Recycling Product News May/June 2023, Volume 31, Number 4

THE HOUSE MADE FROM 75 PERCENT C&D WASTE

32 COVER STORY

Q&A: DJ VANDEUSEN ON COLLABORATION, INDUSTRY CHALLENGES & THE EVOLVING ROLE OF BALERS

28

BÜSCHER BUILDS HOUSE MADE FROM 75 PERCENT C&D WASTE

A MOBILE SOLUTION TO RECYCLE DEGRADED WIND TURBINE BLADES 42 20 5 EMERGING TECHNOLOGIES IN THE METALS RECYCLING INDUSTRY

May/June 2023 | Volume 31, Number 4

FEATURES

20 5 emerging technologies in the metals recycling industry

22 Sort compostable and conventional plastics with high accuracy

24 Report shows U.S. recyclers acquired over 5 billion pounds of plastic in 2021

26 First Terex Recycling Systems plant installed at C&D and C&I recycling facility

28 Büscher builds house made from 75 percent C&D waste

32 Q&A with DJ VanDeusen of Harris Equipment

42 A mobile solution to recycle degraded wind turbine blades

44 Traditional versus hydraulic truck scales

48 2022 saw increase in solid waste worker fatalities

50 Looking eastwards for recovered paper exports

DEPARTMENTS & SECTIONS

MAY/JUNE 2023 | VOLUME 31 • NUMBER 4

EDITOR IN CHIEF Kaitlyn Till ktill@baumpub.com

604-291-9900 ext. 330

EDITOR

Slone Fox sfox@baumpub.com

604-291-9900 ext. 335

ASSOCIATE PUBLISHER/ VICE PRESIDENT OF SALES

Sam Esmaili sam@baumpub.com

604-291-9900 ext. 110

ADVERTISING PRODUCTION MANAGER

Tina Anderson production@baumpub.com

604-291-9900 ext. 222

HARRIS EQUIPMENT CENTURION BALER

Harris Equipment President DJ VanDeusen discusses collaboration, industry challenges, and the evolving role of balers in the waste and recycling industry.

Turn to page 32.

CONNECT WITH US @RecyclingPN

DESIGN & PRODUCTION

Morena Zanotto morena@baumpub.com

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PRESIDENT/PUBLISHER

Ken Singer ksinger@baumpub.com

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VICE PRESIDENT/CONTROLLER

Melvin Date Chong mdatechong@baumpub.com

FOUNDER

Engelbert J. Baum

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A LONG WAY TOGETHER

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FROM THE EDITOR

THE BENEFITS AND CONCERNS OF AI IN RECYCLING

Technology is advancing rapidly, and it’s undeniable that artificial intelligence has been one of the biggest driving factors behind the recent revolution. AI has emerged as a game-changer for the recycling industry by addressing key issues such as efficiency, sustainability, and versatility in the face of mounting environmental challenges.

By leveraging machine learning algorithms, AI recycling systems can accurately identify, sort, and process recyclable materials at a pace that has never been seen before in the industry. Traditional recycling methods relied heavily on manual sorting, a time-consuming and error-prone process. AI-powered systems can accurately recognize different types of materials such as plastics, metals, and paper, which has not only sped up the sorting process, but has also improved the quality, and therefore the value, of recycled materials. AI algorithms can also forecast demand for certain materials, optimize collection routes for haulers, and even predict equipment maintenance –resulting in reduced costs and improved efficiency.

Even with so many advantages, it’s still important to weigh the pros and cons of AI’s integration into the recycling industry. While AI brings major benefits and potential, it also presents challenges when it comes to responsible deployment across the industry.

One notable concern regarding artificial intelligence is the effect it could have on human workers. Since AI enables a high amount of automation, this could lead to major job losses in the recycling sector. It’s crucial to make sure that as AI is integrated, training opportunities are provided to workers who could be displaced by it.

Data privacy is another concern associated with AI. The collection of such massive volumes of data leaves room for a potential breach that could reveal sensitive information, and security measures need to be taken accordingly.

Additionally, the potential for developing a reliance on AI introduces a technological dependency which has its own set of risks. Malfunctions, system errors, and power outages can disrupt operations and even stop recycling processes altogether. When adopting these technologies, recyclers should have solid

plans in place to prepare for AI failures.

The development of artificial intelligence is an incredible opportunity for the recycling industry and is already transforming day-to-day operations. As the industry embraces the potential of AI, it’s vital to take the necessary steps to make sure that people and technology can coexist by mitigating job displacement, addressing data privacy concerns, and managing technological dependencies. By embracing AI while ensuring responsible practices, we can harness its benefits while minimizing potential risks.

As the industry embraces the potential of AI, it’s vital to take the necessary steps to make sure that people and technology can coexist by mitigating job displacement, addressing data privacy concerns, and managing technological dependencies.

ISRI CALLS FOR STRONGER LAWS AGAINST CATALYTIC CONVERTER THEFT

ISRI has called for the U.S. Congress and state legislatures to pass stronger laws to help curb the theft of catalytic converters while supporting the legal recycling of them. ISRI has worked with law enforcement and other stakeholder groups to identify potential legislative solutions that would deter the growing problem of catalytic converter thefts.

More than 30 million catalytic converters are legally recycled every year – mainly through the recycling of end-of-life automobiles. Catalytic converters contain critical minerals the U.S. Department of Interior deems essential to national and economic security. These materials are used in making electronics, new converters, catalysts, medical devices, and other consumer products.

ISRI’s desired catalytic converter requirements include:

An identification and national registry for catalytic converters: ISRI wants to mark and track attached and functioning catalytic converters through state and national registries. This would involve marking the devices with an identifying number in a permanent manner at the time of the initial sale of the vehicle.

Proof of catalytic converter legitimacy: ISRI wishes to restrict the possession of detached catalytic converters or catalytic converter substrate to entities who should reasonably be in possession through their normal course of business, or individuals who can provide proof of legitimate ownership. This would provide law enforcement with the necessary information to identify entities that would be allowed to legitimately purchase detached catalytic converters.

Increased catalytic convertor record keeping: Requiring a record for all purchases of detached catalytic converters at every level of purchase would also help to decrease the theft of catalytic converters. Records should be required for individual and business-to-business transactions, including the date of sale, the entities involved in the sale, and the volume of converters sold.

ISRI’s policy recommendations came from member volunteers working in ISRI’s Catalytic Converter Theft Working Group established in 2020 when the U.S. began to see a sharp increase in this type of crime.

LI-CYCLE AND GLENCORE PARTNER TO DEVELOP EUROPEAN HUB

Li-Cycle and Glencore have signed a letter of intent to jointly study the feasibility of and later develop a battery recycling hub facility in Portovesme, Italy. The Portovesme Hub would produce critical battery materials, including nickel, cobalt, and lithium, from recycled battery content.

The Portovesme Hub will leverage Li-Cycle’s hydrometallurgical technology and Li-Cycle expects the hub to be the largest producer of sustainable battery-grade products in Europe.

Located in Sardinia, Italy, the Portovesme metallurgical complex consists of a lead-zinc smelter and hydrometallurgical facility which first started operations in 1929. The Portovesme site has substantial existing infrastructure, including access to a port, utilities, processing equipment from the hydrometallurgical plant, and an experienced workforce.

The definitive feasibility study is expected to be completed by mid-2024. Subject to a final investment decision by the parties, the project will proceed to construction with the commissioning of the Portovesme Hub expected to commence in late 2026 to early 2027.

Li-Cycle and Glencore also anticipate forming a 50/50 joint venture that would repurpose part of the existing Glencore metallurgical complex in Portovesme to create the Portovesme Hub. This would enable a cost-efficient development plan. The project also contemplates competitive long-term financing from Glencore to fund Li-Cycle’s share of the capital investment.

Once operational, the Portovesme Hub is expected to have a processing capacity of up to 50,000 to 70,000 tonnes of black mass annually, or the equivalent of up to 36 GWh of lithium-ion batteries. The black mass processed at the Portovesme Hub is expected to be supplied from Li-Cycle’s growing network in Europe and through Glencore’s commercial network. Together with Li-Cycle’s battery recycling network, and Glencore’s battery circularity platform, this facility will enable Europe to get one step closer to closing the loop in manufacturing scrap, as well as end-of-life batteries, fully within Europe.

ALUMINUM INDUSTRY ENDORSES NET-ZERO EMISSIONS STRATEGY

The Can Manufacturers Institute (CMI) and all of its aluminum beverage can manufacturer and can sheet producer members have endorsed Mission Possible Partnership’s (MPP) transition strategy for a net-zero, 1.5-degrees-Celcius-aligned aluminum industry. These endorsements reflect the aluminum beverage can industry’s aim to reduce the carbon footprint of primary aluminum in beverage cans.

