or expand recycling programs, solid waste coordinators, county landfill operators or other public service representatives with limited exposure to the field of recycling, suddenly find themselves dealing with collected recyclable materials. These newly appointed recycling coordinators must learn, often by trial and error, how to prepare recyclable materials for market. This guidebook is intended to aid those with limited experience in recycling. It should be used as a primary resource for learning the basics of processing recyclable materials and a source for finding more detailed information and personal contacts with recycling experts and markets. The guidebook is organized so that each type of recyclable material, or commodity, can be quickly referenced for information. The introduction provides a brief overview of the components of the recycling process. A list of trade association contacts are included at the end of each commodity section to assist in locating markets. Before making a decision to collect a recyclable commodity or invest in processing equipment, coordinators should first determine where to market the commodity and what material specifications are required by the market. A section on facility design and operation is also presented with the intent of providing enough information for the recycling coordinator to ask informed questions when considering building or equipment acquisition. The appendix, lists sources of information that give more thorough guidance on all aspects of the recycling process, contacts specific to each state and a glossary of terms. v vi 7DEOH RI &RQWHQWV Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Facility Design and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Steel Cans/Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Major Appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Yard Trimmings and Other Organics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Automotive Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Scrapped Automobiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Lead-Acid Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Used Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Used Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Used Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Appendix National and Regional Contacts State Contacts ,QWURGXFWLRQ :KDW &DQ %H 5HF\FOHG" In theory, everything can be recycled. In practice, however, processing costs, transportation costs, manufacturing costs and technological capabilities are all limitations on the practicality of recycling. Your community must decide on the reasons for recycling and set goals based on the community's desires and the limitations set by the market place. Reducing the volume of waste entering the landfill will produce different results than reducing the weight of solid waste collections. One community may act on purely environmental concerns while another community may act on economic reasons yet the two communities may decide on the same course of action. In any case, local market conditions and community values should be the overriding factors in making such a decision. Landfill volume of materials in MSW, 1993 (in percent of total) Materials generated in MSW by weight, 1993 (Total weight = 206.9 million tons) Paper & paperboard 37.6% Paper & paperboard Plastics 23.9% 30.2% 77.8 million tons Yard trammings 32.8 million tons 15.9% Others 1.4% Glass 2.2% Aluminum 2.4% Yard Trimmings 8.1% Food wastes Textiles 6.2% Ferrous metals 7.9% Rubber & leather 7.8% Wood 6.8% 3.2% Other 9.0% 18.7 million tons Glass 6.6% 13.7 million tons Metals Plastics 9.3% 19.3 million tons 8.3% Food 6.7% 13.8 million tons Wood 6.6% 13.7 million tons 17.1 million tons $VVHVVLQJ WKH 0DUNHWSODFH Before making a decision on what to recycle, you should analyze market conditions. Market supply and demand; prices for recyclables; technological development; projected trends in generation and disposal; transportation costs and specific materials considerations will determine the processing and marketing system appropriate. There are many examples of recyclables being remanufactured into the same product such as paper, aluminum cans, glass bottles, steel and others. However, less traditional markets for recyclables may be an option. Creative uses for recyclables such as glass mixed with asphalt; lumber made from plastics; insulation and animal bedding made from paper; and tires for artificial reefs and landscaping are but a few of the new and innovative uses for recyclables. Even small communities can take advantage of new processes and technologies by keeping abreast of changes. Innovations are often driven by regional differences. Alternatives may be necessary if local markets do not exist for some recyclables or if more lucrative markets exist elsewhere. For example, some West Coast cities have found foreign markets for recyclables. Likewise, some southern states also may have the advantage of more favorable overseas markets. The choice of 1 what to recycle and where to sell it should rely on regional market statistics and not simply national indices. Planners need to explore creative options. Goals should focus on realistic local conditions realizing that what has worked well for one community may not work well for another. A good place for guidance are the state economic and recycling market development agencies and organizations. They can provide your community with assistance in setting up a program and finding markets for recyclable commodities. 