Recycling Product News January/February 2024, Volume 32, Number 1

8 WAYS AIM RECYCLING IS COMBATTING THE LABOUR SHORTAGE JANUARY/FEBRUARY 2024 recyclingproductnews.com PUBLICATIONS MAIL AGREEMENT NO. 40069270

WINTER MAINTENANCE TIPS FOR WASH PLANT OPERATORS THE ROLE OF AI IN THE MRF

SUPPLIER TO 7 NWRA “RECYCLING FACILITY OF THE YEAR” AWARD WINNERS Murphy Road Recycling, LLC Berlin, CT 2023

GFL Environmental Toronto, Canada 2022

Mazza Recycling Services Tinton Falls, NJ 2021

FCC Environmental Services Houston, TX 2020

Republic Services Plano, TX 2019

FCC Environmental Services Dallas, TX 2017

Sims Municipal Recycling Brooklyn, NY 2015

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Model 4 The new model 4 E-Z log Baler is just what mid size scrap yards have been asking for! Priced right for any yard — small, mid size, or large!

Like the Model 3, the NEW Model 4 has no set up time and a very low cost to operate.

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COVER STORY 8 WAYS AIM RECYCLING IS COMBATTING LABOUR SHORTAGES IN METAL RECYCLING

28 34

6 THINGS TO CONSIDER WHEN TRAINING MATERIAL HANDLER OPERATORS

40

KIA TO USE OCEAN PLASTIC IN FUTURE ELECTRIC VEHICLES

THE ROLE OF AI IN THE MRF

January/February 2024 | Volume 32, Number 1

FEATURES

DEPARTMENTS & SECTIONS

18

8 ways AIM Recycling is combatting labour shortages in metal recycling

8 10

News Room

Robot to save more than 1 million aluminum beverage cans annually from landfill

16

Spotlight

18

Metals

26

Size Reduction

28

Plastics

30

Paper

24 26

Shredding boosts sustainability for John Lawrie Tubulars

From the Editor

28

Kia to use ocean plastic in future electric vehicles

32

C&D

30

Paper recycling update

34

Equipment

32

5 winter maintenance tips for wash plant operators

40

Technology

42

Events Calendar

46

Advertiser Index

34

6 things to consider when training material handler operators

40

The role of AI in the MRF

JANUARY/FEBRUARY 2024 | VOLUME 32 • NUMBER 1 EDITOR IN CHIEF Kaitlyn Till ktill@baumpub.com 604-291-9900 ext. 330

DESIGN & PRODUCTION Morena Zanotto morena@baumpub.com 604-291-9900 ext. 325

EDITOR Slone Fox sfox@baumpub.com 604-291-9900 ext. 335

PRESIDENT/PUBLISHER Ken Singer ksinger@baumpub.com 604-291-9900 ext. 226

ASSOCIATE PUBLISHER/ VICE PRESIDENT OF SALES Sam Esmaili sam@baumpub.com 604-291-9900 ext. 110

VICE PRESIDENT/CONTROLLER Melvin Date Chong mdatechong@baumpub.com FOUNDER Engelbert J. Baum

ADVERTISING PRODUCTION MANAGER Tina Anderson production@baumpub.com 604-291-9900 ext. 222

Published by: Baum Publications Ltd.

FROM THE COVER AIM Recycling’s modern solutions are helping attract and retain talent in the scrap metal sector.

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Drop us a line any time.

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FROM THE EDITOR

FROM THE EDITOR ELECTRIC VEHICLES FUEL SURGE IN SCRAP TIRES

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hile the growing popularity of electric vehicles (EVs) bodes well for sustainability goals by encouraging more environmentally friendly transportation, many of the components used in EVs necessitate specialized recycling methods to mitigate environmental impacts and safety issues.

Despite widespread awareness of disposal challenges associated with EV recycling – most commonly the unique challenges presented by lithium-ion batteries – a recent white paper from the Recycled Rubber Coalition (RRC) titled An Unexpected Electric Vehicle Environmental Problem with Common Sense Solutions sheds light on a different issue: electric vehicles produce substantially more scrap tires than conventional cars.

Since the batteries in electric vehicles weigh more than combustion engines, the additional weight puts additional stress on the tires, leading to increased wear and tear and an overall reduced lifespan. The quick acceleration made possible by electric motors also leads to more aggressive tire wear, causing these heavier vehicles to consume tires up to 30 percent faster, as reported by the RRC. The increase in end-of-life tires from EVs poses a unique challenge for recyclers since more tires entering the waste stream heightens the risk of improper disposal. Tires decompose very slowly and are made from synthetic materials and chemicals that can lead to leaching and groundwater contamination. Additionally, the highly flammable nature of scrap tires poses environmental and health risks through the release of toxic smoke and other pollutants during tire fires.

While there are currently several end markets for recycled tires – most commonly rubberized asphalt and playground turf – and many successful methods to reuse and recycle them, the RRC notes a concerning trend. Tire production has now exceeded the demand for recycled rubber, causing the reuse rate to drop from 96 percent in 2013 to 71 percent in 2021. As the increase in EVs continues to compound this issue, more research into new markets for recycled rubber is needed.

To address this challenge, it’s essential to promote tire recycling programs, increase regulations against illegal dumping,

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recyclingproductnews.com | JANUARY/FEBRUARY 2024

Tire production has now exceeded the demand for recycled rubber, causing the reuse rate to drop from 96 percent in 2013 to 71 percent in 2021. and explore more sustainable alternatives to traditional tire materials. As the electric vehicle market continues to expand, advancements in tire technology will play a crucial role in combatting the increase in scrap tires associated with EVs. Establishing partnerships and collaboration with electric vehicle manufacturers can facilitate the development of tire solutions that are specifically tailored to the requirements of different EV models, taking into account factors such as weight distribution and regenerative braking. By implementing these strategies, tire manufacturers can contribute significantly to alleviating the challenges associated with the increased generation of scrap tires from electric vehicles, fostering a more sustainable approach to tire production, reuse, and recycling.

SLONE FOX Editor sfox@baumpub.com recyclingproductnews.com

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recyclingproductnews.com | JANUARY/FEBRUARY 2024

elly Green Products’ new manufacturing facility in Connecticut is now fully operational, recycling food and beverage cartons 24 hours a day, seven days a week.

The plant transforms cartons into durable building materials, expanding the U.S. market for recycled cartons.

Kelly Green Products manufactures Kelly Green Board, a roof and wall cover board made primarily from recycled aseptic and gable top cartons. Using a zero-waste process with a minimal carbon footprint, Kelly Green Board uses every part of the carton, including caps and straws, and is made without water, formaldehyde glues, or hazardous chemicals.

“Made mainly of paper with thin layers of aluminum and polyethylene, cartons provide the ideal combination of materials to create strong, hail- and moisture-resistant building supplies,” says Tom Kelly, president of Kelly Green Products.

“Each truckload of Kelly Green Board diverts approximately 30,000 pounds of cartons from landfills, allowing them to live on as roofing or wallboard for years to come.”

The Carton Council provided Kelly Green Products with an infrastructure grant to help establish this new end market for food and beverage cartons.

Kelly Green Products is actively sourcing bales of Grade #52 cartons from materials recovery facilities in the New England and Mid-Atlantic region and is exploring parts of eastern Canada. This provides another U.S. end market for cartons when sorted into Grade #52 bales, which can benefit all MRFs and communities.

“We are encouraged by the developments at Kelly Green Products,” says Jimmy Lawler, vice president of commodities at Balcones Recycling. “The more options we have for our bales of food and beverage cartons, the better. This regional end market is great motivation – for us and other MRFs here in the Northeast – to increase the number of cartons we capture and sort.”

TOYOTA TO SOURCE CRITICAL BATTERY COMPONENTS FROM REDWOOD MATERIALS

T

oyota Motor North America (TMNA) and Redwood Materials have expanded their battery recycling collaboration.

The expansion aims to create additional pathways for end-of-life Toyota EV batteries. Toyota’s automotive battery recycling needs are expected to grow in the coming years as more of Toyota’s EVs reach the end of their life cycle. With many of Toyota’s retiring fleet of EVs in California, Redwood’s Nevada recycling facility will support Toyota’s North American supply chain.

