GRIMES IRON & METAL’S EQUIPMENT EVOLUTION HOW ROBOTIC SORTERS ARE REDEFINING RECYCLING SEPTEMBER/OCTOBER 2023 recyclingproductnews.com PUBLICATIONS MAIL AGREEMENT NO. 40069270
Q&A WITH RYAN FOGELMAN OF FIRE ROVER
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COVER STORY GRIMES IRON & METAL ELEVATES ITS OPERATIONS WITH EQUIPMENT INVESTMENTS
34 46
THE RIGHT AND WRONG PLACES FOR BALLISTIC SEPARATORS
Q&A WITH RYAN FOGELMAN OF FIRE ROVER
42
HOW ROBOTIC SORTERS ARE REDEFINING RECYCLING
September/October 2023 | Volume 31, Number 6
FEATURES
DEPARTMENTS & SECTIONS
18
Grimes Iron & Metal elevates its operations with equipment investments
10 12
News Room
24
Plastics recycling update
16
Spotlight
28
Move over, 3Rs
18
Metals
24
Plastics
34
The right and wrong places for ballistic separators
28
Automotive Recycling
42
How robotic sorters are redefining recycling
42
Robotic Sorting
34
Equipment
46
Q&A with Ryan Fogelman of Fire Rover
46
Safety
50
Commodity Focus
54
Advertiser Index
50
The auto impact
From the Editor
SEPTEMBER/OCTOBER 2023 | VOLUME 31 • NUMBER 6 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
FROM THE COVER: GRIMES IRON & METAL’S NEWEST PIECE OF EQUIPMENT The Sierra T409 material handler plays a versatile role at the Grimes yard, from loading and unloading
Published by: Baum Publications Ltd. 124 - 2323 Boundary Road Vancouver, BC, Canada V5M 4V8 Tel: 604-291-9900 Toll-free: 1-888-286-3630 Fax: 604-291-1906
trucks, to general material handling, to feeding
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materials into the Sierra T715SLK shear/baler/logger.
FOR ALL CIRCULATION INQUIRIES
Turn to page 18.
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Recycling Product News accepts no responsibility or liability for reported claims made by manufacturers and/or distributors for products or services; the views and opinions expressed are those of the authors and not necessarily those of Baum Publications Ltd. We acknowledge the financial support of the Government of Canada. Copyright 2023 Baum Publications Ltd. No portion of this publication may be reproduced without permission of the publishers. Printed on paper made of FSC®-certified and other controlled material. ISSN 1715-7013. PUBLICATIONS MAIL AGREEMENT NO. 40069270.
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FROM THE EDITOR
FROM THE EDITOR IS IT TIME TO SAY GOODBYE TO THE CHASING ARROWS?
T
he push for clearer recycling instructions on product packaging has been ongoing. Even when consumers try to recycle, they are often perplexed by the mixed messages and vague instructions stamped on products. This confusion has an immense impact on recyclers down the line, underscoring the urgent need for standardized and transparent labelling practices. Universally recognized as a symbol of recyclability, the iconic chasing arrows recycling logo – sometimes called a Möbius loop – has often been at the forefront of this debate. For many, seeing this symbol on a product means that the item can be recycled. However, this is not always the case and this symbol can be misleading. While the three arrows represent “reduce, reuse, recycle,” this doesn’t actually mean that all three apply. In some cases, the logo is only meant to signify that the item is made from recycled materials, not that it’s recyclable. This has led many consumers to believe that all products bearing the logo are completely recyclable, when it actually comes down to the capabilities of local recycling facilities and the demand for certain materials. The chasing arrows logo further complicates matters when it comes to plastics, which are already notoriously hard to recycle. In the United States, less than six percent of plastics are recycled each year. The number inside the arrows indicates the type of plastic used to make the product, but doesn’t guarantee recyclability, especially for resin identification codes three through seven which don’t generally have end markets or are expensive to process. Some countries are starting to take proactive steps to address this issue. The Government of Canada, for example, introduced rules last year that prohibit the use of the chasing arrows symbol on plastic products unless 80 percent of Canada’s recycling facilities accept and have end markets for the materials. Ideally, these rules will improve plastic packaging design, generate higher-quality recycled plastics, and enhance public participation in recycling. The Canadian government has also proposed regulating terms such as “compostable” and “biodegradable” in the labelling of plastic packaging.