7\SHV RI 0DUNHWV By targeting the market it is best suited to serve, your community can take advantage of its unique situation. Potential markets for recyclables are processors, brokers, cooperative or regional markets and end users, any of which may be combined at the various stages and by different entities. Processors separate materials intended for recycling and prepare the material for transport. The degree of processing needed--separation, cleaning, crushing, baling or compacting-- will depend on market requirements. Processing may be as simple as collecting and shredding yard waste for composting or as technical as a materials recovery facility (MRF). MRFs may be as simple as hand separation of a few materials or as involved as a highly automated system capable of separating hundreds of tons of commingled recylables per day. Brokers act as the middlemen in getting recyclable materials from the source to the manufacturing sector much the same as distributors in the more traditional retail market. Brokers often perform the processing task and may have direct ties to the manufacturer. Communities that generate small quantities of recyclable commodities can benefit from selling to brokers who collect material from several communities, thus reducing transportation costs. Cooperative or regional marketing refers to a group of entities that voluntarily agree to work together to sell their recyclable materials. Cooperative marketing programs take many forms, from a "loose knit" organization to legally structured membership, and offer a wide array of services. In whatever form, the common factor is that they all market recyclables together on the assumption that together they can do so more efficiently and cost effectively than alone. Cooperative marketing programs provide guaranteed outlets for collected materials and usually provide information and training through informal sharing, market databases, workshops, and other types of technical assistance to participants. End users generally are manufacturers who either produce a final product or supply others with ready-for-use materials. Common examples are paper mills that supply newsprint. Again, buyer requirements and the capabilities of your community's recycling program will determine the proper target market. When designing a recycling system, the local decision maker needs to understand the different market options available and the advantages and disadvantages of each. Contracting with a processor may prove the easiest route but the monetary returns may fall short of expectations. Brokers may be willing to pay more for recyclables but the system that the community implements may not meet the requirements of the broker. An end user may offer a premium price for recyclables yet the community will need to provide the premium quality demanded by the end 2 user. What is most important to this decision is that the community match the capabilities and the goals of the community with the requirements of the buyer. &ROOHFWLRQ In a successful collection program, quality control begins with the consumer. Educating the public about what is being collected and how it should be prepared yields benefits throughout the recycling process. The type of collection system employed may affect all other stages of the recycling process. Collection costs, quality control and recovery rates are important factors affecting which collection system to implement. Since the collection system employed will have such an impact on the success of the recycling program, familiarity with as many collection systems as possible is extremely important. Several good sources for learning about the variety of collection systems are listed in the appendix. 1HJRWLDWLQJ $JUHHPHQWV Once a market has been chosen, it may be desirable to enter into a written agreement for the purchase of recyclable materials. A contract will ensure a ready buyer of recyclable commodities and perhaps even establish a guaranteed price, although current market rates may be the best a buyer will guarantee. A community that attempts to sell on the open market could receive higher returns but, at times, may not find anyone to buy their commodities. Before entering an agreement, your community should be aware of any statutory requirements regarding bidding procedures and requests for proposals. Necessary requirements may differ considerably from county to county and state to state. When entering into any agreement, your community should know with whom it is dealing. Contractors in the recycling industry should receive the same scrutiny as contractors in other industries. What does this company do with the recyclables purchased? Does it pay its bills? Will it increase the liability of the community? These are just some of the questions that should be answered. *DLQLQJ 5HSXWDELOLW\ DV D 6XSSOLHU Once the community has decided what to recycle and has found a buyer, it must foster a good reputation as a supplier. Manufacturers plan their facilities based on a predetermined volume and quality of resources. Quality control and dependable, consistent supply are key to a manufacturer's viability. Just one ceramic coffee mug can ruin a whole load of glass intended for new glass production and shipments of material that fall short of negotiated amounts may cause a facility to shut down. A community that fails to meet agreed upon specifications will soon fall out of favor with buyers. In fact, shipments of material not meeting negotiated specifications will often be rejected at the expense of the community. The cooperative marketing agreements mentioned earlier are an attempt to address some of these concerns. 