Toyota will source cathode active materials (CAM) and anode copper foil from Redwood’s recycling activities as part of the collaboration. Cathode active material recovered and produced from Redwood’s recycling activities is expected to feed recycled material into future new battery production at Toyota Battery Manufacturing North Carolina (TBMNC). The use of recycled materials is anticipated to help increase the focus and relevance of U.S. supply chains versus the extensive, carbon-intensive current supply chain of procuring outside of the United States. Toyota plans to bring its nearly $14 billion TBMNC automotive battery manufacturing facility online in 2025.

Redwood is making investments to scale its technology and facilities to supply U.S. battery cell manufacturers and automakers with battery materials produced in the U.S. Redwood continues to expand its Northern Nevada facility and will break ground on its second battery materials campus outside Charleston, South Carolina. Both of Redwood’s campuses will recycle, refine, and manufacture battery materials, aiming to scale the production of components to 100 GWh annually. Based on this agreement, Redwood will provide materials that include a minimum of 20 percent recycled nickel, 20 percent recycled lithium, and 50 percent recycled cobalt in their cathode and target recycled copper in their anode copper foil.

THE GOVERNMENT OF CANADA OPENS $1.5 BILLION CRITICAL MINERALS INFRASTRUCTURE FUND

M

inister of Energy and Natural Resources Jonathan Wilkinson has launched the call for proposals (CFP) of the Critical Minerals Infrastructure Fund (CMIF). The CMIF will look to address key infrastructure gaps to enable sustainable critical minerals production in Canada and to connect resources to markets. With up to $1.5 billion available over seven years, the fund will support clean energy and electrification initiatives as well as transportation and infrastructure projects.

Critical minerals are key enablers of clean technologies like batteries and clean energy sources, such as wind turbines and solar panels. These technologies are essential to achieving a net-zero-emissions future.

This CFP will be the first of several, with up to $300 million in contribution funding available under two streams: the pre-construction and project development stream and the infrastructure deployment stream. Through these streams, applicants can seek access to up to $50 million per project for nongovernmental applicants and up to $100 million per project for provincial and territorial governments investing in public projects.

The CMIF is a component of Canada’s Critical Minerals Strategy and will complement other clean energy and transportation support that is already benefitting the critical minerals sector. By investing in the infrastructure needed to develop critical minerals projects, the Government of Canada aims to help realize economic opportunities all along the value chain.

MODERN SOLUTIONS AIM Recycling is leveraging technology to build its team and tackle the labour shortage in the metal recycling industry.

Turn to page 18 to read more.

JANUARY/FEBRUARY 2024 | recyclingproductnews.com

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NEWS ROOM The new system is equipped with the latest Machinex sorting equipment such as ballistic separators, MACH Hyspec optical sorters, a SamurAI sorting robot for HDPE quality control and HDPE positive sorting, and an eddy current separator. Optical sorters that were not present in the original design were added to clean paper, and another was added to the container line to remove 3D fibre and film.

MACHINEX AND REPUBLIC SERVICES BRING ARIZONA MRF BACK TO LIFE AFTER FIRE

R

epublic Services and Machinex Technologies have collaborated to reopen a single-stream recycling facility in Scottsdale, Arizona. Back in 2019, the MRF was completely lost due to a fire incident.

The new system increased processing capacity from 25 to 40 tons per hour. This presented a significant challenge during the design phase, primarily due to the limited space available within the existing building. Republic Services had outgrown the facility, and due to contractual requirements between Republic and the Salt River Pima-Maricopa Indian Community where the building is located, it was required to be built back to the original specifications, necessitating the development of an innovative and space-efficient system to meet their evolving needs.

NEW REUSABLE BAG RECYCLING PROGRAM IN WESTERN CANADA

A

s part of its Planet Impact program, Vitacore has developed a scalable technology that enables the efficient recycling of reusable bags. The program will be available in all Pattison Food Group retail locations across Western Canada including Save-On-Foods, Buy-Low Foods, Choices Market, Nature’s Fare Markets, PriceSmart Foods, Nesters Market, and Quality Foods.

While the shift toward reusable bags in grocery stores across Canada has been a positive step, these bags are typically made from plastics such as polypropylene and have presented new environmental challenges. Existing recycling facilities are not equipped to process reusable bags, leaving Canadians with an accumulation of bags that lack a proper recycling pathway. It is estimated that reusable polypropylene shopping bags must be reused 10 to 20 times to have a lower environmental impact than single-use plastic bags.

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recyclingproductnews.com | JANUARY/FEBRUARY 2024

TERRACYCLE’S NEW PROGRAM BRINGS RECYCLING SERVICES TO VETERINARY CLINICS

T NOVAK AUTO PARTS WINS CERTIFIED AUTOMOTIVE RECYCLER OF THE YEAR

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ovak Auto Parts, a family-owned auto recycling business based in Pennsylvania, has garnered industry recognition from the Automotive Recyclers Association (ARA). ARA has recognized Novak Auto Parts as Certified Automotive Recycler of the Year.

At Novak Auto Parts, vehicles undergo a rigorous automotive dismantling process in which all fluids are drained, safely contained, and put to good use. Gasoline is repurposed to power on-site work vehicles, oil is used to heat buildings, and windshield washer fluid is purified and resold. Recycled Freon is also sold to repair shops and even the water used to wash car parts is collected, filtered, and reused on site.

erraCycle has launched VetCycle, a program designed to provide veterinary professionals with recycling options for hard-to-recycle waste commonly found in veterinary clinics, animal shelters, and labs.

It is estimated that 300 million pounds of pet food and treat bags are generated in the U.S. every year. Over 99 percent of those bags aren’t recycled. To address this typically non-recyclable waste, VetCycle utilizes TerraCycle’s Zero Waste Box program to recycle the most common waste streams found in veterinary settings like pet food packaging, pet products, plastic packaging, disposable gloves, disposable masks, safety equipment and protective gear, cleaning supplies, and synthetic disinfectant wipes.

Veterinary staff can order boxes that suit their needs and place them in high-traffic areas throughout the office to collect various categories of waste. Once full, the boxes can be shipped to TerraCycle to be recycled.

MORE NEWS

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NEWS ROOM ment service for developing infrastructure, including charging hardware, software, site design, obtaining permits, installation, utility coordination, and charging equipment maintenance.

Mack developed the Turnkey Solutions program to help companies transition to electric vehicles. Companies can choose which partner to bundle charging hardware and services with the purchase of their vehicles from InCharge Energy, Blink Charging, Gilbarco Veeder-Root, or Heliox.

Mack currently has two electric vehicles in its lineup: the MD Electric and the LR Electric. Ryan Saba, the energy solutions manager at Mack, says that this program expansion will make it easier for users to develop and install charging infrastructure for Mack’s lineup of electric vehicles.

WASTE CONNECTIONS TO PURCHASE 30 CANADIAN FACILITIES

MACK TRUCKS ADDS TWO NEW PARTNERS TO ITS EV INFRASTRUCTURE PROGRAM

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M

ack Trucks has added two new full-service partners, InCharge Energy and Blink Charging, to its Turnkey Solutions program for battery-electric vehicles.

These new partnerships are two of Mack’s current four with charging infrastructure development companies. Mack’s Turnkey Solutions program is an end-to-end fleet manage-

aste Connections has agreed to acquire 30 energy waste treatment and disposal facilities in Western Canada from Secure Energy Services for $1.075 billion.

As part of the agreement, Waste Connections will acquire 18 treatment, recovery, and disposal facilities; six landfills; four saltwater disposal injection wells; and two disposal caverns following Secure’s 2021 merger with Tervita Corporation.

The transaction remains subject to customary closing conditions, including receipt of Canadian Competition Bureau approval, and it is expected to close during the first quarter of 2024.

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6/29/22 3:07 PM

PET BOTTLE RECYCLING RATES HELD STEADY IN 2022

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he National Association for PET Container Resources (NAPCOR) has released its 2022 PET Recycling Report.