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recyclingproductnews.com | SEPTEMBER/OCTOBER 2023
While widespread change can be challenging, it’s essential to use clear labelling practices to ensure that recycling remains viable. Across the border, the U.S. Environmental Protection Agency recently called for the removal of the logo from certain classes of plastics, a move aimed at reducing misleading claims on packaging. Ahead of this, the state of California has already enacted a law that limits the use of the logo, as well as other advertising and labelling restrictions for manufacturers. As the recycling industry grapples with the need for clearer and more accurate recycling instructions, the future of the chasing arrows logo hangs in the balance. While widespread change can be challenging, it’s essential to use clear labelling practices to ensure that recycling remains viable. In the quest for a more environmentally responsible world, the evolution of recycling symbols is a crucial step in the right direction.
SLONE FOX Editor sfox@baumpub.com recyclingproductnews.com
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NEWS ROOM
NOVELIS TO TRIAL HYDROGEN USE AT ALUMINUM RECYCLING FACILITY
N STAY CURRENT www.recyclingproductnews.com CONNECT WITH US
@RecyclingPN
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recyclingproductnews.com | SEPTEMBER/OCTOBER 2023
ovelis’ Latchford plant in the U.K. has been awarded £4.6 million to establish hydrogen burning trials as part of the U.K. Government’s £55 million industrial fuel switching competition, £1 billion Net Zero Innovation Portfolio, and the wider regional HyNet project which aims to provide the infrastructure to produce, transport, and store low-carbon hydrogen across the North West and North Wales in the U.K. Novelis joined HyNet in 2017 and has been supporting the development of the regional infrastructure project as well as conducting its own technical feasibility studies on the use of hydrogen as a direct replacement for natural gas. “Switching to renewable energy sources is a key initiative to advance on our journey toward carbon-neutral production,” says Emilio Braghi, executive vice president of Novelis and president of Novelis Europe. “Besides decarbonizing our own facility, this collaboration drives the industrial decarbonization of the whole North West region in the U.K.” With the recently awarded grant by the Department for Energy Security & Net Zero, Novelis’ Latchford plant will test the use of hydrogen on one of its recycling furnaces in a demonstration phase in 2024. The trial has been set up in collaboration with Progressive Energy, a U.K. energy company, and requires the installation of new burners and regenerators – capable of operating with hydrogen or a blended hydrogen/gas input – and replacing the furnace lining material with one suitable for hydrogen. Depending on the final configuration, replacing natural gas with hydrogen to feed the remelting furnace could reduce carbon dioxide equivalent emissions by up to 90 percent compared to using the same amount of natural gas. In addition to its contribution to HyNet, Novelis’ research and development teams worldwide are investigating the ability to use plasma, electricity, and biomass to power its manufacturing operations.
MCNEILUS ELECTRIC COLLECTION VEHICLE EARNS ZERO-EMISSION CERTIFICATIONS
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cNeilus’ Volterra ZSL, a fully integrated, zero-emission electric refuse collection vehicle, has earned three certifications from the United States Environmental Protection Agency (EPA) and California Air Resources Board (CARB). The McNeilus Volterra ZSL refuse collection vehicle is manufactured by McNeilus and Oshkosh Corporation. The vehicle brings together Oshkosh’s experience in severe-duty vehicles and McNeilus’ expertise in collection vehicle bodies. The truck has earned the EPA Heavy Duty Greenhouse Gas Certificate of Conformity, CARB Heavy Duty Greenhouse Gas Executive Order, and the CARB Zero Emissions Powertrain Executive Order certifications. The EPA certificate signifies the Volterra ZSL electric refuse vehicle conforms with phase 2 greenhouse gas emissions standards and fuel efficiency standards for medium- and heavy-duty engines and vehicles. In addition, CARB approvals provide written documentation of compliance with CARB regulations pertaining to greenhouse gas emissions and zero emissions for heavy-duty powertrains. CARB recently announced the advanced clean fleets rule, which says refuse vehicle fleets across the state of California must transition to zero emissions by 2040. To support fleet owners with this change, the state offers a variety of purchase incentive programs such as the Hybrid and Zero Emissions Voucher Incentive Project. The CARB certifications also satisfy the zero-emissions vehicle reporting requirements necessary for compliance with the advanced clean truck regulations now in effect in eight states. The Volterra ZSL meets or exceeds clean energy mandates and the battery management system is optimized for refuse collection, enabling all-day route collection on a single charge. Other features include an e-axle architecture with a B10-rating of 300,000 miles.