5HJXODWLRQV As with nearly any public or private endeavor, local, state and federal laws must be observed. Certain laws and regulations will apply regardless of whether the facility is for recycling. However, some regulations will apply specifically to a recycling facility or specific recyclable 3 commodity. You should contact state and local authorities to determine requirements for your community's facility before implementing a program. For those commodities with specific regulations, a brief explanation of the requirements is provided in the following individual commodity sections. (GXFDWLRQ This guidebook is intended to educate those responsible for processing recyclables. However, educating the general public and businesses is equally important. By taking an active role in public education, you may be able to greatly enhance your community's recycling program. The following individual commodity sections provide more detailed information concerning quality control and processing requirements. These guidelines will help build a strong link between the processor (your community) and the buyer. Educating the public will make this link stronger. 4 )DFLOLW\ 'HVLJQ DQG 2SHUDWLRQ 2SHUDWLRQDO &RQVLGHUDWLRQV This section is intended to provide an understanding of the technical aspects associated with the planning, design and operation of a processing facility, often called a materials recovery facility (MRF - pronounced "murf"). Although processing adds value to the commodities and allows for greater storage potential, the community does not have to do anything but collect recyclable commodities if buyers for loose materials can be located. However, processing at least some materials can greatly enhance a community recycling program. For other materials, such as used oil, batteries, tires and large metal objects, storage may be the primary role of the community. For these materials, specific requirements are given in the following commodity sections. Most MRFs typically process the following group of commodities: Plastic containers Aluminum cans Steel cans Glass containers Newsprint High grade and/or mixed paper Corrugated cardboard Although these are the most common commodities, you do not have to limit your program to only these materials. Processing requirements will be only one of the factors in determining which commodities to deal with. You should not reinvent the wheel. However, you should be creative. The information presented in this section addresses the following fundamental topics for processing the typically recycled commodities listed above. Preliminary Planning Facility Space Requirements MRF Equipment Guidelines Sources of information about equipment, buildings and further guidance for processing any type of recyclable commodity are given at the end of this section and in the Appendix. 3UHOLPLQDU\ 3ODQQLQJ Before a MRF can be designed, implemented, and successfully operated, the community must determine which recyclable commodities will be recovered, as outlined in the "Introduction," and how to handle the material upon arrival at the facility. During the early planning stages, a realistic approach should be taken when determining the specific materials that will be processed through the facility. This preliminary choice of materials 5 will have a direct impact on dictating the design and configuration of the MRF's overall floor plan and equipment selection. Attempting to process too many materials can quickly overwhelm and complicate operations. A good starting point in making this decision is to focus on materials that best satisfy the following criteria: The handling and processing of the material should not subject workers to increased hazards or jeopardize safety or code compliance at the facility. (Although recycling facilities have not generally come under the same direct standards as other manufacturers and processing facilities, you need to check with your appropriate state agency for code compliance information. Some of these state agencies are listed in the appendix.) The material should have physical properties that readily allow for compaction or volume reduction techniques to be applied at the facility. The costs and level of effort required for reception, processing and storage of the material should not greatly exceed that which is justified by the historical market value of the material. There must be a ready buyer for the commodities. %XLOGLQJ 'HVLJQ DQG /RFDWLRQ )DFLOLW\ 6SDFH 5HTXLUHPHQWV The previous paragraphs provide some insight into the selection of which materials to process. This section begins to illustrate how existing, well-run MRFs handle and process a variety of commonly recycled commodities. The configurations and floor plans of existing MRFs differ greatly from one facility to another in many ways. Yet there is something nearly all of the numerous designs have in common -- three distinct and separate working areas. There typically is a reception or tipping area where materials are transferred from the arriving collection vehicles to receiving bins or dedicated floor space. There must be a sorting or processing area where materials are separated by type or, if already separated at the source, at least inspected for contaminants before being readied for transport to the markets. There must be an area for temporary short-term storage of the ready materials prior to shipment. In analyzing the processing capacity of a given floor area or in determining the required floor area for a desired daily throughput, the designer must first recognize that calculations for a 10 tons-per-day (TPD) facility are not directly proportional to those for a 100 TPD facility. That is to say, a 100 TPD operation will not simply be 10 times larger than a 10 TPD operation. The reasons for this are readily apparent once the size relationships between the three fundamental working areas found in almost all MRFs are understood. The following simplified diagram illustrates and compares the relative size of these working areas in two facilities with substantially different daily production capacities. 6 In this example the overall area of the 100 TPD facility is obviously larger than the 10 TPD facility, but not by more than a multiple of 3. This floor space comparison is fairly representative because of the fact that larger operations process materials at greater hourly volumes. They also ship ready materials to buyers in the marketplace more frequently. Both of these factors act jointly to lessen the floor space requirements in the tipping and storage areas of the larger facilities. This multiplier becomes an even smaller number when, for example, a typical 100 TPD facility is compared to a typical 300 TPD facility. The following chart shows the normal floor space requirements for material recovery facilities processing from less than 10 TPD through 300 TPD. Although many MRFs in the United States operate within building areas that are significantly larger or smaller for their respective daily throughput levels, the figures shown closely reflect the industry averages. (TXLSPHQW 1HHGV Contemporary MRFs generally receive recyclable materials in one of two basic forms, either commingled or source-separated. When materials are commingled they are typically received in bulk loads of the two following individual categories. Commingled containers: Plastics Glass Aluminum Steel Cans Milk Cartons & Drink Boxes Commingled paper products: Cardboard Newsprint Magazines High Grade Papers Because of the very different physical properties of the materials in these two basic groups, most recovery facilities will handle them using separate processing lines. A large number of material recovery operations with daily production levels of less than 50 tons utilize predominantly manual sorting methods to separate, inspect, and classify these recyclable materials. This work is usually done along three- to four-foot wide sorting conveyors which move the various materials to the sorting personnel at a waist-high level. The workers are then able to classify and place their assigned material(s) into nearby storage bins from a standing position. Depending on the volumes involved, these sorting lines are sometimes constructed just above the main floor level or they may be part of an elevated platform, allowing large gravity-fed material bins to be positioned under the structure. In either situation a front-end loader typically moves the incoming materials from the tipping floor to the in-feed hopper of an inclined conveyor leading to the sorting positions. As an 7 initial step in sorting and processing, steel cans and other ferrous materials are magnetically separated from the other commingled containers. Smaller facilities usually have only one sorting conveyor/platform and will process containers for some portions of the operating day and papers or cardboard during others. Few facilities attempt to mix or process the two categories as one stream, but in MRFs processing very small quantities this is sometimes done. Following the sorting and classification operations, the grouped materials will need to be prepared for shipment to the various buyers in the marketplace. The methodology and equipment used to process the individual recyclables varies from one facility to the next and is generally dictated by the requirements of the buyers. Specifications and quality control guidelines which mandate the size, shape, and weight limitations of the delivered materials are routinely made part of most market agreements. In order to meet these specifications, some of the more commonly recycled materials are processed as indicated below. Plastic, steel and aluminum are typically: Baled, Flattened, Shredded, or Shipped loose with minimal or no volume reduction Glass containers are typically: Shipped whole or semi-broken, Crushed into small chips called cullet, or Shipped by individual color or as mixed colors Cardboard and papers are typically: Baled as whole or shredded sheets, or Shipped loose The following individual commodity sections give more detailed information concerning specific processing requirements for different materials. Brief descriptions of some of the material separating equipment and size-reduction equipment employed