The report found that PET recycling rates held steady with the U.S. rate at 29 percent and the North American PET recycling rate at 37.8 percent. Demand for recycled PET (rPET) also remained strong in 2022, and a new milestone was reached with over 50 percent of end market consumption in the U.S. and Canada in bottle markets for the first time.

The PET recycling collection rate has remained steady, while there is a growing demand for more post-consumer recycled content among North American end markets. To meet this increased demand, more PET packaging needs to be collected through new policies and changes in consumer habits.

EPIROC TO ACQUIRE STANLEY INFRASTRUCTURE BRANDS INCLUDING LABOUNTY

E

piroc has agreed to acquire STANLEY Infrastructure – a global manufacturer of excavator attachments and handheld hydraulic tools – from Stanley Black & Decker. The strategic acquisition will strengthen Epiroc’s presence in the attachments business, especially in the United States.

The purchase price is MUSD 760 (SEK 7.8 billion.) The acquisition is an all-cash transaction with secured financing through a bridge facility. The acquisition is subject to customary regulatory filings and is expected to be completed in the first quarter 2024.

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SPOTLIGHT

SPOTLIGHT

INTRODUCTIONS & UPDATES

Static jaw crusher

Electric skid-steer loader

Cedarapids

JAW CRUSHER

The TJ2440 static jaw crusher is one of the most aggressive jaws in the 24-inch inlet gape by 40-inch inlet width size range, according to Cedarapids. The single-toggle jaw crusher is designed for tight closed-side settings while keeping an aggressive nip angle and crushing stroke. Its design helps ensure reliable operations with minimal downtime, supplying smooth crushing. The precision cast steel frame helps enable longevity but also minimizes maintenance and reduces operating costs, along with easy drop-in installation. The TJ2440 single-toggle jaw crusher is ideal for handling different types of materials like recycled concrete.

FirstGreen

ELECTRIC SKID-STEER LOADER

The Elise Clean Building Logistics (CBL) is a cabinless, fully remote-controlled, full-size skid steer ideal for indoor work. Removing the cabin from the design reduces the overall machine height and eliminates the need for FOPS/ROPS certification.

Loading capacity is improved, and weight distribution is more balanced with a lower centre of gravity that helps enhance stability. With no operator, the risk of injury or exposure to hazardous materials is reduced, making the machine suitable for high-risk applications. The loader also incorporates AI-powered analytics and Internet of Things connectivity, as well as an advanced materials database, allowing for real-time data processing and decision-making.

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recyclingproductnews.com | JANUARY/FEBRUARY 2024

Inclined screen

EvoQuip

INCLINED SCREEN

The EvoQuip Falcon 820 inclined screen combines scalping, screening, and stockpiling in one self-contained unit. It features a double-deck two-bearing screen box and can operate in multiple applications such as crushed stone, topsoil, and demolition waste. It also offers adjustable incline angles, allowing operators to optimize the screening process based on specific material requirements. Selected Falcon screens come with the T-Link telemetry system fitted as standard, providing operators with real-time information on the performance of the machine. This provides comprehensive information on the location, fuel consumption, tonnages, wear ratings, operating hours, and more.

Shredder

Hooklift

Stellar

Terex Ecotec

Stellar Industries’ NXT40 is the latest telescopic hooklift in the NXT Series and features a Z-channel base design and a universal body latching system. The NXT40 is a 40,000-pound-capacity hoist that is built for a tandem axle chassis with a 54/61.75-inch hook height and rectangular-style secondary jib. With approximately a 10.5-inch lost load height, the hooklift offers a low profile and provides a lower vertical centre of gravity and the ability to accommodate down to six-inch subframe heights. The NXT40 also has a universal hydraulic reservoir.

Terex Ecotec’s TDS 815 shredder is designed to tackle the diverse challenges that waste materials present. At the heart of the TDS 815 shredder is its compact 1.5m twin shaft shredding unit, which allows for highly efficient material reduction and makes it a versatile choice for a wide range of waste materials. The TDS 815 also offers users flexibility, with the option to operate the shredder with either synced or independent shafts to deal with various application requirements. Design features include a robust track sub-frame with bolt-on tracks, catering to both track and track/hooklift versions.

HOOKLIFT

SHREDDER

JANUARY/FEBRUARY 2024 | recyclingproductnews.com

17

METALS

8 WAYS AIM RECYCLING IS

COMBATTING LABOUR SHORTAGES IN METAL RECYCLING

HOW MODERN SOLUTIONS ARE HELPING ATTRACT AND RETAIN TALENT IN THE SCRAP METAL SECTOR

BY SLONE FOX, EDITOR

AIM Recycling has grown to include over 4,000 employees at more than 135 sites worldwide.

METALS

T

ing recruiting strategies by targeting underrepresented groups like immigrants, refugees, or individuals with disabilities. We’re continually researching automation and innovation to increase efficiency and productivity, as well as to improve working conditions and retain personnel.”

According to Melanson, AIM Recycling attributes labour shortages in the metal recycling sector to factors such as a lack of public awareness about the role metal recycling plays both economically and environmentally, as well as an absence of formal training programs and apprenticeships tailored to the industry’s specific needs. Moreover, Melanson notes that there’s a critical lack of skilled trades workers with expertise in recycling, metal processing, and heavy machinery operation, all of which are essential skills in the industry. Economic downturns have also contributed to a reduction in construction and manufacturing, directly impacting demand for labour in the scrap metal sector.

Addressing these challenges will be crucial in ensuring the industry can meet the rising demand for recycled metals, an uptick that Cooper says is fuelled by infrastructure development, automotive manufacturing, and the widespread use of consumer electronExpansion not only leads to efficiency ics. To meet these needs, facilities must expand to handle the growing volume of improvements, but also enhances materials.

“Expansion not only leads to efficiency operational efficiency, reduces processing improvements, but also enhances operacosts, and increases competitiveness. It tional efficiency, reduces processing costs, and increases competitiveness,” says Cooenables facilities to offer a broader range of per. “It enables facilities to offer a broader recycling services, including electronic waste range of recycling services, including electronic waste recycling, opening up new recycling, opening up new revenue streams revenue streams and meeting changing and meeting changing customer demands. customer demands.”

As the company continues to grow, AIM Corey Cooper Recycling is equipping employees with the necessary skills and opportunities for Director of Marketing, AIM Recycling growth by investing in training, promoting from within, encouraging cross-functional “The shortage has created growth opportunities for existing skills, and fostering mentorship, all of which contribute to employees, with a focus on training and advancement proattracting and retaining employees in the long run. Here are grams,” says Melanson. “As AIM Recycling continues to develop eight strategies that AIM Recycling is leveraging to build its our current and future workforce, we’re investing in advanced team and tackle the labour shortage in the metal recycling training to enhance the skills of our workforce, while diversifyindustry. he scrap metal recycling industry has long faced a shortage of skilled labour, negatively affecting both operational efficiency and processing capacity at recycling facilities. To combat this issue, recyclers are turning to modern solutions – such as artificial intelligence and social media – to mitigate the adverse effects of a lack of available workers.

Taking the lead in these initiatives is AIM Recycling, a division of American Iron & Metal (AIM), a family-owned enterprise and a significant player in ferrous and non-ferrous metal recycling. Founded in 1936, AIM Recycling has grown to include over 4,000 employees at more than 135 sites worldwide, distinguishing itself by placing employee development at the core of its business strategy. To better understand how one of the largest metal recyclers is tackling this critical issue, I spoke with Director of Marketing Corey Cooper and Talent Acquisition Manager Ryan Melanson to get their perspective on the challenges and opportunities associated with labour shortages.

Inside one of AIM Recycling’s yards.

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recyclingproductnews.com | JANUARY/FEBRUARY 2024

AIM Recycling’s California drivers show their pride.

1

RECRUITMENT AND ACQUISITION

As part of their hiring strategy, AIM Recycling strategically uses platforms like Indeed, LinkedIn, and Glassdoor to recruit new employees, something that Melanson says has doubled AIM Recycling’s reach. Taking charge of recruitment internally through a centralized talent acquisition function has further enhanced the selection process, allowing the company to identify, attract, and hire workers without the need for external agencies.