Since the 1990s, the carbon footprint of aluminum beverage cans made in North America has dropped by nearly half. Endorsing and acting on the MPP strategy will result in further reductions in the carbon footprint of the aluminum beverage can since the primary aluminum incorporated into aluminum beverage cans would have a reduced carbon profile.

Transitioning the aluminum industry to net-zero greenhouse gas emissions by 2050 while complying with a target of limiting global warming to 1.5 degrees Celcius from pre-industrial levels will require a variety of actions including deploying new technologies, decarbonizing power supplies, and increasing material and product efficiency.

Enacting the sector transition strategy will take time and large investments. MPP believes cumulative investment of approximately $1 trillion across the primary production value chain will be needed to deliver a net-zero sector or a 1.5 degrees Celcius pathway. CMI, its aluminum beverage can manufacturer members, its aluminum beverage can sheet producer members, as well as The Aluminum Association will be working with a variety of stakeholders inside and outside of the industry to catalyze the necessary actions and investments to pursue this transition strategy.

EMERGING TECHNOLOGIES

Key technological advancements, such as AI, smart equipment, and advanced robotics, are unlocking new possibilities for the metals recycling industry.

Read more on page 20.

EPIROC TO UTILIZE EMISSIONFREE RECYCLED STEEL IN SELECT MACHINES

Epiroc has signed a delivery agreement with Swedish steelmaker SSAB for SSAB Zero. SSAB Zero is fossil carbon emission-free recycled steel produced using sustainable energy sources. The steel will be used in Epiroc’s battery-electric range of underground mine trucks and loaders that will be introduced as soon as the third quarter of 2023.

The partnership with SSAB is part of Epiroc’s long-term commitment to halve carbon dioxide equivalent emissions by 50 percent by 2030 compared to 2019.

CASELLA WASTE SYSTEMS TO ACQUIRE SELECT GFL SOLID WASTE OPERATIONS

Casella Waste Systems has signed an equity purchase agreement to acquire the collection, transfer, and recycling operations in Pennsylvania, Delaware, and Maryland from GFL Environmental for $525 million. The proposed acquisition includes nine hauling operations, one transfer station, and one material recovery facility with aggregate annualized revenues of approximately $185 million. The acquisition is expected to close by the third quarter of 2023.

GRAPPLES MAGNET GENERATORS SCRAP MAGNETS ALLIGATOR SHEARS

CYCLIC MATERIALS RAISES $27 MILLION FOR METALS RECYCLING TECHNOLOGY

Cyclic Materials has raised $27 million in an oversubscribed Series A financing round. This funding round brings the company’s total capital raised to over $30 million and will contribute to scaling up its technologies.

Cyclic Materials is creating a domestic supply chain for rare earth elements (REEs) and other metals through a recycling process that recirculates REEs back into the manufacturing process, reducing the environmental impact of the global energy transition. REEs are key components of electric vehicle motors,

wind turbines, and consumer and industrial appliances and are among the least recycled metals due to the difficulty of separating the various magnetic materials in end-of-life products. However, with the global market for REEs forecast to increase three-fold by 2030, establishing new sources of REEs is needed.

Cyclic Materials’ process recycles copper, aluminum, steel, cobalt, and nickel – metals that are also required for electrification and decarbonization. Cyclic Materials has also successfully developed pilot plants and distributed high-quality REE samples to prospective clients, secured supply chain agreements with internationally recognized companies, and obtained Sustainable Development Technology Council of Canada funding.

COVANTA TO ACQUIRE CIRCON

Covanta has agreed to acquire Circon Holdings, marking the largest single acquisition for Covanta in two decades and bringing with it more than 600 new employees and 2,500 customers. The addition of Circon’s services doubles Covanta’s wastewater footprint and grows its engineered fuels business five-fold. It also expands the company’s footprint in the Gulf Coast and Midwest regions.

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RECOLOGY ACHIEVES GOAL OF POWERING 90 PERCENT OF

WITH LOW-CARBON FUEL

Recology has achieved its goal of powering its fleet with more than 90 percent renewable or alternative energy in 2022.

“We made a commitment in 2019 to significantly reduce

vice, including the Pacific Northwest, so we knew it would be tough. Through concerted efforts, we achieved the goal, and in doing so, we helped broaden the availability of cleaner fuels on the West Coast.”

Most Recology collection and transfer trucks now operate on renewable diesel or renewable natural gas. Both fuels are lower-carbon replacements for conventional diesel and conventional natural gas.

MARCH STEEL SHIPMENTS UP 6.6 PERCENT

The American Iron and Steel Institute has reported that for the month of March 2023, U.S. steel mills shipped 7,372,430 net tons, a 5.9 percent decrease from the 7,835,600 net tons shipped in March 2022. Shipments were up 6.6 percent from the 6,917,842 net tons shipped in February 2023. Shipments year-to-date in 2023 are 21,438,542 net tons, down 6.1 percent versus 2022 shipments of 22,826,084 net tons for three months.

A comparison of shipments year-to-date in 2023 to the first three months of 2022 shows that corrosion-resistant sheets and strips are down 5 percent, hot rolled sheets are down 8 percent, and cold rolled sheets are also down 8 percent.

REDWOOD MATERIALS ESTABLISHES ELECTRIC BIKE BATTERY RECYCLING PROGRAM

Rad Power Bikes has partnered with Redwood Materials to launch an electric bike battery recycling program. Rad has a ridership of nearly 700,000 electric bikes and as that number increases, the need for an electric bike recycling program becomes more and more prevalent.

Redwood Materials facilitates the reuse of up to 95 percent of the critical metals found in batteries. These recovered materials can be reused to build more e-bikes and EVs to keep up with de-

Crushers and Shredders

mand. The partnership also helps reduce the negative impact of batteries on the environment by keeping waste out of landfills.

All the Rad Power Bikes locations in the U.S. are battery dropoff locations for used e-bike batteries. Rad Power Bikes will ship the old lithium-ion batteries to Redwood Materials for recycling, refining, and repurposing to help create a more circular ecosystem for batteries. Select Rad retail locations will be equipped with collection bins for small-format lithium-ion batteries as well.

VAN DYK SUPPLIES EQUIPMENT FOR NEW SASKATCHEWAN MRF

Installation is underway in Regina, Saskatchewan, where Crown Shred & Recycling is building a brand new 30-tph single-stream system. With the popularity of single-stream collection rising in Western Canada, Crown Shred saw an opportunity to step into the market with a highly automated system. The new facility anticipates a substantial increase in the volume of material processed by Crown Shred, which plans to truck in material from up to 500 miles away.

The new single-stream recycling facility was designed with advanced technology and equipment to increase the efficiency of the recycling process. The facility can process a variety of materials including plastics, paper, cardboard, glass, and metals. Crown Shred chose Van Dyk Recycling Solutions to supply the equipment and build the MRF.

SPOTLIGHT INTRODUCTIONS & UPDATES

Caterpillar

MATERIAL HANDLER

Caterpillar’s MH3050 material handler utilizes an advanced electrohydraulic system that improves cycle times to handle more material. The MH3050 is powered by a Cat C9.3B engine capable of operating on up to B20 biodiesel. The engine uses a maintenance-free aftertreatment system that lowers operating costs and maximizes machine uptime.

Boom and stick offerings combine to provide up to 18 metres (59 feet 3 inches) of reach, allowing operators to move more

material without repositioning the machine. The MH3050 also offers high swing torque to quickly move material. With standard SmartBoom, the boom freely travels up and down without using pump flow and the operator is able to focus on stick and grapple control for a more fuel-efficient cycle.

The MH3050 also utilizes an e-fence feature to prevent the machine from moving outside operator-defined envelopes, while Cab Avoidance stops any potential contact between the attachment and the cab.

Material handler

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. The one man operations are all handled from the newly designed cab. With the 400º rotation crane and a reach of 27’ adding the continuous rotation grapple, it makes loading the larger chamber a breeze. Taking your loose scrap to a highly sought after shreddable log.

— Cycles in under 2 minutes!

— Produces up to 70 tons per day.

— Fully portable in the closed position.

— New seat design for more operator comfort.

SPOTLIGHT INTRODUCTIONS & UPDATES

NRT OPTICAL SORTER

NRT’s SpydIR-HS optical sorter is a near-infrared platform with multiple technological advancements including nearly 10 times the detection resolution with the addition of a hyperspectral imaging camera, double the air ejection precision, integration with the Max-AI visual information system, and lifetime calibration. The broad spectral diversity of HSI combined with NRT’s software algorithms creates an optical sorter calibrated at the factory that doesn’t need routine or auto-calibration. When integrated with Max-AI VIS, the combined unit can eject or suppress PET trays from a PET material stream or eject HDPE-N containers from a mixed HDPE stream.