at many existing MRFs are given below. TROMMEL SCREENS These are devices that incorporate a rotating perforated drum as their main component. The perforations or drilled holes incrementally increase in size along the length of the cylinder, allowing smaller materials to drop out early in the process. Larger items are carried further along as the rotation continues, dropping through openings of increasing diameter as their size 8 permits. Items too large for any of the openings pass through the trommel and can be moved to various areas by a conveyor or other means. VIBRATORY SCREENS This equipment consists of a perforated steel plate or large diameter wire mesh screen mounted within a steel box frame and positioned at a slant angle off horizontal. The screen and frame are typically mounted on springs with vibratory motion induced by an electric motor driving an eccentric flywheel. These types of screens are sometimes used to accomplish the same results as a trommel screen, but more often are used to simply screen off fine grit and broken glass from the recyclables. MATERIAL BALERS Balers produce densified bales of a number of different compressible materials. These machines are powered by electric motors that drive hydraulic systems used to compact material into bales of various sizes. Most of the recovered containers and paper products can be baled successfully for transport to the marketplace. The three basic types or designs of balers are: Vertical baler - This type of low-density baler is often used to bale cardboard at supermarket receiving areas. The design makes it suitable for small volume operations where only a few bales need to be produced each day. Bales formed in vertical balers need to be tied manually with wire straps before the bale is fully released from the baling chamber. Single-ram or horizontal baler - This higher-density baler design uses one medium to large bore hydraulic ram to both form the bale and to eject the bale from the machine. This design is sometimes referred to as an open-end baler because the bale is formed within an open-ended tapering baling chamber. This type of baler allows bales to be formed in an almost sausage-like fashion. The length of the finished bales can be varied and controlled as dictated by the material being baled or the buyer's specifications. A similar horizontal baler design is manufactured having a hinged bale door blocking the normally open end of the machine. This design loses the ability to vary the length of the bales produced and is limited to somewhat slower production rates. Automatic and manual wire strapping options are available for horizontal balers. Two-ram baler - Balers of this type include a second hydraulic ram, positioned perpendicularly to the main baling ram, which is used to eject the finished bale from the machine. The design of this baler allows the baling ram to compress materials against the heavy steel sidewall of the baling chamber, producing higher density bales. Other variations of this design include a bale door which lowers in guillotine-like fashion to fully enclose the baling chamber during formation of the bales. Two-ram balers are usually fitted with an automatic wire tying apparatus that applies wire strapping to the bale as it is ejected from the baler. Facilities with high daily production volumes use one or more of this type of baler to quickly bale paper products and containers for transport to the market place. Many of these machines are capable of baling 25 to 30 or more tons of material per hour. 9 Can densifier - Densifiers are really a variety of small balers that compress and shape aluminum cans into “biscuits” that weigh roughly 40 pounds each. Unique form given to the biscuits by some densifiers allows them to be interlocked to form a palletized load, meeting the specific requirements of the aluminum products industry. CAN FLATTENERS AND FLATTENER/BLOWERS These devices achieve the results that their nomenclatures suggest. They are relatively small machines which, in their larger versions, weigh several hundred pounds with a footprint of approximately 5'x10'. A flattener is typically used to reduce the volume of cans being loaded into a container such as a rolloff box for transport. Flattener/blowers allow a directionally adjustable spout to blow flattened cans into a semi-trailer for transport. The recycling industry also uses similar equipment such as GLASS CRUSHERS, PLASTICS PERFORATORS, GRANULATORS and MATERIAL SHREDDERS for volume reduction and to facilitate economical transport of these recyclable commodities. EXISTING FACILITY TOURS During the planning and preliminary design phases of your MRF development program, it will be very beneficial to visit and tour existing recycling facilities. You should tour facilities that are processing the various materials you are considering and at similar daily volumes. *The effort and time spent at these facilities will provide creative insight and valuable knowledge into the realities of planning and operating an efficient and cost-effective material recovery facility. The contacts listed below can direct you to recycling facilities in your area. Also, the various state agencies and organizations can provide insight and assistance in setting up your facilities. 