Melanson says that AIM Recycling also incorporates artificial intelligence into its recruitment process, generating tailored behavioural questions, interview guides, and other resources for each specific position.

2 AWARENESS CAMPAIGNS

Through collaboration with government agencies, industry associations, and educational institutions, AIM Recycling works to enhance public awareness of the benefits of careers in the metal recycling sector. According to Melanson, emphasizing the industry’s contribution to sustainability and resource preservation serves as a strategy to attract new talent.

AND 3 STANDARDIZATION TRAINING

With the labour shortage making it difficult to find workers with the necessary skills and qualifications for positions in the scrap metal industry, AIM Recycling provides training and development programs for its staff, helping to bridge skills gaps and promote career advancement through cross-training, says Melanson.

This approach ensures that employees are prepared to take on various roles seamlessly, promoting operational resilience and flexibility.

Moreover, the company is implementing standardized management training programs across all of its sites, aiming to create a cohesive approach to leadership and management within the organization. As a key part of this initiative, AIM Recycling also creates in-house train-

ing manuals and conducts assessments.

“Our company has taken proactive steps to address the challenges of finding qualified candidates by implementing our own training manuals specific to our industry standards,” says Melanson. “For example, new hires that will be operating the crane are required to complete an evaluation at the end of their training guaranteeing that they possess the necessary skills and knowledge.

By adopting these measures, our company not only maintains a skilled workforce but also contributes to the overall development of industry standards.”

4 ASSET MANAGEMENT

According to Cooper, AIM Recycling’s dedication to asset management has resulted in some of the best equipment life cycles across its entire fleet, helping the company gain a competitive edge within the industry.

5 ENVIRONMENTAL STEWARDSHIP

When it comes to green initiatives, Cooper says AIM Recycling leads by example, integrating environmental responsibility throughout its operations in the form of sustainable practices, emissions reduction, and an overall minimization of its ecological footprint.

As an integral part of this, Cooper highlights that AIM Recycling actively advocates for policies supporting recycling, environmental sustainability, and the circular economy, factors that play a key role in shaping the industry’s future.

“Our vision is centred around sustainability, aiming to reduce the environmental impact of metal extraction and processing, while conserving natural resources,” says Cooper. “Improving productivity, sorting accuracy, and overall environmental performance requires embracing sophisticated technologies with automation and data analytics. AIM Recycling envisions a future where materials are continuously recycled and reused, thereby reducing waste and minimizing the need for primary resource extraction.”

JANUARY/FEBRUARY 2024 | recyclingproductnews.com

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METALS

An AIM Recycling locomotive.

6 RECYCLING PRACTICES

When it comes to its day-to-day operations, Cooper says AIM Recycling actively pursues new recycling techniques, seeks to improve material recovery rates, and explores innovative methods for recycling and recovering valuable materials from sources such as electronic waste, industrial machinery, and automotive parts.

“By continuously seeking new methods for recycling and recovery, AIM Recycling positions itself as an industry pioneer, attracting employees who are passionate about environmental sustainability and innovation,” says Cooper.

7 COMMUNITY SUPPORT

By engaging with local communities, providing educational programs, and supporting initiatives that promote recycling and environmental awareness, AIM Recycling has been able to foster positive relationships in the areas it operates in, says Cooper.

“We’re dedicated to helping with the development of new programs, mentorship opportunities, and extra fundraising initiatives while investing in the communities we are a part of and supporting regional and national organizations and causes,” says Cooper. “In the last five years alone, AIM has donated over $15 million to the communities it serves, focusing on healthcare and education, as well as children and youth.”

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Cooper also notes that the expansion of recycling facilities generates positive effects for surrounding communities by creating job opportunities in operations, maintenance, administration, and management.

The increased economic activity associated with expansion, including relationships with suppliers and local spending by employees, can also play a role in stimulating the local economy.

8 EMPLOYEE WELL-BEING

Recognizing the importance of employee well-being in today’s job market, Melanson says AIM Recycling offers competitive salaries and benefits packages, paid time off, and a Years of Service program that recognizes and rewards employees.

Beyond monetary incentives, the company is actively developing a collection of initiatives intended to increase employee satisfaction, well-being, and recognition, which in turn increases productivity and employee engagement.

“Our commitment to employee well-being is prevalent throughout our history. As one of the first metal recyclers globally to bring our operations indoors and into a heated warehouse, we were invested in providing a comfortable and safe working environment, further demonstrating our dedication to the health and comfort of our workforce, while setting us apart from competitors,” says Cooper. RPN

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METALS

ROBOT TO SAVE MORE THAN 1 MILLION ALUMINUM BEVERAGE CANS ANNUALLY FROM LANDFILL CMI TO SUPPORT ADDITIONAL CAN CAPTURING EQUIPMENT AT MRFS WITH LEASING MODEL

T

he Can Manufacturers Institute (CMI) is funding a robot at a California MRF owned by Caglia Environmental.

Designed by artificial intelligence and robotics company EverestLabs, the robot is expected to capture a little over 1 million used beverage cans (UBCs) per year.

CMI used funding from its members Ardagh Metal Packaging and Crown Holdings to fully finance the two-year equipment lease for Caglia, which will share 50 percent of all revenue from the UBCs captured with the leased equipment with CMI. The lease program is the latest in a multi-year effort by CMI to demonstrate potential additional revenue for the recycling system through capturing missorted UBCs and to spur the installation of additional can capturing equipment in MRFs. “We are excited about the lease model because it highlights that aluminum beverage cans are consistently one of the most valuable recyclable commodities and further exemplifies how this recycled beverage container pays its own cost of recycling due to that high market value,” says John Rost, vice president of global sustainability and regulatory affairs at Crown. “CMI research has concluded that without the vital revenue from UBCs, most MRFs would not be able to operate without a change to their business model.”

The potential to capture missorted UBCs at MRFs is significant. CMI’s 2020 research Aluminum Beverage Can: Driver of the U.S. Recycling System found that up to one in four aluminum beverage cans is missorted at a typical MRF. CMI also supported on-the-ground testing in 2022 at five loss points across three diverse MRFs. This testing found an average loss of seven to 36 UBCs per minute, which represents an annual average revenue loss of $71,900 with a payback period of three years per the

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The revenue from the cans captured with the leased equipment can be used to finance even more can capture equipment at additional MRFs. Jens Irion CEO, Ardagh Metal Packaging North America return-on-investment calculator that CMI commissioned and published online for MRFs to use.

At Caglia’s Cedar Avenue Recycling and Transfer Station (CARTS) in Fresno, California, there is the potential to capture additional cans. This facility, which focuses on continuous improvement and has a recently upgraded single-stream sort line, will place the leased robot on its “last chance line” to capture UBCs mistakenly sorted to material destined for landfill.

“We put EverestLabs’ robot on the last chance line and have it focusing on aluminum beverage cans so that it’s picking ‘gold’ out of the trash,” says Corey Stone, plant maintenance manager at CARTS. “This lease provides a no-risk, no-cost way for Caglia to advance its goal of capturing all recoverable material coming through its facility.”

This lease provides a no-risk, no-cost way for Caglia to advance its goal of capturing all recoverable material coming through its facility.

Corey Stone Plant Maintenance Manager, CARTS riod of time. Caglia plans to use the experience with this robot to see how else it can deploy technology at its MRF to maximize its recovery efforts. CMI intends to support additional can capturing equipment at MRFs with the lease model and will use learnings from this first lease to refine its approach to can capturing equipment financing.

Along with this first lease, CMI has also funded grants from The Recycling Partnership with capital from Ardagh Metal Packaging and Crown. The five grants funded in 2021 doubled expected performance with 140 million aluminum beverage cans captured each year by the equipment installed with the grants.

Caglia will share 50 percent of all revenue from the captured cans with CMI.

Caglia estimates with previously conducted vision studies and analysis that EverestLabs’ robot will capture 32,000 pounds of UBCs per year that otherwise would have gone to landfill.