REDWAVE SORTING MACHINE

The REDWAVE XRF fine sorting machine is designed specifically for sorting fine metal materials from 4 to 25 mm. The unit features 30 percent more sensors with decreased spacing between valve and sensor components, ensuring a higher purity and increased metal recovery. The sensor technology also offers fast scan rates, a higher resolution, and precise material detection. REDWAVE’s sorting machine features a belt system instead of a chute system which ensures a consistent speed and uniform material composition across the belt.

Optical sorter

Sorting machine

ELECTRIC SHREDDER

Eggersmann’s high-torque single-shaft shredder, the Z 50 E, is an emissions-free mobile shredder that suits a wide range of applications, such as shredding organic waste, municipal solid waste, C&D materials, and bulky items such as mattresses and solar panels. The Z 50 E is equipped with a chassis on tracks, a radio remote control system, and a battery pack that allows the unit to be moved around the site without being connected to power, eliminating the need for a towing vehicle. Since the drive no longer generates any exhaust, the shredder can also be used indoors.

TROMMEL SCREEN

Terex Ecotec’s Phoenix 2100T trommel screen is ideal for medium-sized operations and can accurately screen a variety of materials including compost, biomass, soil, green waste, C&D waste, and aggregates. With a rapid set-up time, the machine is ready to work in minutes with no tooling required. The fully proportional, hydrostatic feeder combined with an intelligent control system continually monitors the machine, adjusting the feeder speed to optimize screening performance and throughput. The Phoenix 2100T is also fitted with a 1.94- by 6.45-metre screening drum with heavy-duty mesh or punch plate options available.

Trommel screen

Shredder

5 EMERGING TECHNOLOGIES IN THE METALS RECYCLING INDUSTRY

ROBOTICS, AND OTHER INNOVATIONS THAT INCREASE CIRCULARITY

BY SLONE FOX, EDITOR

The metals recycling industry plays a critical role in promoting sustainability and resource conservation by transforming discarded metals into valuable raw materials. As the industry continues to evolve, recyclers are embracing new technologies that reshape operations and optimize processes to bring the sector closer than ever to a fully circular economy.

Key technological advancements, such as artificial intelligence (AI), smart equipment, and advanced robotics, are unlocking new possibilities for the industry through market trend prediction, increased traceability, and the ability to repurpose materials in new ways. By harnessing the power of these emerging technologies, the metals recycling industry is poised to achieve greater sustainability and profitability by ushering in a new era of circularity and responsible resource management.

1. ARTIFICIAL INTELLIGENCE

Artificial intelligence is a topic that has recently found its way into the news almost daily. In the metals recycling industry AI is used to predict market trends and help recyclers make more informed decisions regarding the buying, selling, and inventory management of scrap metals. AI algorithms can analyze large volumes of market data – including prices, supply and demand, and trade patterns – and then identify patterns within the data to predict future market trends. This helps recyclers plan their operations better by optimizing production and managing inventory based on the expected demand for specific metals.

AI can also be used to analyze news articles, social media posts, and other texts related to the metals recycling industry. By extracting attitudes and opinions from this data, AI can gauge market sentiment and predict shifts in the market. These insights enable recyclers to stay ahead of the game and make proactive decisions.

2. COLLABORATIVE ROBOTICS

Collaborative robotics, also known as cobots, are being used more and more in the metals recycling industry. Cobots use cameras, robotic arms, grippers, and conveyor systems to lift, move, and stack materials as needed, and can perform a wide range of tasks such as material handling, assembly, inspection, and maintenance alongside human workers. These machines utilize safety features like force sensors, collision detection, and speed reduction when working near people.

Unlike sorting robots, which automate material identification and separation, cobots perform a broader range of tasks. Cobots can assist in the maintenance of recycling equipment by performing inspections, lubrication, and minor repairs which

AI,

By harnessing the power of these emerging technologies, the metals recycling industry is poised to achieve greater sustainability and profitability by ushering in a new era of circularity and responsible resource management.

in turn minimizes downtime. Cobots can also work in hazardous and confined spaces, reducing the risk of injuries for human workers. By taking over repetitive and physically demanding tasks, cobots enhance worker safety, increase productivity, and improve overall operational efficiency.

3. BLOCKCHAIN

Blockchain technology is being explored in the scrap metals recycling industry to address challenges related to traceability, transparency, and authentication. With blockchain, transactions and transportation are recorded and documented, ensuring a reliable record of each step from collection all the way through to processing. Moreover, blockchain verifies the authenticity of recycled metals by storing information on the origin, composition, and quality control data of the material. Blockchain-based “smart” contracts can also automate agreements, triggering payment when predetermined conditions –such as weight verification or quality inspections – are met. Still in its early stages, the adoption of blockchain technology requires industry-wide collaboration to be in place before widespread adoption becomes possible.

4. DRONES

When it comes to increasing safety on the job, drones can monitor and identify potential safety hazards in a scrapyard, such as fire risks and leakages in scrap metal piles. By providing real-time surveillance from above, drones enable scrapyards to proactively address safety concerns and minimize the risk of accidents.

Additionally, drones can be equipped with cameras and sensors to transform scrapyard inventory management. Using light detection and ranging technology (LiDAR) technology, drones

can create 3D models of stockpiles and estimate the volume and weight of materials. This data provides valuable insights into inventory levels, enabling scrapyards to optimize storage space and transportation plans. Drones can also be used to measure the current capacity of a scrapyard and identify areas for improvement.

5. 3D PRINTING

While the role of 3D printing in the metals recycling industry is still evolving, its integration has the potential to contribute to increased waste reduction and sustainability. By melting down and reprocessing scrap metal, these materials can be transformed into a filament that can then be used as feedstock for 3D printers. This allows for the creation of new products or parts, reducing the need for virgin materials and minimizing waste. By using 3D printing, specific components can be manufactured on demand, even if they are no longer in production.

LOOKING AHEAD

The metals recycling industry is poised to experience a transformation in efficiency, sustainability, and profitability as these emerging technologies continue to evolve and gain broader adoption. By harnessing the power of AI, robotics, and more, recyclers can optimize processes, improve decision-making, and drive positive environmental impacts. Embracing these innovative solutions will not only benefit individual operations, but also contribute to the overall circularity of the metals recycling sector. The possibilities are vast, and as recyclers continue to explore and implement these innovations, they will undoubtedly play a pivotal role in shaping a more sustainable future for the metals recycling industry. RPN

Key technological advancements, such as AI and robotics, are unlocking new possibilities for the industry.

Scrap metal can be made into filament for 3D printers.

Drones can monitor and identify potential safety hazards in a scrapyard.

SORT COMPOSTABLE AND CONVENTIONAL PLASTICS WITH HIGH ACCURACY

HOW MACHINE LEARNING CAN BE USED IN INDUSTRIAL RECYCLING AND COMPOSTING

UP TO PERFECT ACCURACY

The researchers worked with different types of plastics measuring between 50 mm by 50 mm and 5 mm by 5 mm. Conventional plastic samples included PP and PET, often used for food containers and drinking bottles, as well as LDPE, used, among other things, for plastic bags and packaging. Compostable plastic samples included PLA and PBAT which are used for cup lids, tea bags, and magazine wraps, as well as palm leaf and sugarcane, both biomass-de-

BEYOND THE VISIBLE

“Currently, most compostable plastics are treated as a contaminant in the recycling of conventional plastics, reducing their value. Trommel and density sorting are applied to screen compost and reduce the presence of other materials. However, the level of contaminants from the current screening process is unacceptably high,” explains Miodownik. “The advantages of compostable packaging are only realized when they are industrially composted and do not enter the environment or pollute other

waste streams or the soil.”

To improve accuracy, a team of scientists from UCL’s Plastic Waste Innovation Hub tested different types of conventional, compostable, and biodegradable plastics using hyperspectral imaging (HSI) for classification model development. HSI is an imaging technique that detects the invisible chemical signature of different materials while scanning them, producing a pixel-by-pixel chemical description of a sample. AI models were used to

interpret these descriptions and make a material identification.

Plastic mismanagement in recycling and industrial composting processes is high, making reliable sorting mechanisms essential.

“Currently, the speed of identification is too low for implementation at industrial scale,” Miodownik says. “However, we can and will improve it since automatic sorting is a key technology to make compostable plastics a sustainable alternative to recycling.”

packaging

REPORT SHOWS

U.S. RECYCLERS ACQUIRED OVER 5 BILLION POUNDS OF PLASTIC IN 2021

NORTH AMERICAN PLASTIC RECYCLING VOLUMES HAVE RECOVERED FROM PREPANDEMIC LEVELS

Recyclers acquired more than 5 billion pounds of post-consumer plastic recovered for recycling in the United States in 2021, an increase of 280.3 million pounds compared to 2020 volumes, according to a new report by the Association of Plastic Recyclers (APR), The Institute of Scrap Recycling Industries (ISRI), and the U.S. Plastics Pact.