439,.98$4:7.08 City of Eureka Springs Solid Waste Management Department 44 South Main Eureka Springs, AR 72632 (501) 253-7773 Lakeway Recycling and Sanitation P.O. Box 1894 Morristown, TN 37814-1894 (615) 587-3257 Patrick Engineering, Inc. 346 Taft Avenue Glen Ellyn, IL 60137-6290 (708) 858-7050 Recycling Data Management Corporation P.O. Box 577 Odgensburg, NY 13669 1-800-267-0707 10 !,507 ,QWURGXFWLRQ Paper and paper products have been recovered and recycled for as long as paper has been made. Over the years, paper making and recycling have gone through many changes. With the introduction of groundwood mills in the 1800's, trees became the primary fiber source for making paper and paper products. Paper mills can use either farm raised trees, recovered paper or a combination of both in the paper manufacturing process. The Paper Stock Institute (PSI) defines 51 grades of paper. PSI produces a "Scrap Specifications Circular" that is widely used in the paper industry to define paper grades. Guidelines for Paper Stock is a publication produced by the PSI and should be consulted for more information on grades and specifications. Some of the grades most commonly collected for recycling in residential and commercial recycling programs are as follows: Old Newspaper (ONP) -- Newspaper makes up about 10 percent of the solid waste stream. The average American home produces 28 pounds of newspaper each month. Newspaper, collected for many years in paper drives, is one of the most commonly collected residential materials. ONP is most commonly used to produce new newsprint. Insulation materials, paperboard containers, low grade paper and paper products and animal bedding also are produced from recovered ONP. Old Corrugated Containers (OCC) -- Corrugated containers are "cardboard" cartons with waffle-like ridges or tunnels. OCC is the single largest source of and most recovered paper grade in the waste stream. Commercial recovery of OCC is the most common source of OCC. Grocery stores and retailers have recycled OCC for many years. Communities are beginning to add OCC to residential curbside and drop-off recycling programs. Demand for OCC usually increases in the summer when businesses gear up to ship Christmas goods in cartons. OCC is used to make new corrugated cartons, linerboard, paperboard and wallboard. Mixed Waste Paper (MWP) -- Paper and paper grades vary tremendously. Paper has different fiber lengths and strengths. It may or may not be colored, coated or bleached. Mixed paper is most often defined as just that, mixed paper. Generally, MWP is any paper that you might find in an office file cabinet. This may include computer paper (CPO) and white ledger paper (WLP), copy paper (white and colored), file folders, envelopes (manila and colors), letterhead, cardstock, etc. Many paper recyclers accept mixed paper and remove the higher grades for marketing separately. MWP is used to make printing, writing, towel and tissue paper, paperboard packaging and construction material. Computer Print Out (CPO) -- CPO is computer paper generated in a data processing machine. CPO may include green bar computer paper and may be impact (laser) printed. CPO is used to make high grade paper and paper products. White Ledger Paper (WLP) -- WLP is strictly white paper - computer, copy, letterhead, etc. WLP is used to make high grade paper and paper products. 11 Milk Cartons and Drink Boxes (MCDB) -- MCDBs are polycoated paper gabletop milk and juice cartons and aseptic drink boxes. Most MCDBs are collected in residential and school recycling programs. MCDBs are a high grade paper similar to CPO and WLP. Old Magazines (OMG) -- Most magazines and catalogs are printed on coated groundwood paper. Many new newspaper deinking mills are now using flotation systems that require clay, like that used as clay coating on magazines, for the process. The mix is generally 70 percent ONP and 30 percent OMG. Many residential recycling programs are beginning to accept OMG. 0DUNHW 3HUVSHFWLYH Paper stock markets continue to improve, both in the US and overseas. Paper can be remanufactured into many different kinds of paper and paper products, depending on the type of fiber used. Markets are continuing to open for nontraditional uses of paper, such as animal bedding, insulation and fuel pellets. As virgin wood prices continue to rise, the demand for recyclable waste paper should continue to grow. 4XDOLW\ &RQWURO Paper specifications often will list: A baled weight -- Each buyer may have individual requirements for bale weights and dimensions. A maximum moisture content -- The maximum moisture content is usually 10 percent. Special equipment is available to determine moisture content, but the buyer will generally determine the need for such testing. Since paper is most often bought by the ton, a high moisture content would mean that the buyer is paying too much for a load of wet paper. Also, if paper remains wet for extended periods, the fibers can degrade. The maximum percentage of contaminants allowed -- As a general rule, contaminants to paper grades are known as outthrows - usually paper of a different type, a small percentage of which may be acceptable; and prohibitive materials - usually non-paper items, which are normally not accepted even in small percentages. The table below broadly outlines the percentages of outthrows and prohibitive materials that are acceptable, common contaminants, and acceptable outthrows for each