KAL TIRE’S MINING TIRE RECYCLING FACILITY ACHIEVES ISCC PLUS CERTIFICATION
K
al Tire’s Mining Tire Group has received ISCC PLUS certification which verifies that the mining tire recycling facility in Chile processes circular feedstocks. At Kal Tire’s facility in Northern Chile, ultra-class tires are converted to their base elements (carbon black, oil, and steel) so they can be reused in new products instead of raw materials. The facility’s thermal conversion processes use heat and friction to induce a process that sees virtually 100 percent of the tire reused, according to the company. The ISCC PLUS certification verifies that the Chile recycling facility meets the circular materials standards for reclaimed oil, carbon black, and syngas using a mass balance chain of custody approach. Kal Tire is one of just a few mining tire recycling facilities in the world to have achieved ISCC PLUS certification for producing circular feedstocks. “Years ago, we set out to invest in a solution at the top of the mining tire recycling hierarchy to help customers solve the great challenge of handling end-of-life mining tires more sustainably, at a time when government also began calling for environmental leadership and contribution to climate action plans,” says Dan Allan, senior vice president of Kal Tire’s Mining Tire Group. Kal Tire’s facility has the capacity to process five 63-inch tires (20,000 kg) every day, creating 8,000 kg of carbon black; 6,500 L of oil; 4,000 kg of steel; and enough synthetic gas to fuel the plant itself for seven hours. The company also sees growing demand for recovered carbon black, which can be used to produce tires and plastic products.
THE PROS AND CONS OF SORTING ROBOTS As technology advances, robotic sorters are becoming a staple in recycling facilities worldwide and are redefining recycling as we know it. Turn to page 42 to read more.
SEPTEMBER/OCTOBER 2023 | recyclingproductnews.com
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NEWS ROOM
LEFORT ACQUIRES SHEAR AND BALER MANUFACTURER
M
etal recycling equipment manufacturer Lefort has acquired 100 percent of the capital of Copex. Based in France, Copex specializes in the design and manufacturing of hydraulic shears and balers for the treatment of scrap metal and solid waste. Copex exports its equipment worldwide to meet specific and varied industrial needs such as nuclear dismantling, baling agricultural plant fibres, and packaging waste from wastewater. Copex’s expertise and production capacity will provide Lefort with the opportunity to increase its activity and strengthen its local and international presence.
NTH CYCLE OPENS NEW NICKEL AND COBALT REFINING FACILITY
N
th Cycle has commissioned a 21,000-square-foot nickel and cobalt refining facility in Fairfield, Ohio. The new facility will utilize Nth Cycle’s electro-extraction technology which will recover the outputs of metal scrap, electronics waste, untapped mining resources, and refinery waste into metals including nickel and cobalt through its mixed hydroxide precipitate (MHP) processor called the OYSTER. The processor yields metal and mineral purity with what Nth Cycle says is the highest concentration of nickel hydroxide and cobalt hydroxide available.
SPLIT AND SORT Split Your Material Stream with CP Auger Screen
Sort it with MSS FiberMax
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recyclingproductnews.com | SEPTEMBER/OCTOBER 2023
net-zero emissions by 2050. About 85 percent to 90 percent of a wind turbine’s mass is made from materials that can already be commercially recycled. The bulk of the unrecycled materials is composed of fibre-reinforced composites. These materials can be found in wind turbine blades, nacelle covers, and the cover for the hub that connects the blades to the wind turbine. The wind energy industry also depends on critical minerals, such as rare earth elements (including the neodymium and dysprosium magnets used in generators), which do not currently have U.S. commercial-scale recycling options. This prize seeks to develop recycling options for fibre-reinforced composites and rare earth elements, which can lessen the need to extract and process raw materials.