This is equivalent to collecting a little more than 1 million UBCs per year, or around three UBCs per minute of operation. Caglia will share with CMI 50 percent of all revenue from the cans collected via the leased robot, including the revenue from the sale of the UBCs and the revenue from California’s beverage container recycling refund program.

“Considering metal recycles forever – with 93 percent of recycled aluminum beverage cans turned into new cans and recycled aluminum 94 percent less carbon-intensive than making primary aluminum – it is imperative that recycling sortation facilities capture all cans for the aluminum industry to buy and recycle,” says Jens Irion, CEO of Ardagh Metal Packaging North America. “We are proud to have instituted a circular financing model for the textbook example of the circular economy – the aluminum beverage can. The revenue from the cans captured with the leased equipment can be used to finance even more can capture equipment at additional MRFs.” Now that EverestLabs’ 3D depth-sensing camera, AI, and robot have been installed at Caglia’s Fresno MRF, the RecycleOS data platform is delivering daily reports on the number of missorted UBCs each day, along with the economic value of these cans and the greenhouse gas emissions saved from recycling them. So far, the equipment is seeing up to 1,400 UBCs per day and recovering a majority of them so that they go into the circular supply chain rather than going to landfill.

Caglia, CMI, and EverestLabs plan to provide updates with further data after the equipment has operated for a longer peJANUARY/FEBRUARY 2024 | recyclingproductnews.com

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SIZE REDUCTION

SHREDDING BOOSTS SUSTAINABILITY FOR JOHN LAWRIE TUBULARS A NEW UNTHA SYSTEM ENABLES IN-HOUSE RECYCLING OF ITS TUBULAR BY-PRODUCTS The RS40 four-shaft shredder from UNTHA UK.

J

ohn Lawrie Tubulars – a company that processes, supplies, and distributes tubular steel products for the construction industry – is investing in a system that enables the 100 percent in-house recycling of its tubular by-products. A specially configured RS40 four-shaft shredder from UNTHA UK is now in operation, following successful trials earlier in the year.

With operations in the UK and the U.S., John Lawrie Tubulars’ 15-acre Montrose facility in Scotland houses a full-service manufacturing, cleaning, recycling, and warehousing operation, supplying an international customer base.

The company purchases steel tubulars from the oil and gas industry before giving the products a new lease of life in construction piling. Repurposing the materials achieves 97.21 percent carbon emission savings compared to using raw materials, with no detriment to quality.

Aiming to continually improve its sustainability agenda, John Lawrie Tubulars has now also invested in an UNTHA plastic shredder. The machine can process half a tonne of screw caps per hour, shredding the otherwise bulky material down to a homogenous 15mm fraction.

Drum and overband magnets affixed to the discharge conveyor extract metal content from the output material for local resale and recycling in Aberdeen while the clean, high-quality plastic is also sent for remanufacturing. This results in the 100 percent reuse of material that was previously unusable.

Commenting on the investment, John Lawrie Tubulars’ UK sales and purchasing manager Iain Bell says, “We had heard that UNTHA shredders are valued for their longevity and reli-

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As the RS40 was already in stock and immediately available from our North Yorkshire headquarters, we simply configured the technology to meet John Lawrie Tubulars’ specific requirements.

Lewis Horne Sales Consultant, UNTHA UK ability, which is something we value as a company. We therefore arranged a trial with a small sample of material, to see if the technology could tackle our input material. Impressed from the outset, we then arranged a second shred test to see how the machine performed with a full load.”

“As the RS40 was already in stock and immediately available from our North Yorkshire headquarters, we simply configured the technology to meet John Lawrie Tubulars’ specific requirements,” says UNTHA UK Sales Consultant Lewis Horne. “That’s the beauty of this flexible recycling system. Only the conveyor required manufacturing, which shortened the lead time to commissioning. We’ve invested heavily in stock machines for this reason.”

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PLASTICS

KIA TO USE OCEAN PLASTIC IN FUTURE ELECTRIC VEHICLES WASTE RETRIEVED FROM THE OCEAN WILL BE UPCYCLED TO CREATE VEHICLE COMPONENTS

K

ia plans to use recycled plastic from a 55-ton haul recently reclaimed from the Pacific Ocean in its new electric vehicle models. The record-breaking amount of plastic reclaimed by Kia’s global partner, The Ocean Cleanup, marks the next phase in a seven-year global partnership that started in April 2022.

The Ocean Cleanup, an international non-profit project with the mission of ridding the oceans of plastic, landed its plastic catch in Victoria, B.C. The record catch was removed from the Pacific Ocean using The Ocean Cleanup’s System 002 extraction technology following a lengthy voyage through the Great Pacific Garbage Patch (GPGP). The GPGP is the world’s largest accumulation of floating waste and has an estimated surface area of 1.6 million square kilometers – equivalent to three times the size of France.

After recycling the captured plastic, Kia will use a proportion of the material in future models of vehicles. Already, Kia has successfully implemented more than 30 sustainable solutions in various product areas, including fabrics and carpets using recycled PET, bio-based alternative leather, and BTX-free paint.

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In the case of the brand’s all-electric SUV flagship model, the EV9, upcycled waste, such as fishing nets retrieved from the ocean, is used to create the vehicle’s floor carpets. The components used in the construction of the EV9 are made from recycled plastic and bio-based, eco-friendly materials and weigh approximately 34 kilograms.

SCALING UP

Immediately after bringing the record haul to shore, The Ocean Cleanup announced the introduction of its new System 03 technology. Almost three times larger than System 002, System 03 can capture much larger quantities of plastic at a lower cost per kilogram on a continuous year-round basis. It also features more sophisticated environmental monitoring and safety technology, such as a new Marine Animal Safety Hatch designed to protect marine life. This scale-up marks the next phase toward The Ocean Cleanup’s objective of removing 90 percent of floating ocean plastic by 2040.

“This record delivery marks the end of the System 002 era for The Ocean Cleanup, and the perfect platform as we launch System 03. We are moving forward step-by-step, and

According to The Ocean Cleanup, it set a new record for the amount of plastic reclaimed from the ocean.

we believe that System 03 represents the size of the system required to scale up and expand our cleanup in the most economical way. Beyond System 03, we plan to deploy a fleet of systems that together will be capable of removing 50 percent of the GPGP every five years,” says Nisha Bakker, director of partnerships of The Ocean Cleanup. “However, we cannot do this alone. Committed and valued partners, and particularly our global partner Kia, remain essential for The Ocean Cleanup to bring our shared ambitions of plastic-free oceans to reality.”

“The record catch of plastics brought to shore by The Ocean Cleanup for recycling is tangible proof of how technology can deliver sustainable solutions at scale. Kia’s partnership with The Ocean Cleanup demonstrates the brand’s commitment to having a positive impact. Initiatives such as this one perfectly align with Kia’s transition to a sustainable mobility solutions provider and our Plan S strategy, through which we embrace the needs of our customers and the protection of our environment by acting as a responsible corporate citizen,” says Charles Ryu, senior vice president and head of the Global Brand & CX Division at Kia.

The record-breaking amount of plastic reclaimed

by The Ocean Cleanup marks the next phase in a seven-year global partnership with Kia.

Beyond System 03, we plan to deploy a fleet of systems that together will be capable of removing 50 percent of the GPGP every five years.

Nisha Bakker Director of Partnerships, The Ocean Cleanup

JANUARY/FEBRUARY 2024 | recyclingproductnews.com

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PAPER

PAPER RECYCLING UPDATE AVERAGE RECYCLED CONTENT OF CANADIAN-MADE PAPER PACKAGING IS MORE THAN 80 PERCENT

T

he latest research results from the Paper and Paperboard Packaging Environmental Council (PPEC) show the success of the paper packaging circular economy and confirm that the feedstock used for the production of boxboard and containerboard in Canada is made of primarily recycled content fibres.

The latest report represents the results of the 17th biennial Recycled Content Survey, which is conducted to determine the average recycled content contained in the major paper packaging grades made by Canadian mills.