paper grade. Outthrows Prohibitive Common Contaminants Materials ONP OCC MWP 2% 5% 10% .5% <1% 2% Phone books, junk mail, wax/plastic coated paper Acceptable Outthrows Inserts Wax/plastic coated cartons, food Newspaper waste, adhesives Nonpaper items, newsprint, coated paper ------ 12 Outthrows Prohibitive Common Contaminants Materials CPO WLP 2% 2% 0 <1% Any other paper Colored paper, ink, coated/treated paper, heavily printed paper Residual liquids, nonpaper items Acceptable Outthrows Groundwood Groundwood MCDB OMG 2% 3% <1% 1% ------ glue bindings, pressure sensitive Paperback books labels, coatings, plastic covers, inserts Paper and non-paper contaminants will vary greatly depending on the requirements of individual processors and mills. Likewise, materials recovery facilities (MRFs) and paper brokers often market to many different end user mills. The needs and specifications of end user mills will vary depending on the end product being manufactured and the type of equipment in use at the mill. One processor may have an end use for a mix of paper that another processor would consider unacceptable. Be sure to check with your buyer for exact paper grades and specifications. 3URFHVVLQJ6WRUDJH Buyers will determine bale size requirements based on their specifications set by the mills using the paper. These requirements can be quite variable allowing the community to use the same baling equipment for different commodities. Baling makes shipping easier and more economical by allowing greater amounts to be shipped in the same load. Baling reduces the amount of storage space necessary for both the community and those using the material in manufacturing processes. Grade specific requirements are outlined below. Old Newspaper (ONP): Most mills prefer ONP to be either baled or shipped loose in a tractor-trailer and free from contaminants except as outlined in their individual specifications. ONP is most frequently dumped onto a tipping floor where any contaminants are removed prior to baling or loading. ONP can be stored inside or outside after baling, depending on buyer requirements. Over time, however, sunlight and rain will degrade the paper. Old Corrugated Containers (OCC): Commercial generators of OCC collect the material in a commercial size (40 yard) compactor, four to eight yard containers or bale the material on site. Residential generators normally flatten the cartons and place them on top of their recycling bin. OCC is usually taken to an intermediate processor or MRF where it is baled for shipment to a mill. OCC, like ONP, can be stored inside or out, depending on buyer requirements. Mixed Waste Paper (MWP): MWP is generally collected from offices and drop-off centers and taken to an intermediate processor where it is sorted by hand to cull out the high value paper such as white ledger and 13 computer paper. The remaining mixed paper is normally baled and marketed to an end user. MWP also can be stored inside or out, depending on buyer requirements. Computer Printout (CPO): CPO is either collected as a separate grade in commercial recycling programs, or sorted out from mixed paper and baled. CPO should be stored inside and away from other contaminants such as glass and dirt. White Ledger Paper (WLP): WLP is often sorted from mixed paper. It also can be collected as a separate grade, as in many office recycling programs. The paper is then baled and stored inside, away from other contaminants such as glass and dirt until shipped to the end market. Milk Cartons and Drink Boxes (MCDB): MCDBs are collected in residential and school recycling programs and should be clean and dry for recycling. The material is usually collected as a commingled container and sorted at a MRF. In curbsort, source separated and drop-off programs, a separate container or bin is provided for MCDBs. The MRF bales the material and stores inside, away from other contaminants such as glass and dirt. Old Magazines (OMG): Magazines should be baled or placed in gaylord boxes and stored indoors prior to shipment. Magazines can be difficult to bale because of their slippery coatings. Shredding before baling may help. 6KLSSLQJ7UDQVSRUWDWLRQ Many buyers do not have minimum load requirements. However, shipping charges are negotiable. The community may have to pay shipping expenses on small loads while the buyer may pay shipping charges for larger loads. Again, proper baling saves on transportation costs and may allow a community to negotiate for shipping charges to be paid by the buyer. 439,.98$4:7.08 American Forest and Paper Association 1250 Jefferson Avenue, NW Washington, DC 20036 (800) 878-8878 Aseptic Packaging Council 1225 I Street, NW, Suite 500 Washington, DC 20005 (800) 277-8088 Paperboard Packaging Council 1101 Vermont Avenue, NW, Suite 411 Washington, DC 20005 (202) 289-4100 14 Paper Stock Institute of America 1325 G Street, NW, Suite 1000 Washington, DC 20005 (202) 466-4050 Technical Association of Pulp & Paper Industries P.O. Box 105113 Atlanta, Georgia 30348 (404) 446-1400 15 16 3ODVWLFV ,QWURGXFWLRQ Plastics are inherently recyclable. In fact, many manufacturers have been recycling in-house scrap since the early part of this century. Today, increased attention is focused on recovering plastics that would otherwise become part of the consumer waste stream. There are six major resin types commonly found in household