Based on surveys conducted by Stina and the National Association for PET Container Resources (NAPCOR), the 2021 U.S. Post-consumer Plastic Recycling Data Report details U.S.sourced post-consumer plastic recovered for recycling.

INCREASING RECOVERY VOLUMES

The increase in 2021 volumes recovered for recycling in the U.S. show that all major categories of plastic had a net increase in total pounds in 2021 compared to 2020, specifically bottles, non-bottle rigids, and film categories. Within those broader categories, there was a slight decline in the recovery of high-density polyethylene (HDPE) bottles and polypropylene (PP).

The report also indicates that the vast majority of plastics recovered are being recycled in North America, primarily by U.S. reclaimers. North American plastic reclaimers acquired a total of 4,693 million pounds, or 92.3 percent, with 391 million pounds, or 7.7 percent of plastic recovered for recycling bound for overseas export markets.

“The 2021 rate report shows the strength of the recycling industry as they face ongoing challenges including competition with low disposal costs, collection rates, and virgin resin prices,” said Steve Alexander, APR president and CEO. “APR works with companies to increase yields and supply by ensuring plastic packaging is designed for recyclability through the APR design guide and other programs, but in order to see bigger increases, there’s a need for systematic change led by public

policy to drive collection, improve sortation, and stabilize demand for recycled resins. APR is supportive of extended producer responsibility laws and recycled post-consumer content requirements recently enacted in several states. APR also supports a national bottle bill and other federal legislation that can drive change through a combination of supply and demand policies, targeted funding and incentives, as well as streamlined collection programs.”

A MORE SUSTAINABLE SUPPLY CHAIN

The report shows that the five billion pounds of materials recovered in 2021 includes bottles (2,886.7 million pounds and 56.8 percent of total); non-bottle rigids (1,071 million pounds and 21.1 percent of total), film (1,106.2 million pounds and 21.8 percent of total) and “other plastics” (20.2 million and 0.4 percent of total).

“The recycled materials industry is doing more than ever to ensure that at the end of a product’s life, less material goes to waste,” said ISRI President Robin Wiener. “Our goal is to make the supply chain ever more sustainable by providing manufacturers with high-quality material and reducing the need to extract natural resources to make new products we rely on every day.”

The net bottle increase of 142.5 million pounds in 2021 was primarily due to the increase in PET bottle volumes recovered for recycling. This was offset by declines in the valuable natural HDPE commodity market (e.g., recycled milk jugs). Non-bottle rigids were up slightly from 2021, primarily due to increases in HDPE and PET non-bottle materials recovered for recycling, for a net 13.6-million-pound increase. Also contributing to the 2021 increase was an additional 120.5 million pounds in film recovery from 2020 volumes, primarily in polyethylene mixed colour film.

“The U.S. Plastics Pact is working to raise the quality and quantity of post-consumer recycled plastics, particularly for PET and HDPE packaging, which make up the largest tonnages of packaging represented by our members,” said Emily Tipaldo, U.S. Plastics Pact executive director. “If we expect to achieve true recyclability, we need high demand for recycled plastics. Achieving true recyclability, as well as using higher percentages of PCR, requires significantly greater tonnages of recycled plastics. The U.S. Plastics Pact is glad to see increases in the amount of plastic recovered for recycling and that the majority of the plastic is being recycled in North America.”

The 2021 rate report shows the strength of the recycling industry as they face ongoing challenges including competition with low disposal costs, collection rates, and virgin resin prices.

Steve Alexander President and CEO, APR

Recyclers acquired more than 5 billion pounds of post-consumer plastic in the United States in 2021.

FIRST TEREX RECYCLING SYSTEMS PLANT INSTALLED AT C&D AND C&I RECYCLING FACILITY

THE PLANT WILL HELP COLLARD GROUP RECOVER CLEANER PRODUCTS OF HIGHER VALUE

Collard Group has chosen a Terex Recycling Systems plant to increase the processing capacity of its site and recover cleaner products of higher value without adding to the manual labour requirements. Collard Group initially intended to upgrade the plant, but opted for a full plant installation after being pleased with the first phase of the installation.

A CUSTOMIZED SOLUTION

The plant, which is the first Terex Recycling Systems installation, was tailored to suit Collard Group’s site and the material which would be fed into it. Terex Recycling Systems developed a process that incorporated advanced mechanical separation that increases Collard Group’s processing capacity and recovers products of a higher purity than what was previously achieved. The team worked with space constraints such as fitting the plant inside and around the existing building, all while planning the installation around Collard Group’s site works, including the erection of a new building.

Close collaboration between all parties ensured our requirements in terms of output were met, whilst also keeping the plant footprint to a minimum to aid their site operations.

Robert Collard Managing Director, Collard Group

“Terex Recycling Systems and Molson Green worked with us to ensure the design, delivery, and installation of our new plant worked around our site operations, also taking into con-

sideration our site preparation works to include foundations, building modifications, and power supply,” says Robert Collard, managing director at the Collard Group. “Close collaboration between all parties ensured our requirements in terms of output were met, whilst also keeping the plant footprint to a minimum to aid their site operations.”

SORTING, SEPARATING, AND SUCCESS

The process starts with skip material being loaded into a waste feeder and conveyed to a combi screen, which separates material into four size fractions using a combination of 3D and flip-flow screening (0 to 10 mm, 10 to 50 mm, 50 to 100 mm, and over 100 mm). Overband magnets recover ferrous metals from 0 to 10 mm, 10 to 50 mm, and 50 to 100 mm, and air separators remove light material from 10 to 50 mm and 50 to 100 mm. A manual quality control picking station has operators working to remove any remaining contaminants from the 10 to 100 mm heavy fraction.

Following this, an eddy current separator recovers non-ferrous metal from the 10 to 100 mm heavy fraction. Another

manual picking station has operators recovering materials such as wood, card, and plastic from the over 100 mm fractions, and an overband magnet recovers ferrous metal. Finally, an air separator removes light material from the over 100 mm fractions.

The outcome is a plant that is processing skip waste – a mixture of commercial and industrial (C&I) and construction and demolition (C&D) waste – to produce 0 to 10 mm fines, ferrous metals, clean 10 to 100 mm heavy fraction (inert), non-ferrous metals, wood, plastic, paper, and card, and clean over 100 mm heavy fraction (inert) materials.

“We are delighted to have sold and installed Terex Recycling Systems’ first plant to the Collard Group,” says Thomas McKiver, sales director at Molson Green, distributor of Terex Recycling Systems. “This plant will help them achieve their desired targets of increasing processing capacity and to recover greater percentages of cleaner recycling products, thus diverting more material from landfill.”

A GROWING NETWORK

This installation comes on the heels of Terex Recycling Systems expanding its distributor network to include Powerscreen of California, and Frontline Machinery and Voghel in Canada. All three distributors will represent the full range of Terex Recycling Systems’ modular recycling solutions for their respective territories. These new appointments have been made following the recent amalgamation of the sales teams for Terex Recycling Systems and ZenRobotics.

“In the next 10 years, stationary recycling systems are expected to grow more than double compared to the mobile recycling equipment,” says Marcel Vallen, sales manager of North America at Terex Recycling Systems and ZenRobotics. “Selling affordable and modular recycling systems, with the latest cutting-edge technologies, is what customers across North America are looking for. Every operator knows how important it is to have local sales, service, and parts support. Thanks to a well-established relationship with other Terex brands, Powerscreen of California, Frontline Machinery, and Voghel are well-placed to seamlessly integrate Terex Recycling Systems and ZenRobotics into their operations. They are great partners to have and are essential to our success in the North American market.”

This plant will help them achieve their desired targets of increasing processing capacity and to recover greater percentages of cleaner recycling products, thus diverting more material from landfill.

Thomas McKiver Sales Director, Molson Green

Collard Group has chosen a Terex Recycling Systems plant to increase the processing capacity of its site.

BÜSCHER BUILDS HOUSE MADE FROM 75 PERCENT C&D WASTE

KEESTRACK’S ZERO-EMISSIONS EQUIPMENT POWERED THE SUSTAINABLE PROJECT

Even with decades of experience in the industry, Büscher, a concrete producer based in Germany, recently took on a project that was something it had never tried before: building a house made out of 75 percent recycled construction and demolition (C&D) waste.

When Büscher first started out in 1961, it made concrete like everybody else – with gravel, sand, cement, and water. Now, the company has changed the recipe so that 100 percent construction and demolition waste replaces the sand and gravel completely in the prefab load-bearing and non-load-bearing interior wall elements. The outside walls, however, are not made out of recycled materials.

Through its disposal service offerings, Büscher routinely received a lot of C&D waste which was recycled into aggregates for road construction. Since this material was difficult to sell and was available in high stock quantities, brothers Wolfgang and Hans-Jürgen Büscher started to explore other ways that the materials could be reused. Their conclusion was to use this C&D waste as a raw material for prefab concrete and concrete elements.

