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MATERIALS RECOVERY FOR THE FUTURE:How Can We Capture More Value From Recycling?
SPC AdvanceOctober 9, 2019Beth Coddington, Senior Consultant, RRS
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The packaging recovery value chain is working together to perform a proof-of-concept pilot to collect and sort the current ton of packaging in single stream to make a new rFlex product bale and cleaner paper.
© RRS 2017
RESEARCH NEED
WE CAN DO BETTER ON FLEXIBLES & FILM RECYCLING
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1. Flexible Packaging Association .(2013). Flexible Packaging Industry Segment Profile Analysis (Commercial material removed and projected to 2015)2. American Chemistry Council .(2017). 2015 National Post-consumer Plastic Bag & Film Recycling Report. In . (Ed.). N.p.: Moore Recycling. Retrieved from https://plastics.americanchemistry.com/2015-National-Post-Consumer-Plastic-Bag-and-Film-Recycling-Report.pdf
12 BILLION LBS.(6 million tons)
Post-consumer flexible packaging market size1
209 MILLION LBS.(104,500 tons) (1.7%)Post-consumer film recycling, includes both retail drop-off and MRF curbside2
MRFF MEMBERS
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MRFF Steering Committee
American Chemistry CouncilFlexible Packaging AssociationLyondellBasell IndustriesCanadian Plastics Industry AssociationPlum Organics
The Plastics Industry AssociationSealed AirSC JohnsonJohnson & JohnsonMondelēz International
Chevron Phillips Chemical CorporationWestlake ChemicalMARSThe Association of Plastic RecyclersUnilever
Hosted by:Foundation For Chemistry Research & Initiatives
MRFF Supporters
Launching the first large-scale opportunity to collect flexible packaging loose in curbside bins
– the same way other packages get recycled.
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FIRST PROGRAM IN THE NATION
MRFF RESEARCH HAS TWO THRUSTS
• Technical feasibility of automated optical sorting to separate 2D flexible packaging from paper on MRF fiber lines• Economic feasibility of
processing and recycling the material into end market products
2019 MRF PILOT : TOTAL RECYCLE, BERKS COUNTY PA
• Owner J.P. Mascaro & Sons, 4th generation family owned business
• Large high speed MRF 700 TPD single stream in growth mode
• Introduce flexible packaging into their residential single-stream specification
• Recover maximum flexible packaging from the stream
• Create a viable bale for sale with a sustainable market
• Clean up the fiber bales • Provide a scalable model for other
MRFs across North America
http://www.wastetodaymagazine.com/article/jp-mascaro-sons-built-to-last/
PERFORMANCE GOALS OF THE MRFF MASCARO PILOT
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These five performance goals act also as the metrics for the pilot.
1 2 3 4 5Capture at
least 90% of FPP in
feedstock;
Minimize paper in FPP product (less than 15% by
weight);
Even with increased FPP in feedstock, reduce the
amount of FPP going into
fiber products;
Reduce fiber quality control
staff requirement by a minimum of 30%; and,
Controls integrated
with existing MRF control
system.
2019 PILOT: COMMUNITY COLLECTION PROGRAM
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• First collection program in Pottstown, PA launched in September 2019•Wide variety of
material added to residential curbside recycling
© RRS 2017
MRFF DEVELOPING END MARKETS IN PARALLEL WITH SORTING
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PEonly
Export
Lumber/ Extruded profiles
Film/Sheet
Durable Products
Pyrolysis
Engineered Fuel Pellets
Cement Kilns
WASHING
PELLETIZING
SHREDDINGSORTING
Growth for MRF Material
Potential Growth for rFlex
Nofiber
WASHING SHREDDINGSORTING
SHREDDING
NofiberSORTING
6 M lbs/yr(Pilot)
Building Products
SHREDDING
MIXED RESIN PRODUCTS PRODUCED IN EUROPE
END MARKET FOCUS ON LOCAL CIRCULAR ECONOMY
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• Continuus Materials (acquired ReWall) wallboard and roof system elements• Current plant in Des Moines, IA• Expansion plans – 2 additional facilities, one in PA• Successfully tested test rFlex bale
• Expert, well-established plastic recyclers testing in PA –UltraPoly, Ecostrate, Zzyzx plus others with variety of potential end uses for pellets
• Additional rFlex performance tests scheduled for 2019• Engage PA Recycling Markets Center as innovation hub
LEARNING FROM PILOT RESEARCH: THEORETICAL à REAL-WORLD
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What is the composition of the post-consumer FPP stream?
What resources are needed to sort FPP in the single stream MRF?
What is the resulting output?
What can be produced from the MRF output?
Which manufacturers want to utilize it as a feedstock?
IN CLOSING OUR OPPORTUNITY
Collaborate to
1) improve sorting of single stream materials
2) make a new flexible plastics bale for sale to sustainable markets
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