plastic packaging and products. Each resin type can be further separated by grade. This is discussed in greater detail in the section on Quality Control. The following list gives the proper name for each resin type and the Society for the Plastics Industry (SPI ) (See Quality Control) coding system number assigned to each. Polyethylene Terephthalate -- #1 (PET): PET represents about 22 percent of the plastic bottle market and is the most commonly recycled consumer packaging resin. It is primarily used for soft drink bottles, but also is used to package edible oils, liquor and peanut butter. PET is clear, tough and a good gas barrier, which seals in carbonation. High-Density Polyethylene -- # 2 (HDPE): HDPE is valued by packagers for its stiffness, ease of forming and resistance to breakage. Its uses include milk, water and juice bottles, bleach and detergent bottles, motor oil bottles, margarine tubs and grocery sacks. HDPE represents more than 56 percent of the plastic bottle market. Unpigmented HDPE bottles, such as clear or translucent milk jugs, are valued by reclaimers because they can be used in a wide variety of applications. Markets for recycled mixed-color HDPE containers include motor oil bottles, irrigation and drain pipes and pails. Polyvinyl Chloride -- # 3 (PVC): Because of its blending capability, polyvinyl chloride -also called vinyl -- can be used to manufacture products ranging from heavy-walled pressure pipes to crystal-clear food packaging (most often bottles for cooking oils, water, health and beauty aids and household chemicals). Vinyl's characteristics include good clarity and chemical resistance. Vinyl bottles make up less than six percent of the consumer plastic bottle market. Low-Density Polyethylene -- #4 (LDPE): LDPE is flexible and is commonly used as a film, as in bread or trash bags. LDPE is clear, inert, easy to process and acts as a good moisture barrier. Polypropylene -- # 5 (PP): Polypropylene is resistant to chemicals and fatigue and is used in applications ranging from fibers and films to screw-on caps and lids, and food packaging such as yogurt and margarine tubs, syrup bottles and straws. Polypropylene is the primary material for automotive battery casings because it is lightweight and durable. Polystyrene -- # 6 (PS): Polystyrene is a clear, versatile resin that is easy to process and can be "foamed" to create insulating and protective packaging. Relatively little polystyrene is used in common household packaging, although it is used in yogurt cups, egg cartons, meat trays and disposable plates, cutlery and cups. The National Polystyrene Recycling Company (NPRC) was formed by the nation's largest manufacturers of polystyrene resins to establish a nationwide polystyrene recycling infrastructure. 17 There are other plastics, but the six listed above represent the majority (97 percent) found in household packaging. 0DUNHW 3HUVSHFWLYH The largest and most profitable market for recycled plastics is for single, unpigmented resins such as clear PET soft drink containers or PE pallet stretch wrap. High quality and purity standards are required to maintain the same product performance characteristics in recycled resins that are found in virgin material. Buyers of recyclable plastic commodities, often called processors, reclaimers or vendors, have specific requirements that, if met, provide a niche for a local recycling program. The variety of products made with recycled plastics continues to grow. Recycled PET is used to produce soft drink and other bottles, deli and bakery trays, carpeting, fiberfill and geotextiles (such as landfill liners). Recycled HDPE can be used for bottled laundry products, recycling bins, agricultural irrigation pipes, grocery bags, and motor oil bottles. These two, PET and HDPE, are the most commonly recycled plastics used in packaging and constitute about 96% of the total plastic bottle waste stream. Other plastics, such as PVC, can be used to make plumbing pipes, fences and nonfood containers. Recycled LDPE is used for shopping bags and stretch wrap. Auto parts and battery casings, carpeting, geotextiles and industrial fibers often are made from recovered polypropylene (PP), while office supplies, cafeteria trays, toys, video cassettes and cases, and insulation board are common uses for polystyrene (PS). Researchers are now exploring a new approach to plastics recycling that may increase the overall quantity of plastics thatcan be recycled. Advanced recycling technologies have been developed that break post-consumer plastics down to the molecular building blocks from which they were made. Tests are now underway to determine whether advanced recycling can cost-effectively overcome the sorting and quality control problems associated with some conventional recycling efforts. 4XDOLW\ &RQWURO In 1988, the Society of the Plastics Industry, Inc. (SPI) developed a voluntary resin identification coding system for plastic containers. The container coding system was created, using the input of recyclers and collectors, to meet the needs of the recycling industry. Although consumers often refer to it in determining which plastics to separate for recycling, the coding system is not intended for consumer use. Under the SPI coding system, each of the six primary packaging resins is assigned a number. 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