RESEARCH AND DEVELOPMENT

The idea was sustainable, but it was hard to convince both authorities and specialists in the field that it was feasible. Getting 100 percent prefab concrete certified was difficult, and it took Büscher eight years of research and development to get approval.

“Concrete specialists, laboratories, and certification specialists were very doubtful this could be done,” said Wolfgang Büscher. “They all said it is impossible and not legal.”

Büscher gave researchers from laboratories and universities the parameters of what the company wanted to achieve with the materials, and waited to see if it could withstand the tests.

“By now, all scientific research has been done and it shows exactly what is possible with 100 percent recycled prefab concrete and concrete elements. The new material functions perfectly, and the recipe has changed at Büscher,” says Hans-Jürgen Büscher.

A house made from 75 percent recycled construction and demolition waste.

According to Büscher, the main advantage of the certified production process is the efficiency of resources. The company is using local, highly available C&D materials that produce a sustainable, climate-neutral product with less carbon dioxide emissions. This also saves on transport costs, since the materials are already on hand.

“No costly raw materials are used, so the price of the end products is also cheaper. A real win/win situation,” says Thomas Overbeeke, operations manager at Büscher.

While the research took nearly a decade, it took Büscher only four months to build the entire house. Built with paint-ready prefab elements, the piping and electricity are all integrated into the prefab panels which have a smooth surface so no plaster is needed. And when it is time to demolish it, the house will be recycled into new concrete using the Büscher method.

SUSTAINABLE PRODUCTION

Since Büscher believes that a sustainable product should be produced with sustainable equipment, the Büscher site is equipped with solar panels delivering up to 323 kW/h of renewable electricity. This electricity is not only used to power the concrete facility, but also powers an electric Keestrack R3e ZERO impact crusher and a K4e ZERO screen.

The choice to use Keestrack crushing and screening equipment is part of Büscher’s goal to minimize its ecological footprint. When plugged into the grid, the R3 and K4 produce zero carbon emissions with energy savings totalling approximately 152kWh. Operational and maintenance costs have also decreased drastically since there is no engine on board to maintain.

The R3e ZERO is equipped with a vibrating feeder with a pre-screen of 1,200 mm by 920 mm to optimize crushing results

Thomas Overbeeke Operations Manager, Büscher

and minimize wear. The machine has an inlet opening of 770 mm by 960 mm and a rotor diameter of 1,100 mm. The installed wind sifter eliminates contaminations of plastics, wood, or paper, and the overband magnet separates out metals.

The K4e ZERO offers high productivity with a capacity of up to 350 tph. The double-deck screen box of 4,200 mm by 1,500 mm, standard heavy-duty plate apron feeder, and a hydraulic adjustable screen angle give it enhanced screening capabilities. The numerous options and screen decks available make the K4 suitable for a wide range of applications. The Büscher recycling site chose to have the fine and middle fraction conveyor on the same side of the screen to improve accessibility for the wheel loader.

Both Keestrack machines at Büscher are equipped with remote controls to operate the crusher and screen from the excavator and come equipped with a Keestrack-er UMTS system. The telematics software system provides real-time data and analytics that enables users to check the location of the machines and see if they are working correctly.

No costly raw materials are used, so the price of the end products is also cheaper. A real win/win situation.

The Keestrack electric combination R3e and K4e ZERO.

Q & A DJ VANDEUSEN ON COLLABORATION, INDUSTRY CHALLENGES & THE EVOLVING ROLE OF BALERS

In an age where sustainable practices and environmental responsibility are paramount, collaboration between industry leaders is playing a crucial role in fostering innovation and propelling the recycling industry forward. Back in February, Harris Equipment, American Baler, and International Baler joined forces to form the AVIS Recycling and Waste Equipment Division, leveraging their collective expertise and resources to tackle the challenges faced by the recycling and waste sector.

I connected with DJ VanDeusen, president of Harris Equipment and AVIS’ Recycling and Waste Equipment Division, to discuss supply chain issues, the evolving role of balers in waste management initiatives, and his vision for the future.

BY SLONE FOX, EDITOR

Can you talk a bit about how the AVIS Recycling and Waste Equipment Division came to be?

Greg King served as the president of Harris prior to being named the CEO of Avis Industrial. I was fortunate enough to be selected for the leadership role at Harris just over two years ago, and that led to Greg and I discussing the fact that there were three baler companies – Harris, American Baler, and International Baler – that were part of the Avis portfolio of companies, yet we acted like competitors and completely independent businesses in the industry. When Avis completed the acquisition of the remaining shares of International Baler last summer, the discussions on how to bring the three companies together became a lot more tangible.

What can we look forward to seeing from this new division?

We’re just getting started with the alignment and integration of the three businesses, and our early focus is on procurement synergies, production capabilities, product line coverage and redundancies, and commercial go-to-market strategies. As you can imagine with three companies that have been in business –and in competition – for a combined 289 years, there’s a lot of well-earned pride in how each business operates and has been successful over the long haul. Our goal is to honour the legacy that each business brings, leverage the competitive advantages that each business has established in the industry, and provide a depth and breadth of compaction and size reduction products across our three

brands that is unmatched.

We believe that there’s an opportunity to provide even greater service coverage for our installed base through the optimization of the field technician resources we have within the three companies, and the distributor network that is such a critical part of our success. We’re confident we’ll be able to provide shorter lead times on new units and mission-critical maintenance parts by redistributing and duplicating key production activities that take place across our four manufacturing locations.

The organization that will help guide the division forward is now in place with manufacturing, procurement, and sales integration roles filled and critical functional leadership positions named. We were proud to have all three businesses together under one trade show roof at WasteExpo back in May as the first steps in the integration process.

What are some of the key challenges that the baler industry faces today, and how is Harris Equipment addressing these challenges? What more needs to be done as an industry?

We might need a special edition of Recycling Product News to cover all of the challenges the baler industry faces today. With that said, it’s a great time to be in the business as demand for size reduction and compaction equipment has been very strong over the last 24 months, and the generation of waste and recyclable materials continues to increase each year. The single largest challenge facing our industry today

is the lack of skilled tradespeople for heavy industrial manufacturing – welders, fabricators, and machinists, to name a few. It’s not just the lack of those resources today that is a concern, but the fact that the demographics of production employees today suggest that this gap is only going to widen as skilled resources approach retirement with a pipeline entering the workforce at a much smaller rate. Support and funding for local and regional trade schools is absolutely critical for attracting energetic young men and women looking for a career path that does not include the college route. This has to be coupled with clear messaging to high school students that learning a trade is not somehow a lesser success and achievement than pursuing a college degree.

Private industry plays a role in this by taking the initiative to establish true apprentice program opportunities for early career hires that include broad, handson job training and educational skills and leadership training to position these apprentices for success beyond the initial job requirements. At Harris, we have made a significant investment in education and training through the advent of our recognized apprentice program, the purposeful development of Harris University, and the engagement of time and resources with the high schools and technical schools in our communities. We simply have to make this investment and get it right in order to change the downward trajectory of the talent pipeline.

SF

The more introductions of successful waste management and recycling initiatives, the better for the baler industry if those initiatives lead to more material being captured and reused. We also support the activities underway to drive a more circular economy and reduce unnecessary packaging for consumer and industrial goods – even if this results in there being less material to be recovered tomorrow. Our purpose has always been to allow for reusable material to be moved simply and cost-effectively from the collector of the material to the re-user of the material.

In order for recycling initiatives to sustainably work, there has to be an economic return for the recycler and the recyclable material consumer. Baling equipment is a key element of that financial equation regarding transport costs. I continue to believe that baler manufacturers need to have a seat at the table for the discussions around recycling and

How do you see the role of balers evolving in the broader context of waste management and recycling initiatives, especially relating to things such as EPR?

A Predator ferrous baler.

packaging initiatives as key stakeholders in the process, and to ensure that our innovation journey is aligned with those initiatives and how the recycling and waste stream may change as a result.

Can you touch on the supply chain issues of the last few years? In your opinion, is there an end in sight or do you see this continuing?

Input cost inflation has been the single largest challenge for baler manufacturers as steel experienced unprecedented price increases from mid-2020 through mid2022. While prices have somewhat stabilized over the past nine months, there are no solid indicators of any near-term steep price corrections.

Overall steel demand declined in 2022 as the post-pandemic rebound appears to

have peaked, and the fears of a pending recession coupled with interest rate hikes may slow investment in construction and heavy industrial equipment. But despite these impacts, most forecasts expect there to be a modest increase in steel demand over the coming 24 months as the global economy continues to recover post-pandemic. All of this has resulted in necessary product price increases despite all efforts to minimize the effect on product cost through strategic sourcing, increased inventory levels, and product redesign.