U.S. DEPARTMENT OF ENERGY LAUNCHES $5.1 MILLION WIND TURBINE RECYCLING PRIZE
T
he U.S. Department of Energy has launched the Wind Turbine Materials Recycling Prize. The prize is a $5.1 million competition that will help the U.S. develop a cost-effective recycling industry for two important materials used in wind turbines: fibre-reinforced composites and rare earth elements. By helping to create a circular wind energy economy, this prize will increase the sustainability of wind energy and support the U.S.’ goals of achieving a carbon pollution-free power sector by 2035 and Okada_Rotar_RPN_08__25_2023.pdf
MCCLOSKEY REORGANIZES MATERIAL PROCESSING BRANDS
M
cCloskey has reorganized its existing business lines by naming Materials Processing Products Global as the new internal structure for Lippmann, McCloskey International, McCloskey Environmental, TESAB, and MWS Equipment. The new structure leverages the abilities within each business line and allows the group to benefit from the synergies of global processes.
ON THE JOB. DOING THE JOB.
• Breakers • Processing Buckets • Scrap Shears • Cutter Crushers • Pulverizers • Grabs/Grapples 12950 SE Highway 212 Clackamas, Oregon 97015
904 Medina Road Medina, Ohio 44256
3701 Windmill Road Joshua, Texas 76058
800-270-0600 • OkadaAmerica.com
SEPTEMBER/OCTOBER 2023 | recyclingproductnews.com
15
SPOTLIGHT
SPOTLIGHT
INTRODUCTIONS & UPDATES
Shredder
Ballistic separator
Sparta Manufacturing
BALLISTIC SEPARATOR
Sparta’s Olympus accelerated ballistic separator is engineered to seamlessly integrate into a recycler’s existing recycling process and combines the features of a ballistic separator and a disc screen separator. Equipped with conveyor belts travelling at 600 feet per minute integrated into ballistic paddles, the unit quickly separates 2D materials and operates at a steeper angle which accelerates 3D fraction recovery. The sectional mesh screens’ incline is customizable and electronically controlled through an HMI control panel and electrical actuators. Due to the new addition of belts, steeper elevation angles can be used to make sorting more accurate.
TANA
SHREDDER
From TANA’s Shark shredder series, the electric TANA 440ET is ideally suited for high-volume production facilities where industrial-grade 1,000-amp and 400/480-volt three-phase electrical connections are available. Compared to diesel models, the service interval is twice as long, and spare parts are also cheaper due to the reduced maintenance requirements. The 440ET utilizes combined hydraulics and electricity. The electrified power unit powers the traditional hydraulics that then rotate the shredder rotor knives. Although the shredding itself is powered by the electricity mains, the 440ET is equipped with a small diesel engine that allows the machine to be driven independently.
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recyclingproductnews.com | SEPTEMBER/OCTOBER 2023
Telescopic hooklift
PALFINGER
TELESCOPIC HOOKLIFT
PALFINGER’s HT 160 SLD 3 hooklift is designed for high performance and easy installation. The HT 160 SLD 3 hooklift highlights higher performance with a 10 percent reduction in dead weight while maintaining a consistent lifting and tipping capacity of 16,000 pounds at a 36-inch hook height and 18,000 pounds at a 54-inch hook height. Coupled with a subframe design that includes a raised front cross member, the hooklift is versatile and fits a wide range of trucks. It also has a standard advanced mounting system which enables quick and easy installation, minimizing downtime.
AI intelligent detection cameras
Container loading system
Best Process Solutions
Brigade Electronics
The BPS container loading system is engineered to load 20foot and 40-foot shipping containers quickly and efficiently for the export of ferrous and non-ferrous metals. The three major components of this system are the vibratory hopper feeder, loading belt conveyor, and system controls. The robust surge hopper has a holding capacity of approximately 15 cubic yards and includes a manually adjustable product flow control gate for the operator to control the product feed rate. The heavy-duty cantilevered belt conveyor is engineered with a belt speed of 500–1,000 fpm to allow for more material to stack up in the container.
Brigade Electronics’ AI intelligent detection cameras are a new generation of active blind-spot detection that utilizes artificial intelligence to recognize humans within a predefined detection zone and warn drivers visually and audibly before a possible collision occurs. Compared to traditional vehicle cameras, AI cameras have a range of improved features, such as built-in image processing and detected person overlay, and are quick and easy to install. Brigade’s AI cameras require no configuration software, making them ideal for busy fleets across a range of industries, including transport, logistics, construction, and passenger vehicles like buses and coaches.
CONTAINER LOADING SYSTEM
DETECTION CAMERAS
SEPTEMBER/OCTOBER 2023 | recyclingproductnews.com
17
METALS
FROM RUST TO GRIMES IRON & METAL ELEVATES ITS OPERATIONS WITH STRATEGIC EQUIPMENT INVESTMENTS BY SLONE FOX, EDITOR
O RICHES
What initially started out as a car-crushing service and salvage yard eventually expanded to include a scrapyard.