The 2022 results show that the average recycled content of domestic shipments for the top two major packaging grades was 80.2 percent. The average recycled content for domestic shipments of boxboard was 86.2 percent, while the average recycled content for domestic shipments of containerboard was 81 percent.

“These latest results continue to validate the success of our industry’s circular economy in collecting and recycling paper-based packaging and ensuring they are remade into new products again and again,” says Chris Bartlett, chair of the PPEC. “With a recycled content rate of over 80 percent and confirmation that our boxboard and containerboard made in Canada is primarily recycled content fibres, we are proud of the progress our industry has and continues to make.”

In Canada, mills produce the raw material used to make paper-based packaging – the majority of which use 100 percent recycled content – which is sent to a converter where it is made into packaging products. Once used by the customer, it is recycled, making its way back to the mill to be remade into new paper packaging products.

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ISRI LAUNCHES ONLINE TOOL TO CHECK RECYCLABILITY OF FIBREBASED PACKAGING

I

SRI has launched a new tool to help recycle more packaging in the United States. The new Fiber Recycling Readiness Tool is a research-based online resource developed by ISRI that assesses the compatibility of typical consumer fibre-based packaging in the U.S. residential recycling system. As one of the most widely recycled materials in the world, fibre-based packaging recycling recovers fibre used to manufacture other paper products while producing jobs and protecting the environment.

Retail shelves across the country are filled with a growing number of fibre-based packaging like paper, paperboard, and corrugated boxes. ISRI’s new tool will provide brands, packaging developers, and other stakeholders with clear guidance on whether their packaging will successfully pass through the current recycling infrastructure,” says ISRI President Robin Wiener. “This tool is a great advancement for the recycled materials industry.”

The tool is based on industry expert knowledge, including a comprehensive ISRI-commissioned Moore & Associates study on the current material recovery facility and paper mill infrastructure across the United States. Currently, many brands test package recyclability by running tests at MRFs and universities specializing in fibre recycling. This tool represents a major advancement in that it captures the package design, processing, and end use in one resource.

The online resource automatically scores each criterion and shares a simple, colour-coded result that will determine whether the packaging meets the criteria (green), has challenges that require modifications (yellow), or does not meet the criteria (red). The tool also provides individualized feedback on design choices that could improve the package’s recyclability.

CARTON COUNCIL OF CANADA AND INNOFIBRE PARTNER TO RESEARCH NEW MARKETS FOR CARTONS

M

anufacturers of packaging, insulation, and other products made from recycled fibres are facing a shortage of raw materials due to the decline in newsprint and office paper volumes and increased demand for corrugated cardboard boxes.

To provide them with an alternative source of quality fibre, Innofibre, a cellulosic-product innovation centre, will undertake two studies in partnership with the Carton Council of Canada (CCC) that could lead to the creation of new end markets for food and beverage cartons.

The first of these applied research projects focuses on moulded pulp packaging such

as egg cartons and protective trays for electronic equipment, as well as thermoformed items often designed to replace plastic. Moulded pulp packaging is most often produced from unbleached pulp that is placed in moulds and then oven-dried. Thermoforming, on the other hand, typically uses bleached pulp and a high-temperature press to produce items with thinner, smoother, and more rigid walls.

The Innofibre research team will produce the required pulp from post-consumer cartons on-site and will then evaluate the production processes and physical properties of the resulting items,

as well as their potential to be recycled in the future. Work will also be carried out to determine the properties of the PolyAl obtained during fibre separation (i.e., the substance that combines the aluminum and polyethylene in cartons) for industrial uses. This study is primarily funded by the CCC and the first results are expected in early 2024.

The second project aims to evaluate the use of shredded cartons in cellulose insulation

products that are blown into building ceilings and walls.

The study is currently awaiting funding confirmation and could be up and running as early as the beginning of 2024.

A Quebec cellulosic insulation manufacturer interested in the potential of this carton application is already involved.

For this and the packaging study, the CCC will supply the required quantity of carton bales, which it will obtain from a Quebec MRF.

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JANUARY/FEBRUARY 2024 | recyclingproductnews.com

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C&D

5 WINTER MAINTENANCE TIPS FOR WASH PLANT OPERATORS GET READY FOR AN EFFICIENT RETURN TO PRODUCTION IN SPRING WITH EFFECTIVE PLANNING

T

he icy grip of the winter season presents a unique set of challenges for wash plant operators, but with effective planning, materials producers can protect their investment and ensure their operations are ready for an efficient return to production in spring.

When it comes to plant maintenance, any potential complications must be identified and remedied quickly to protect an operator’s investment and ensure optimal performance, particularly during the coldest months of the year when washing and classifying equipment is especially susceptible to the elements.

“In this business, time is money,” explains Mike Matusik, a customer relationship manager at CDE. “Implementing a robust maintenance program year-round will safeguard equipment from the taxing cold weather, helping to minimize downtime for unscheduled maintenance and maximize product output. With planning and preparedness, operators can ensure the safe and efficient shutdown of a wash plant in winter and facilitate an efficient restart of operations in the spring. While there is no one-size-fits-all approach, there are some basic steps operators can take to protect their investment.”

WINTER MAINTENANCE TIPS

1. Water management Effective water management should be paramount for operators as the cold weather sets in.

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It’s advisable to drain all standing water from tanks and pumps when plants are mothballed for the winter season, otherwise lines could freeze and crack, leading to a delayed and costly restart in the spring.

2. Insulate The winter months can bring unforgiving conditions, so consider insulation to protect pipes, valves, and pumps. Ensure your control cabin has been closed, and, if possible, keep the internal heating on to protect the beating heart of your plant from plummeting temperatures.

3. Open valves In addition to draining the system and insulating pipes, valves, and pumps, it’s also advisable to keep valves open during winter shutdown as this will prevent any residual water from accumulating in the system.

4. Spray bars Clean out spray bar nozzle heads and ensure smaller pipework is free of debris such as silt and sand. Make sure your spray bars are receiving adequate water pressure, and that the spray from the nozzles is fanning at the correct angle. This will allow you to get more water onto the screen to ensure the product is getting the best washing treatment.

5. Safety protocols Winter poses additional safety concerns for plant operators. Consider refreshing and rehearsing your training procedures to ensure your teams are well-versed in the appropriate safety protocols when working near a wash plant to avoid slips, trips, and falls.

Implementing a robust maintenance program yearround will safeguard equipment from the taxing cold weather, helping to minimize downtime for unscheduled maintenance and maximize product output.

Mike Matusik Customer Relationship Manager, CDE

our commitment to providing a lifetime of care to customers and ensuring their long-term success.”

As part of its free plant health check initiative, CDE’s service engineers will analyze the plant’s condition, highlight signs of wear or irregular noises, identify parts in need of replacing, schedule regular maintenance, support and advise operators, and recommend fast-moving parts ideal for storage on site.

PROACTIVE PLANT MAINTENANCE

Proactive and preventive approaches to plant maintenance during the winter months are essential for long-term efficiency and profitability. However, unforeseen challenges can still arise despite best-laid plans, explains CDE Customer Relationship Manager Andrew Bunting.

“A responsive service is key when the unexpected occurs. For the CDE CustomCare team, the name of the game is minimizing, and, where possible, wholly eliminating any unexpected downtime by supporting customers to get up, running, and processing material again as fast as possible, whether that’s during the normal production season or when starting up production again once winter is behind us.”

In order to respond in a timely manner, CDE holds stock of parts locally, from screen media and cyclone parts to Marsh Mellow springs, motors, and gearboxes. These are all available for immediate dispatch to customers from CDE’s North American headquarters in Fort Worth, Texas.

“Our CustomCare team holds a complete order history detailing critical plant components and spare parts for each of our customers’ wash plants. This helps ensure straightforward re-ordering and allows our service engineers to maintain a comprehensive overview of how a plant is performing.”

Prevention is always the number one focus, Bunting adds.

“We work closely with our customers to deliver regular preventive maintenance inspections which are highly effective at identifying potential issues before they arise and adversely impact production. Our plant health checks are just one part of

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EQUIPMENT

Operators must undergo adequate training either in a classroom setting or through hands-on instruction.