This is not to say that supply chain issues have been limited to solely steel and steel component inflation. The shipping disruptions that wreaked havoc with production schedules in 2021–2022 have, for the most part, subsided, but there are indications that shipping companies are scaling back on planned voyages to attempt to prop up the sagging shipping rates.

Finally, the shortage of available electronic components such as programmable logic controllers, due in part to the semiconductor shortage, has made dramatical-

ly expanding the supplier base imperative to meeting new unit and maintenance schedules. These supply chain disruptions have been more pronounced over the past three years, but our businesses always have to be prepared with business plans for the disruptions that are part of the everyday environment we operate in.

Are there any upcoming developments or trends in the industry that you are particularly excited about?

I expect that the trend for consolidation in the recycling and waste industry, especially on the post-collection side, will continue as the aforementioned labour shortages and supply chain disruptions have made it increasingly more difficult for the smaller, independent operators to remain competitive. I’m hopeful that this consolidation will lead to the innovation and modernization of collection and sorting systems.

The ongoing push for effective and sustainable municipal recycling programs should serve to increase the amount of recyclable material that is being collected, and as a manufacturer of the machine that is the heartbeat of a recycling centre, that is music to our ears.

Lastly, as technology allows for the recovery of a higher amount of material found in single-stream systems, and for improved methods of handling and separating contaminants, we fully expect the demand for baling and compaction equipment to remain strong.

What is your vision for the future of Harris Equipment, and what are the key areas of focus for you moving forward?

We announced a fundamental change in how we view the future opportunities for Harris with the announcement of the Recycling & Waste Equipment Division in February. Being able to bring together the

best of what Harris Equipment, American Baler Company, and International Baler Corporation have to offer – our people, our products, our processes – will shape the future of all three companies in a way never before examined. It’s important that we don’t lose sight of the legacy that the combined 289 years in business has built, and that we cherish the brands that the industry relies on for its size reduction and compaction needs.

Innovation, performance excellence, and product line optimization are not meant to minimize what has been accomplished over the history of the businesses, but are to ensure that these businesses, collectively, further strengthen their industry leadership position. We intend to be leaders in training and development in rebuilding the skilled trade workforce through our direct investment in Harris programs, as well as through deep-seated community involvement. We intend to develop products that are focused on energy efficiency, ease of maintenance, heightened safety measures, and data collection. We intend to offer an unmatched depth and breadth of products for size reduction and compaction, the largest field service network available in the U.S., and reduce lead times for mission-critical parts and cylinders to support the ongoing needs of our collective installed base.

Growth will come as a result of us doing what we intend to do. Our motto at Harris is simple: Be Harris – by being optimistic, engaged, and motivated; by being dedicated, accountable, and innovative; by being cooperative, responsible, and sincere. RPN

The more introductions of successful waste management and recycling initiatives, the better for the baler industry if those initiatives lead to more material being captured and reused.

A GS-11-E ferrous shear/logger/baler.

TAURUS KAPPA SHEAR BALER

In the waste and recycling industry, the proper management and disposal of materials is a critical concern. Many businesses, such as those in the construction and automotive industries, generate substantial amounts of scrap metal, which, if not handled correctly, can pose environmental and logistical challenges.

The Taurus Kappa shear baler, distributed across North America by ELV Select Equipment, addresses these challenges by offering an efficient and sustainable approach to recycling metal waste. The machine combines the functionalities of a shear and a baler into a single unit, allowing operators to cut and compress various types of ferrous and non-ferrous materials into dense and manageable bales.

TECHNOLOGY COMPOSITION

The Kappa shear baler is built with a heavy-duty internal structure that increases the weight of the machine compared to similar products on the market. Taurus units are also made with extra heavy-duty steel hydraulic piping with double-welded inside and outside couplers, ensuring the 420-bar high pressure of the hydraulics does not leak. Taurus designs and constructs each surface in a way that ensures that the throughput per hour of the Kappa remains consistent throughout the machine’s life cycle when properly maintained. All Taurus machines are completely assembled prior to delivery to ensure manufacturing fines are removed from the hydraulics circuits.

The Kappa shear baler is equipped with advanced technology, including patented over stroke on each wing that provides maximum power in compression. Its design allows for compression forces of up to 650 tons on each wing, allowing large items to be manipulated into the shear box for processing. The shear head of the Kappa is equipped with double cutting cylinders and prismatic guides which reduce wear and ensure reliable cutting operation. The machine does not require foundations or special permits, making it an efficient and cost-effective solution that causes little disruption to existing recycling processes.

OPERATION

The Kappa’s intuitive cabin controls and an optional remote control allows for quick and simple adjustments. The touchscreen control system constantly monitors and optimizes the squeezing and cutting process. The system minimizes downtime since maintenance can be planned efficiently and performed before costly repairs are needed. Numerous programs for different scrap types can be selected at the touch of a button, such as full stroke, partial stroke, relative stroke, and baling. When service is required on Taurus shear balers in North America, ELV Select Equipment makes remote service and parts available to ensure that downtime is limited.

The Taurus Kappa shear baler.

(Photo credit: Dylan Moesker, TruGrit)

1

2 MACHINEX II-RAM SERIES

HARRIS EQUIPMENT CENTURION

1high-capacity balers are designed to maximize density while reducing operating costs. According to Machinex, the exclusive pre-fill valve offers a dry cycle time of up to 2.7 times faster than similar machines, resulting in a significant reduction in energy consumption while also increasing the main ram cycle speed in both forward and reverse modes. Maintenance is simple with convenient bolt-on liners, allowing for easy upkeep and minimal downtime. Additionally, the II-RAM balers feature a single-plate frame construction for maximum strength and durability.

3

AMERICAN BALER W828 SERIES

4

SIERRA INTERNATIONAL MACHINERY REB-4

2Centurion is a high-performance two-ram baler designed specifically for medium- to high-volume applications. The multi-purpose Centurion features a 13-inch bore main cylinder and, like all Harris two-ram balers, has a solid one-piece body design. The machine features laser-guided hydraulic ram cylinders and electronic pumps for millimetre precision control on each cycle, in addition to a reinforced bale chamber with thicker and additional interlocking ribs. The large shear knife is thicker and taller than traditional tworam baler knives to handle the increased shear force from the main ram cylinder.

3Series of two-ram balers is ideal for most paper, plastic, and non-ferrous metal baling applications. Recently upgraded, the W828 models now come with a power unit and manifold block designed with off-theshelf Parker Din Cartridge valves on the manifold and standard directional control valves. Available with either a 43-inch-wide frame or 60-inch-wide frame, the W828 Series of two-ram balers offer several charge box opening lengths, single-side sheet construction, and sequenced motor start-up with an Economizer mode to shut down motors when they’re not in use.

4

Sierra International Machinery’s REB-4 two-ram baler is ideal for non-ferrous metals, OCC, natural HDPE, and paper. Sierra’s patented dual-compression door technology means materials can exceed 30 inches above the cutting knife, and with a force of 55 tons per door, the material is pushed below the knife and into the chamber, resulting in a 20 to 40 percent increase in production capacity. By minimizing the area requiring shearing by 90 percent when fully closed, the REB-4 reduces shear and hydraulic shock while optimizing energy consumption, cutting costs and ensuring a longer lifespan for the baler’s blades and structure.

A MOBILE SOLUTION TO RECYCLE DEGRADED WIND TURBINE BLADES

HOW SSI SHREDDING SYSTEMS IS TACKLING A GROWING WASTE PROBLEM

Wind power production is a growing green industry, and end-of-life wind turbine blades are a sizable recycling problem. There are already over 70,000 wind turbines in the U.S. alone.

Recycling wind turbine blades is a big deal – wind energy represents a large source of clean power, but there’s a side of wind energy that isn’t often thought of: How are those giant wind turbine blades destroyed at end of life?

Wind turbine blades must be rebuilt often – sometimes as frequently as every 10 to 12 years. The blades break down from flexing to erosion, UV damage, lightning strikes, and recalls due to delamination and cracking. Manufacturers construct the blades using various materials, including fibreglass, carbon fibre, balsa wood, foam, and resin.

The variety of manufacturing materials makes them difficult to repair or reuse. Instead, energy companies leave old wind turbine blades on the ground next to their old towers or send them to landfills, counteracting a large part of this clean energy.

There are some solutions in development to address this growing concern, such as recycling these massive waste products, but the recycling of wind turbines is still a new concept.

“We’re in the infancy of wind turbine blade recycling,” says Lee Sage, industrial sales specialist at SSI Shredding Systems. “The problem is that the U.S. dove into wind energy never considering the end of life of those components and where they would go. It was always going to be someone else’s problem.”