METALS
N
estled in the dusty plains of Odessa, Texas, lies a scrapyard with a rich history spanning back to the early 1980s. With Bill Grimes at the helm of what initially started out as a car-crushing service and salvage yard, Grimes Iron & Metal made a name for itself. When Bill’s son Travis urged him to expand his operations to include a scrapyard, the business gained momentum, growing to encompass 10 of the yard’s 16 acres, with still more room to expand. “[Travis’] dad was real worried that this area would dry up of metal,” says Billy Grimes, the yard’s crew foreman and Travis’ son. “But considering how much metal comes through the scrapyards – and how many there are around here – this town has never run out of scrap. It’s a big oil field town, and convincing his dad to come out here and start this yard was probably the best decision he ever made. For this type of business, out here is literally a gold mine.”
I think in this business you just can’t become complacent. As soon as you do, then you’re really going to have a hard time growing and moving on in the future. Billy Grimes Crew Foreman, Grimes Iron & Metal
But even the most promising ideas can succumb to the unpredictable nature of the industry. The Grimes yard faced its share of trials, leading to intermittent closures over the years. In 2009, Travis Grimes took over full-time and breathed life back into the business with little more than the remnants of scrap metal left behind, and he hasn’t looked back since. “When he started it back up, he would literally sell all the material that came in. He would have to stop the yard, go get his money from the people he sells to,
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go to the bank, get it in cash, come back, and open the yard back up so he could buy more material,” says yard foreman Revel Wilson. “He would not stop.” Today, the Grimes Iron & Metal yard stands as a sprawling testament to that revival, with an extensive equipment lineup and a reputation for above and beyond customer service that has played a critical role in its enduring success. “[Travis] had a mindset when he started this that anything he bought, he wasn’t going to buy it until he could pay cash for it. He didn’t want to finance anything, and he stuck with that motto probably all the way up until about 2014,” says Billy.
SECURING SCRAP
In the early days, the Grimes team took its car-crushing endeavors statewide through Texas, Oklahoma, and New Mexico. Car crushing still remains a central part of Grimes Iron & Metal’s business today, with 90 percent of the cars now coming from the Midland– Odessa area. “We buy cars from pretty much any salvage yard that salvages parts. Any of them in the area. That’s a lot,” says Nina Grimes, operations manager and Travis’ daughter. “Yes, people bring cars into the yard, but most of our cars come from those salvage yards.” Grimes Iron & Metal processes a diverse range of metals from an equally diverse set of sources including drop-off recycling, car pickup, and construction site box services. With over 200 collection boxes on the go, Grimes Iron & Metal facilitates the pickup, purchasing, and subsequent processing of the materials for its customers. “If you go to a lot of the real big companies that are in scrap metal recycling, they pay you, get you out, and you’re just another customer number. We’re one of the few that actually let people come in and look around and see if there’s anything they want to buy, so they can resell it and turn a profit, or if it’s something they need personally,” says Billy. “We tend to treat the customers that come in our yard as if they were one of our friends that we’ve known for a long time.” Grimes Iron & Metal’s open-yard approach is distinctive compared to many scrapyards, and, according to Nina Grimes, is just one of the ways the team strives to foster personal relationships. “Our biggest thing is our customer
recyclingproductnews.com | SEPTEMBER/OCTOBER 2023
Nina Grimes, Revel Wilson, and Billy Grimes.
The scrapyard encompasses 10 of Grimes Iron & Metal’s 16 acres, with still more room to expand.
METALS
The T409 plays a versatile role at the yard, from loading and unloading trucks, to feeding materials into the Sierra T715SLK shear/baler/logger.
Grimes Iron & Metal’s equipment lineup includes 11 trucks, five magnets, three grapples, a mobile shear, an air shear, two balers, and two crushers.
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recyclingproductnews.com | SEPTEMBER/OCTOBER 2023
service, because without our customers, we ain’t nothing,” says Nina. “We pride ourselves on trying to be customer-oriented above all else. To make sure that not just we are making money, but our customers, too.”