6 THINGS TO CONSIDER WHEN TRAINING MATERIAL HANDLER OPERATORS FOLLOWING OPERATIONAL INSTRUCTIONS, SAFETY GUIDELINES, AND ROUTINE MAINTENANCE IS ESSENTIAL

BY ALLISON GRETTENBERG

I

nadequate training for heavy equipment operators is a significant contributor to accidents and fatalities, according to the Occupational Safety and Health Administration (OSHA).

Proper training can reduce these risks.

“Material handler operators must possess a deep understanding of safety protocols, regulatory compliance, and effective communication practices,” says Troy Hitchcock, heavy equipment product specialist at DEVELON. Here are several factors to consider when it comes to training and skills development for material handler operators.

TRAINING RESOURCES

All employees who will be operating material handlers need to undergo adequate training, whether it be in a classroom

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setting or through hands-on instruction. They should possess a general understanding of the basic functions of a machine’s controls, gauges, signals, indicators, and monitor displays before operating. A critical component of this understanding is the ability to comprehend the instructions specified in the manufacturer’s operation and maintenance manual.

“The manual serves as a primary guide for proper material handler operation and maintenance, and it is provided upon delivery from your local dealership,” says Hitchcock. “The manual can be kept in the machine’s cab for quick reference.

An electronic copy, such as a PDF, may be available on a smartphone or tablet.”

The Association of Equipment Manufacturers (AEM) safety manuals, available in print and digital formats, also serve as

AVM systems allow operators to identify potential hazards and obstacles that might not be visible from their seat.

references on proper operating practices.

Before operation and maintenance, operators should review safety and instructional decals. Some manufacturers strategically place decals on the interior and exterior of heavy equipment to alert operators about potential hazards, the consequences of injury, and instructions on how to avoid the hazard.

Replace decals that become worn, damaged, or missing.

LOCAL DEALERSHIPS

Hitchcock emphasizes that dealer service technicians also possess the necessary product knowledge and experience to troubleshoot and maintain material handlers. Their familiarity with the machinery enables them to explain recent technology updates, facilitate demonstrations, and help operators maximize their machine’s performance.

SAFETY GUIDELINES

To stay safe at a recycling facility, understand and follow safety guidelines, such as wearing protective clothing and personal safety devices.

Personal protection equipment (PPE) may include the following items: • Hard hat • Safety shoes • Safety glasses • Heavy gloves • Hearing protection • Reflective clothing PPE standards may vary by location, so always check local requirements.

Operators should be able to see the attachment working at ground level from a normal seated position in the cab.

Efficient and safe operation may include using camera systems, such as the around view monitor camera system, which have become very popular on heavy equipment like material handlers. These systems use cameras mounted on the machine to provide as much as 360 degrees of visibility to the surrounding area, giving the operator better situational awareness.

Troy Hitchcock Heavy Equipment Product Specialist, DEVELON

JANUARY/FEBRUARY 2024 | recyclingproductnews.com

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EQUIPMENT “Use the grab handles and steps that are provided for three points of contact when entering and exiting the material handler, wear tight-fitting clothing that cannot get caught on working components or the machine, and always wear a seatbelt,” says Hitchcock.

MACHINE FEATURES

Material handlers can be highly technical, especially with the evolution of smarter technologies. For example, certain machines are equipped with selectable power modes designed to help operators balance fuel consumption and machine power according to working conditions. Select models may feature a lifting work mode, providing increased pump torque, low engine rpm, and automatic power boost.

“Efficient and safe operation may include using camera systems, such as the around view monitor (AVM) camera system, which have become very popular on heavy equipment like material handlers,” Hitchcock says. “These systems use cameras mounted on the machine to provide as much as 360 degrees of visibility to the surrounding area, giving the operator better situational awareness.”

AVM systems allow operators to identify potential hazards and obstacles that might not be visible from their seat, reducing the risk of accidents and injuries. These systems can also improve productivity and efficiency by reducing the time required for operators to look around and check their surroundings manually.

Object detection is another newer technology that improves safety by enhancing operator awareness.

“Sensors emit a sound to alert the operator when they are about to bump into a person or object entering the operation area,” Hitchcock says. “The sound may get louder or more frequent the closer the machine gets to the object or person.”

Familiarize yourself with multi-functional display panels before operating. Display panels show critical machine data, such as speed, engine rpm, transmission gear, machine warnings, coolant temperature, and transmission oil temperature.

Some manufacturers offer display panels that provide machine parameters while showing the rear-view or side-view camera image. Other features can include travel alarms/backup alarms, work lights, mirrors, and a horn, depending on the material handler.

ROUTINE MAINTENANCE Operators should know how to use and maintain scrap-handling attachments, such as grapples, shears, and magnets.

Telematics provides access to vital equipment data, like location and machine information, that helps operators maintain equipment. It also helps reduce the risk of equipment theft and can identify ways to work more efficiently at recycling centres.

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Before beginning work, take a few minutes to walk around the material handler to look for potential issues. A few tips from Hitchcock include: • Check for broken, missing, or damaged parts and make necessary repairs.

• Ensure that there are no damaged or missing safety or instructional decals and replace them if needed.

• For wheel models, inspect tires for cuts, tearing, or over-inflation and replace tires if needed.

• Check wheels for damaged rims and missing or loose wheel nuts or bolts. Repair or replace as needed.

• Review tracks for broken or damaged pins, bushings, or other track parts. Replace worn or damaged tracks.

• Check the fluid levels, including engine hydraulic oil and coolants, and fill as necessary.

• Look for leaks, and have any leaks repaired.

• Remove any flammable debris from the engine compartment and battery box, around exhaust components, under

the machine, and around rotating parts.

• Inspect lights, cab glass, side mirror, and rear-view camera (if present) for damage.

• Clean and inspect all walking surfaces, steps, and grab handles.

• Check the hydraulic risers on select models to make sure they are fully functioning.

Material handler operators should complete pre-operational equipment checks on a routine basis. Some maintenance items may need to be completed by an authorized equipment dealership. Typical maintenance procedures, which are outlined in the maintenance manual, can be performed without any technical training.

ATTACHMENT MAINTENANCE

Lastly, operators should understand how to use and maintain scrap-handling attachments, such as grapples, shears, and magnets. Each attachment functions differently, so work closely with a local dealership to determine the right attachment for your application. Knowing the machine’s specifications before pairing it with an attachment can help reduce operator hazards and increase productivity.

“Operators should be able to see the attachment working at ground level from a normal seated position in the cab,” Hitchcock says. “Being able to comfortably see the attachment out front and having an unobstructed view of the machine’s rear is critical to proper machine operation.”

Telematics provides access to vital equipment data, like location and machine information, that helps operators maintain equipment.

Training and skills development for material handler operators can help reduce the risk of accidents and improve overall operational efficiency in material handling processes. Regular assessments and continuous improvement efforts are essential to keep operators up to date with the latest industry standards and technologies.

ALLISON GRETTENBERG is the PR and content strategy specialist at Two Rivers Marketing in Des Moines, Iowa.

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EQUIPMENT

MATERIAL HANDLERS

FOR WASTE AND RECYCLING APPLICATIONS

DEVELON DX225MH-5 LIEBHERR LH 60 M INDUSTRY LITRONIC

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The DEVELON DX225MH-5 material handler is designed for scrap recycling and material handling applications. It’s fitted with a 4-foot standard fixed cab riser for increased visibility and can be equipped with an optional 6-foot or 6.5-foot hydraulic cab riser.

The straight boom improves reach and lift height for better material placement, while the droop nose arm provides good grapple clearance and enhanced access to containers, trucks, and railcars.

The X-chassis crawler frame design delivers greater ground clearance, improving maneuverability so operators can navigate crowded job sites. Thicker guarding on the DX225MH-5 undercarriage improves component protection for the drive motors.

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With an operating weight between 121,300 and 134,500 pounds (55–61t) and an engine output of 190 kW / 255 hp, Liebherr’s LH 60 M Industry Litronic is designed for heavy-duty scrap handling.