Enter Sean Baisden, the owner of Pitbull Blade Demolition, who was tasked to destroy the thousands of wind turbine blades that are decommissioned each year. To keep his costs down, Baisden needed a machine that was capable of shredding the blades while remaining small enough to move from wind farm to wind farm. He reached out to SSI Shredding Systems who

went on to design a solution to this growing waste problem. Due to their components and enormous profile, wind turbine blades are extremely difficult to shred. The Dual-Shear M120 two-shaft shredder has the torque and technology to break down and recycle wind turbine blades, and is often used for bulky item reduction such as tires, appliances, aluminum, and electronic scrap.

We’re in the infancy of wind turbine blade recycling. The problem is that the U.S. dove into wind energy never considering the end of life of those components and where they would go.

Lee Sage Industrial Sales Specialist, SSI Shredding Systems

“There are a lot of different aspects that go into working or developing a new application, like a wind turbine blade. This has been three years in the works,” says Sage.

Creating a mobile shredder can be challenging since it must be within the weight and height constraints set by the Department of Transportation. Nevertheless, moving the shredder to various turbine disposal sites has been invaluable to Pitbull Blade Demolition.

The shredder itself is mounted on a 53-foot flatbed trailer and hauled with a diesel-powered vehicle. The shredder rotates at a low speed, uses high-torque hydraulics, and runs on a Caterpillar motor. Pre-cut turbine blades are fed into a hopper on top which then pulverizes them into smaller pieces. The waste is then moved up a conveyer belt built with a skid-mount design that empties the shreds into a truck or dumpster.

“An average blade takes about two to three hours to shred and it’s shredded down into sub-four-inch pieces,” says Baisden. “We then supply these shreds to REGEN Fiber, a new company in Iowa that recycles them for reuse as raw materials in various industries. So, none of the material whatsoever goes to the landfill from the wind turbine [blade].”

REGEN Fiber recently started converting shredded turbine blades into reinforcement fibre materials that add strength and durability to concrete and mortar applications such as pavement, slabs-on-grade, and precast products.

Due to their components and enormous profile, wind turbine blades are extremely difficult to shred.

Wind turbine blades must be rebuilt often – sometimes as frequently as every 10 to 12 years.

TRADITIONAL VERSUS HYDRAULIC TRUCK SCALES

CHOOSE THE RIGHT TYPE OF SCALE FOR YOUR WEIGHING OPERATION

BY STEVE HOSP

Today’s hydraulic truck scales combine state-of-the-art electronics with virtually indestructible hydraulic load cells for a weighing system with no electronics in the scale platform, which is the area of greatest potential problems and failures. The design of a hydraulic truck scale allows the weight signals from the load cells via pressure transducers to be totalized and converted to a single data signal which, in turn, is sent to the indicator for viewing and further system processing by the operator.

When selecting scales or upgrading your weighing operation, there are many advantages to choosing a hydraulic truck scale, including the fact that hydraulic scales are considered to be extremely accurate in high-capacity applications. They also have several advantages over a traditional truck scale which uses analog strain gauge or digital load cell technology.

LIGHTNING STRIKES AND POWER SURGES

In locations subject to lightning strikes and power surges, hydraulic truck scales perform better than both digital and analog scales because the load cells are immune to damage resulting from transient voltages.

Unlike traditional truck scales, which use digital or analog strain gauge load cells, hydraulic load cells do not require power in the scale and also don’t have strain gauges or wiring. They will not be affected by lightning strikes or power grid changes –one of the most common reasons for load cell failures.

Hydraulic truck scales use hydraulic tubing from the load cells and are terminated at the scale totalizer by a non-conducting rubber line. This creates a barrier of protection which prevents lightning from travelling into the scale house where the digital weight display is located.

WATER AND HIGH-PRESSURE WASHDOWNS

If your weighing operation is in an area that frequently floods and the scale is continuously submerged in water for an extended period of time, then a hydraulic scale will prevent the water from damaging the weighing components in the scale. Hydraulic truck scales use hermetically sealed load cells that are welded together and then pressure tested to ensure there are no leaks. By keeping the hydraulic fluid inside the load cell, water is kept out, preventing damage that would shut down a traditional truck scale using digital or analog strain gauge load cells.

Cardinal Scale’s Guardian hydraulic truck scales combine electronics with nearly indestructible hydraulic load cells.

Another benefit of a hydraulic truck scale is that the scale’s weighing components will not be damaged by the high-pressure washdown that is routinely performed on scales used in the solid waste industry to remove dirt and grime.

OPERATIONS SUBJECT TO SHOCK LOADING

In any operation, there will be times the scale is subjected to shock loading or vibration. Hydraulic truck scales perform well when this happens due to the design of the load cells. Both analog and digital load cells use a steel spring element to sense the load. Applying a shock load, even one less than the capacity of the load cell, can and will cause permanent damage to the load cell rendering it unusable. Hydraulic truck scale load cells, on the other hand, act much like a shock absorber on your automobile, dissipating the shock load or vibration in the hydraulic fluid and preventing damage to the scale that would result in costly downtime.

TEMPERATURE RANGE

Extreme temperatures can affect a traditional truck scale’s circuit boxes and cause problems with the load cells. Fortunately, there are no electronic components in hydraulic truck scales, allowing them to operate over a wide range of temperatures. Instead of using electronic components, hydraulic truck scales have load cells that use aircraft-quality hydraulic fluid. This type of hydraulic fluid allows a hydraulic truck scale to continue to operate accurately and efficiently in environments with temperatures as low as -65 degrees F (-54 degrees C) and up to 275 degrees F (135 degrees C) resulting in a truck scale that will never stop working because of weather extremes.

USAGE IN HAZARDOUS AREAS

Hydraulic truck scales are ideal for any hazardous environments where explosive materials are present and where a spark could potentially set off an explosion. Furthermore, hydraulic truck scales are a safer alternative in any operation with a pit-type scale, where fuel or other flammable materials leaking from a vehicle and collecting in the scale pit can be ignited.

Traditional truck scales using analog or digital load cells must take extra precautions and use barrier strips to limit the energy to the scale or explosion-proof enclosures to contain the explosion. Those steps are not necessary when you use a hydraulic truck scale. Because hydraulic truck scales contain no electrical circuitry, there are no electrical currents, and therefore, no chance of an explosion-causing spark when used in an explosive atmosphere.

The technology used in hydraulic truck scales has a long history of use in scales – much longer than either the strain gauge or digital technology used in traditional truck scales.

Hydraulic truck scales use hydraulic tubing from the load cells and are terminated at the scale totalizer which protects from lightning strikes.

EQUIPMENT

With all the components that require power located in the scale house and absolutely no power in the scale itself, hydraulic truck scales are inherently safe and highly recommended for hazardous environments.

LOAD CELL OUTPUT

Digital truck scales have the ability to display weight data from each load cell and can alert the scale operator or service technician of a potential problem before the scale weights are affected. Some hydraulic truck scales are available with the same type of load cell controllers that perform the same func-

tions as found in digital truck scales. These controllers digitize each hydraulic load cell output independently allowing the operator or technician to view the outputs of each load cell.

Software is also available to alert the operator when an excessive shift in the no-load output of one or more cells is detected prior to affecting the accuracy of the scale. Another advantage of a hydraulic truck scale with this type of load cell controller is quick and easy calibration.

LEGAL AND METROLOGY STANDARDS

Scales used in commerce, where money is exchanged based on scale weight, must have a National Type Evaluation Program Certificate (NTEP) to verify that they comply with the requirements for use in trade. Just like their digital counterparts, today’s hydraulic truck scales have been thoroughly evaluated and comply with the National Institute of Standards and Technology (NIST) Handbook 44 requirements for Class IIIL scales for use in commerce.

COST OF OWNERSHIP

The technology used in hydraulic truck scales has a long history of being used in scales, much longer than either the strain gauge or digital technology used in traditional truck scales.

Although hydraulic truck scales have not been as popular as the less expensive traditional truck scale, when the costs of ownership are figured in, the hydraulic truck scale is clearly less expensive to own and maintain.

Hydraulic truck scales are easy to maintain as there are very few moving parts. It’s also easy to spot any leakages and therefore easy to know if there are any maintenance issues. With virtually no moving parts, the life expectancy of a hydraulic truck scale can be 30 or more years.

Most manufacturers of hydraulic truck scales offer a lifetime warranty on the primary components (the hydraulic load cells) against damage from voltage surges and water damage, which are the two most common reasons for the failure of strain gauge and digital load cells.

With a lifetime warranty on the primary components of the hydraulic truck scale, components that are waterproof, shockproof, explosion-proof, and resistant to both caustic and corrosive environments, you will never have outof-your-own-pocket expenses to replace these due to damage or malfunction.