A VERSATILE LINEUP
With an equipment lineup including 11 trucks, five magnets, three grapples, a mobile shear, an air shear, two balers, and two crushers, Grimes Iron & Metal is a formidable force when it comes to processing both ferrous and non-ferrous metals. “If we get big pieces of aluminum, cables, ACSR, or anything that’s more on the precious side, we separate it and sell that separately,” says Wilson. “We have an RB6000 Sierra baler strictly just for tin, and we have another one that bales all of our precious metals. Before we got the second RB6000, we would have to stop baling tin for pretty much a whole day, maybe two days, just to bale all of our precious metals. But now we can bale tin all day, and then our RB6000 will bale all the extra stuff like aluminum cans, ACSR, extrusion, sheet aluminum, copper, and sometimes brass. Anything that’s bendable, pretty much.” With a diverse range of metals arriving in various forms and conditions, it’s not always smooth sailing when it comes to maintaining the quality and purity of scrap. Factors such as metal contamination and varying grades of alloys complicate the process, demanding meticulous attention to detail and a deep understanding of the variables at play. “What we run into is that some people will bring in dirty aluminum. Now, it’s our job to figure out if it’s going to be worth it to clean that little bit of aluminum to sell as clean aluminum, or if we want to just sell it as dirty,” says Wilson. “We also have a gun that tests all types of metals. Say we get a lot of stainless steel rods that come in. We’ll go through with that gun and we’ll shoot them. What type it is depends on how we can sell it, because if we put 316 stainless in a 304 box, we’ll be losing money because 316 would be more money for us in the long run.”
EXPANDING THE FLEET
In the words of Travis Grimes, “If you ain’t growing, you’re dying.” Reinforcing its historical commitment to expanding its capabilities and catering to evolving demands, Grimes Iron & Metal recently welcomed a new piece
of equipment – a Sierra T409 material handler – to its fleet. The T409 plays a versatile role at the yard, from loading and unloading trucks, to general material handling, to feeding materials into the Sierra T715SLK shear/ baler/logger. While Grimes Iron & Metal previously used bigger machines for these tasks, Wilson says the size of the T409 eliminates a number of logistical challenges. “It’s a good machine to take off the yard just because of the weight. You don’t have to get an oversized permit ticket for it. You don’t have to take the grapple off or anything. You can put it right on a flatbed trailer and it sits low enough where you ain’t going to worry about it hitting a bridge,” says Wilson. “We chose it specifically because we like Sierra, honestly. Then like I said, you don’t have to dismantle it to go anywhere. It also has tires instead of tracks, which is something we’re trying to get into more. More tires than track machines.” When it comes to serviceability, Revel says that while greasing and servicing certain machines, especially those with grapples, can be tricky, the T409 has eliminated many of those previous pain points. “With this one, they literally have everything on the bottom level. You don’t have to climb up, climb down, or anything like that. The only time you have to climb up there is if you have to put diesel, hydraulic, or DEF in it. Besides that, it has an automatic greaser that’s down on the bottom, and on all the other automatic greasers, you have to climb up top. All the grease ports are right on the bottom. Even the grapple itself is super easy compared to other grapples I’ve had to grease before.”
SCRAPPING SUCCESS
Today, the Grimes yard is not just a scrapyard – it’s a symbol of the transformative potential of human connection, determination, and a dash of humour in the often mechanized world of metal recycling. “I think in this business you just can’t become complacent,” says Billy. “As soon as you do, then you’re really going to have a hard time growing and moving on in the future.” As Grimes Iron & Metal continues to write its story, one thing remains clear: its legacy of resilience, innovation, and a steadfast dedication to nurturing relationships will continue to set it apart. RPN
PLASTICS
PLASTICS RECYCLING UPDATE EASTMAN COMPLETES CLOSEDLOOP AUTOMOTIVE MIXED PLASTIC WASTE RECYCLING PROJECT
E
astman has successfully completed a closed-loop recycling project for automotive mixed plastic waste through a collaborative effort with the United States Automotive Materials Partnership, automotive recycler PADNOS, and Yanfeng. When automobiles reach their end of life, metals, tires, and glass account for 80 to 90 percent of the materials that can be recycled through traditional mechanical recycling streams. The other 10 to 20 percent, referred to as automotive shredder residue, consists of mixed plastic and other non-recyclable materials that currently end up in landfills or are recovered through waste-to-energy technologies. Under this initiative, PADNOS supplied a plastic-rich fraction of ASR as a sustainable feedstock to Eastman’s carbon renewal technology. Eastman successfully demonstrated the addition and conversion of that ASR feedstock into a synthesis gas which is subsequently used downstream in the production of its polyester and cellulosic thermoplastics. Resins from this production process were further formulated and then supplied to Yanfeng. The parts moulded by Yanfeng for the demonstration were successfully tested to meet a variety of OEM requirements, thereby demonstrating proof of concept for a circular solution. The study proved the feasibility of Eastman’s carbon renewal technology (CRT), one of Eastman’s two molecular recycling technologies, which breaks down the plastic-rich ASR into molecular building blocks. By recycling these complex plastics in CRT, Eastman can replace fossil-based feedstock and create polymers without compromising performance for use in new automotive applications.