The hydraulic cab elevation, which can be adjusted for different loading situations, gives the operator an optimal view of the working area. Features such as cab guarding, impact-resistant laminated safety glass, and piston rod protection for cylinders were developed specifically for the demands of scrap handling and maximize reliability in tough conditions. Wide non-slip steps, gangways, and platforms allow optimal access to all maintenance points and ensure easy and safe entry and exit.

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SENNEBOGEN 821 E

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CATERPILLAR MH3260

The SENNEBOGEN 821 E compact material handler in the 23.9 and 25.1-ton class offers a variety of equipment lengths and features a strong mobile undercarriage with 4-point outriggers and an optional bulldozer blade. Ideal for waste recycling, scrap, and timber applications, the machine also features a maximum reach of 9 to 13 metres. A reversible fan for dust discharge at the cooler helps the machine excel in tough environments, and an elevated driver’s cab provides optimal focus on the work area. The 821 E is available in both diesel and electric drive options.

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The Caterpillar MH3260 material handler features a spacious, ergonomic cab, and offers a comfortable work environment for operators. The combination of longer maintenance intervals and lower fuel consumption provides up to 20 percent lower operating costs. A new engine, a reversing fan cooling system, and a wide mechanical variable undercarriage help optimize machine performance.

Operators can also match the machine to the job with three power modes: Power, Smart, and Eco. Smart mode automatically matches engine and hydraulic power to working conditions, providing maximum power when needed and reducing power when it isn’t to save fuel.

JANUARY/FEBRUARY 2024 | recyclingproductnews.com

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TECHNOLOGY

THE ROLE OF AI IN THE MRF ARTIFICIAL INTELLIGENCE CAN EXCEL WHEN USED AS PART OF A HOLISTIC SOLUTION

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alk of artificial intelligence (AI) has taken the recycling industry by storm – and for a good reason. When applied correctly, today’s emerging AI technologies have transformative powers, driving automation and efficiently enabling more granular sorting of complex material fractions. When used incorrectly, however, it can be an enormous waste of both time and financial investment.

Much of this buzz originates from a new type of ejection method for optical sorters – a robotic arm rather than valve blocks. The traditional valve block optical sorter employed in thousands of recycling facilities for decades uses precisely timed pulses of air in a drop-eject method to sort materials at rates reaching eight tons per hour or even higher, depending on the sorting task. Conversely, the new robotic arms more closely mimic a human’s picking motion of multiple fractions at rates slightly higher than that of a person, roughly 0.5 tons per hour.

For this reason, Ty Rhoad, regional director of the Americas for TOMRA Recycling Sorting, advises recyclers to fully understand what exactly makes up AI and what it’s designed to do. He stresses that AI is not the machinery – either the robotic arm or the valve block – and redirects the focus to highlighting how AI can be leveraged at the facility by incorporating it as part of a holistic solution.

“Right now, it’s like AI is the must-have technology for customers,” he says. “Recyclers must fully understand how it works and how it will improve the sort. Otherwise, final product and investment expectations may not be fully realized.”

AI IS NOT NEW

The good news: AI is nothing new to the industry. Most recycling facilities are already using some form of it. Optical sorters with valve block ejection have leveraged traditional AI for decades to drive sorting circuit automation and recycled product purity. Plant builders and technology suppliers have worked with customers to design material flows to improve yield, purity, and throughput with fewer manual sorters.

The heart of AI is software and algorithms, not the hardware.

Traditional AI is used in combination with a variety of sensors – RGB cameras, near-infrared (NIR), laser, electromagnetic, and X-ray – to automatically detect and process fractions.

“Traditional AI was a manual process,” says Anthony Belmares, field service supervisor for TOMRA. “A technician engineers the classifiers and deploys it into the in-house developed sorting software.”

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Every sensor-based sorting machine consists of numerous components, all of which play their role and are chosen according to the sorting task. How well, or poorly, material fractions are sorted depends on how the core components – namely the sensor system, data processing software, conveyor system, and ejection system – work together.

“This is why TOMRA invests roughly eight percent of our revenues on research and development,” offers Rhoad. “We create the software internally, so we can optimize sorting performance for a range of material streams from waste and plastics to metals and wood.”

Advancements in sensors and traditional AI have already led to many automated sorting improvements. Throughout the years, optical sorter designs have evolved with greater computing power and improved algorithms to leverage traditional AI and greatly improve colour sorting.

“This allows the MRF to sort out higher value clear and lightblue PET with higher yields and less contamination for secondary plastics sorters, so bales can be sold as Grade A or B versus Grade C or D,” says Rhoad.

DEEP LEARNING

AI’s deep learning subset further advances sorting accuracy and adaptability to material streams. Large datasets of trained neuronal networks enable deep learning technologies to recover materials that are difficult or even impossible to distinguish

A pre-sorting line inside a MRF.

using traditional technologies.

For deep learning to work, software engineers train the network with thousands of images that hold a pool of object information. The network recognizes patterns in the data and connects this information pool to the sorting task.

Since these most recent advancements in AI are application-specific, Belmares cautions that the technology supplier must provide the recycler with material testing, training, and optimization.

“A supplier cannot just drop AI-based equipment into the circuit and leave,” he says. “Full potential is only achieved through a well-optimized and positioned machine with workers trained on how to get the most out of it.”

Optimization leads to a much more granular sort. Whereas conventional optical sorters accurately identify and sort aluminum from the material stream. “Trained deep learning systems take the next step to detect and sort items like used beverage containers (UBC) from other aluminum in the stream,” Rhoad explains. “Deep learning enables recyclers to selectively target a specific value stream and increase the purity of that product.”

Rhoad is optimistic about the industry’s future with deep learning and sees several areas where AI can play a part in improving the sort.

“We’ve already launched applications like wood sorting for TOMRA’s deep learning–based GAIN and will soon have an application that focuses on the aforementioned UBC cleaning. We

Recyclers must fully understand how [AI] works and how it will improve the sort. Otherwise, final product and investment expectations may not be fully realized.

Ty Rhoad Regional Director of the Americas, TOMRA Recycling Sorting also see value for the industry with PET cleaning and the ability to detect PET food-grade containers from the material stream.”

Because of its ability to be trained to see objects on the belt like a human sorter, AI’s deep learning technology, when combined with conventional sorting technologies, can bring final product qualities and yield to the next level. Because deep learning is application-specific, however, recyclers need to work with a trusted technology supplier to ensure that they get the most out of it.

JANUARY/FEBRUARY 2024 | recyclingproductnews.com

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EVENTS CALENDAR CONNECT WITH THE INDUSTRY GLOBAL WASTE MANAGEMENT SYMPOSIUM

INDIAN WELLS, CA • FEBRUARY 25–28 Held biennially, the GWMS offers content that addresses industry challenges and groundbreaking research for waste management professionals. Network with global professionals while innovative presentations serve landfill owners, operators, engineers, consultants, and vendors. www.wastesymposium.com

BATTERY RECYCLING EUROPE 2024

LONDON, UK • FEBRUARY 28–29 This two-day event is dedicated to advancing knowledge and collaboration in the field of battery recycling within Europe, bringing together industry leaders, researchers, policymakers, and stakeholders to exchange insights, discuss emerging trends, and explore innovative solutions. www.wplgroup.com/aci/event/battery-recycling-europe

THE NATIONAL RECYCLING CONGRESS VIRTUAL • MARCH 5–6

The Recycling Congress’ theme this year is Challenges: The Nuts & Bolts of Recycling and Policy & The Big Picture, with a perspective on waste and recycling’s impact on climate, circularity, and sustainable materials management. With special guest speakers from The United Nations, Environmental Protection Agency, and more, there’s something for everyone. www.nrcrecycles.org/recyclingcongress

COMING SOON OARA CONVENTION & TRADE SHOW

ISRI CONVENTION & EXPOSITION 2024

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TORONTO, ON • MARCH 21–23

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LEADING ASPHALT TRADE SHOW AND CONFERENCE • Learn from industry experts • 120 education sessions available • People, Plants, and Paving Conference

March 25-27, 2024 | Nashville, Tennessee Use promo code PARTNER20 to save 20% off admission

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