2022 SAW INCREASE IN SOLID WASTE WORKER FATALITIES

POST-COLLECTION AND MAINTENANCE ACTIVITIES CONTRIBUTED TO RISE

The Solid Waste Association of North America (SWANA) reported an increase in worker fatalities in 2022 in the United States and Canada after a dramatic drop in 2021. In 2022, 46 solid waste industry worker fatalities were recorded by SWANA compared to 28 the year before.

“SWANA is disappointed by the nearly 65 percent increase in worker fatalities experienced in the industry last year,” stated David Biderman, former SWANA Executive Director and CEO. “The 2022 data is a reminder that we need to make sure that safety is a core value across all lines of business in collection, post-collection, and maintenance and at small and large companies and agencies in both the public and private sectors.”

Looking at worker fatalities month-by-month,

The first goal in SWANA’s Strategic Plan: Forward, Together is getting collection workers off the list of the 10 occupations with the highest fatality rate. In 2022, collection worker fatalities increased modestly from 22 to 25. According to the federal Bureau of Labor Statistics’ (BLS) most recent report, which covers 2021 data, collection workers are seventh on that list, an improvement compared to previous years.

Public sector workers represented a larger percentage of fatalities in 2022, compared to previous years. About 35 percent

of all solid waste workers killed last year worked in the public sector, whereas the average was around 21 percent over the past four years.

Collection remained the leading type of work for fatal incidents. The most common cause of collection worker fatalities continues to be their own truck (e.g., either falling off it, being struck by it, or the truck rolling over). Being struck by a third-party vehicle remains the third leading cause of death for collection workers followed by crashes with other vehicles.

Post-collection and maintenance activities both saw large increases in fatalities in 2022, representing the bulk of the rise in worker deaths from 2021. Fatal incidents at materials recovery facilities (MRFs) jumped from one in 2021 to seven in 2022. Fatalities at landfills went from five in 2021 to eight in 2022.

Maintenance also contributed to the rise in worker fatalities in 2022, with four people killed while working on trucks. Three of these incidents involved working on or around hydraulics.

Mechanical-related fatalities as a whole led the list of fatal events for the first time since SWANA has tracked this data. In addition to truck maintenance, work on and around shredders, balers, compactors, and other equipment led to 11 worker deaths in 2022. Single-vehicle crashes were again the second leading cause of fatal incidents.

OVERALL TRENDS

Looking at worker fatalities month-by-month, overall trends of a spring and then a summer spike followed by a decrease

An increase in worker fatalities in 2022 follows 2021’s dramatic drop.

overall trends of a spring and then a summer spike followed by a decrease through the end of the year continues to hold.

through the end of the year continues to hold.

The 2022 data is unusual in that there was a dip in fatalities in June. The previous three years saw a dip in May followed by a spike in fatal incidents in June. However, a spike did occur later in August in 2022.

In addition to worker fatalities, SWANA also tracks events in which a member of the public is killed in a solid waste related incident. For 2022, there was a decrease in the fatalities after an increase in 2021. After several years of increases, pedestrian fatalities are down compared to 2021, but still

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higher than earlier years. Fatal incidents involving cyclists also jumped significantly in 2022 compared to 2021 when there was only one recorded.

Texas, California, and New York remain on the list of top five states with the most fatalities in 2022. Florida and Pennsylvania join the list this year, replacing Ohio and Georgia who filled out the top five in 2021. These five states represent over 40 percent of all fatalities in 2022. Three fatalities occurred in Canada in 2022, with one in Ontario and two in British Columbia.

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Excavator mounted, continuous rotation, engine block crusher/recycler, auto stripper/sorter, designed to be used in the most severe auto wrecking/metal recycling applications. The hydraulic rotator allows the operator to choose from any position, to grip, flip, rotate or pull. This translates to increased productivity. Lower section is fabricated from a T1 box, this provides strength and keeps the overall attachment weight down. Tips mesh point to point for excellent fine picking and sorting. Put

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List of fatal events in 2022.

he recovered paper business is based solely on supply and demand, and some sections of trade have witnessed semi-steady to stagnant demand through most of 2022. However, supply was weak throughout the year as well, continuing a trend witnessed by the market since the beginning of the COVID-19 pandemic.

By the first quarter of 2023, things improved, but not by much. Still, the industry remains hopeful of supply improving this year as more shoppers return to malls. A higher availability of old corrugated containers (OCC) is also expected as the year goes on, which is positive. However, if the demand is not there, then the depressed market trend of 2022 will likely continue.

LOOKING EASTWARDS FOR RECOVERED PAPER EXPORTS

CHALLENGES AND PREDICTIONS FOR THE RECOVERED PAPER MARKET IN 2023

BY JONATHAN GOLD

was very strong five years ago when China was still an influence in terms of buying directly from the United States. U.S. exporters don’t have that luxury anymore. If they sell recovered paper to other countries, China may purchase from those nations, but direct trade of this material between the U.S. and China is low at present.

A couple of companies have purchased older mills in the U.S. and retrofitted them to produce brown fibre pulp, which is produced and shipped to China directly as a replacement for OCC. However, this is an expensive proposition, especially in terms of business sustainability.

COLLECTION AND MRFS

Southern New England had a mild winter this year. The snowfall also was not as heavy as usual, so moisture – the most feared phenomenon in the recovered paper industry – has also been lower this year. However, other parts of the country witnessed severe winter weather.

Here’s the issue: The material was relatively wet in those regions, and for good export quality paper, moisture needs to be at 12 percent or less.

Collection was also low in some areas of the U.S. that went through major snowstorms in the first few months of the year. If demand had been strong during that period, slow collections would have made a major impact on prices and trade. However, since demand was soft, the weak collections did not make much of a difference.

Moreover, given the latest round of interest rate increases by the Federal Reserve, prices could remain weak if the U.S. economy is in a recession, people are not buying, or goods are not being sold. Some participants in the recovered paper industry believe this will change, but if we are heading into a recession, the OCC market cannot be expected to improve unless there is strong demand from overseas. For example, the exports market

Material recycling facilities compete against wastepaper dealers. The biggest MRFs are usually owned by solid waste companies, such as WM. However, many quasi-MRF operations are owned by public–private partnerships. A lot of paper waste comes from office buildings and homes to these facilities, and MRFs handle the processing and sorting of this material. This has resulted in many issues with quality, which ruined the United States’ business with China.

Today, MRFs are investing in robotics and machines such as

The paper industry’s cyclical nature means that demand will strengthen after the downturn of the last couple of years, and our industry will pick up pace in tandem with the economy.

optical sorters to make the sorting process more quality-driven. There is still a ways to go, and if we take our eye off good-quality recovered paper and specifications, we could witness the setback we did with China.

LOOKING EAST FOR EXPORTS

Exports have remained soft through the first quarter of this year. While the cues for the second quarter of 2023 are still developing, a lot will depend on the U.S. economy and demand, as well as the economies of the countries that import from the U.S. For recovered fibre especially, the next two quarters could be difficult.

For the U.S., export demand will hopefully pick up from Mexico, India, and Canada. Europe has not been a big buyer of U.S. recovered paper and is not expected to return to this market in a big way. Indonesia, Taiwan, and Vietnam remain as other potential growth markets for U.S. recovered paper. Still, these are nothing compared to the competition for material that was witnessed when China was a big buyer of U.S. paper.

Of all the current sets of importers, demand from India could grow exponentially as it becomes a bigger trading partner with the U.S.

Countries that the U.S. exports to have changed over time. Around 45 years ago, most of the exports from the U.S. went to Spain, Italy, France, and Belgium. Then along came Taiwan and Japan, but they too stopped after their domestic industries learned to grow better and recover more within their homeland. After that, there was a long wave of imports by China, and now India is the biggest buyer of recovered paper from the U.S.

THE CHALLENGES WITHIN

Looking back over the years, domestic paper producers have made the same mistake repeatedly. They overwhelm the industry and build more than they can sell. Today, those companies that are fully integrated with their own collections and converting operations are in good hands. However, some that have built paper mills without being integrated, especially on the sales side, will eventually have issues due to overcapacity.

Major paper corporations will most likely continue to mothball less efficient paper mills as they try to build more efficient and sustainable operations that are environmentally friendly. The question is, are these mills offsetting capacities?

The answer in a nutshell would be that it all equals out. The world today is producing more containerboard, not just the United States. Its application will increase in all paper products as the population grows. Today we have less than half a dozen major players, so how much more consolidation is possible among them?

Additionally, the U.S. government always investigates antitrust laws to ensure that no one or two mills have a monopoly on this market. The paper industry’s cyclical nature means that demand will strengthen after the downturn of the last couple of years, and our industry will pick up pace in tandem with the economy. The question now is, when does this upturn begin?

JONATHAN GOLD is the founder of the Gold Group, a consulting firm for the recycling industry. Gold helps other firms’ turnaround and has advocated for the industry across various forums and platforms.

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