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THE RECYCLING PARTNERSHIP REPORTS NINEFOLD INCREASE IN POLYPROPYLENE CAPTURE
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he Polypropylene Recycling Coalition has provided $10.3 million in grant funding to 41 materials recovery facilities to support new and improved polypropylene capture. The Recycling Partnership estimates that once MRFs can install and operation-
alize new equipment, these investments will result in more than 42 million pounds of polypropylene recovered annually for processing in the U.S. As a result of the coalition’s investment, 34.2 million people in the U.S. will have a new or improved ability to recycle polypropylene as part of their recycling programs. With 41 grantees at varying stages of their projects, ranging from ordering new equipment to installation and operation, one-third of grantees have had their equipment in place long enough to provide sufficient data on the impact of the grants. The reporting facilities collectively captured 1.3 million pounds of polypropylene annually pre-grant. Post-grant, they are capturing 11 million pounds of polypropylene annually. Translated into recycling rates, this represents an estimated increase from 1.2 percent pre-grant to 10 percent post-grant.
LYONDELLBASELL AND AFA NORD JOINT VENTURE TO BOOST FLEXIBLE PLASTICS RECYCLING
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yondellBasell and AFA Nord will create a joint venture to recycle post-commercial flexible secondary packaging waste with plans to build a mechanical recycling plant in Northern Germany. This will turn linear low-density polyethylene and low-density polyethylene waste into recycled plastic materials for use in flexible packaging. Production is expected to start in early 2025. Secondary plastic packaging, such as stretch or shrink film, is mainly used to hold packed consumer goods together
and protect them during transportation and storage from contamination and damage. This material is difficult to recycle into high-quality raw materials that can meet the requirements of the packaging industry. The new plant is expected to produce 26,000 tons per year of recycled LDPE and LLDPE grades that LyondellBasell will market through its CirculenRecover family of products for use in various applications from stretch films to collation shrink films.
CLOSED LOOP PARTNERS RECEIVES $10 MILLION NORTH AMERICAN PLASTICS RECYCLING INVESTMENT
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losed Loop Partners has received a $10 million investment in its Closed Loop Circular Plastics Fund from Sumitomo Mitsui Banking Corporation. This investment will help advance the recovery and recycling of rigid and flexible polyethylene (PE) and polypropylene (PP) plastics in the United States and Canada. The Closed Loop Circular Plastics Fund focuses on PE, PP, and flexible plastics. The fund provides catalytic debt and equity financing, which Closed Loop Partners says spurs additional mainstream investments into recovery and recycling and infrastructure that can help address bottlenecks in the recycling system. Fund performance is benchmarked according to a combination of financial and impact outcomes, including tons of PE and PP impacted, and tonnes of greenhouse gas emissions avoided or reduced. Since its launch in 2021, the Closed Loop Circular Plastics Fund has made several catalytic debt and equity investments to both private companies and public organizations, financing post-pilot scale projects that advance collection infrastructure, sortation capabilities, enabling technologies, and re-manufacturing of PE and PP plastics, including:
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Equity investment in Greyparrot, an AI waste analytics platform that links to moving conveyor belts in sorting facilities to increase transparency and automation in recycling and help unlock the financial value of recycled materials. Loan to Myplas USA, a recycling company building a 170,000-squarefoot plastic films recycling plant in Minnesota, aiming to process up to 45,000 tons of plastic waste annually at full capacity. Equity investment in Circular Services, a recycling and reuse company in North America. Follow-on loan to the Waste Commission of Scott County, a solid waste district in Iowa, to finance the purchase of new optical sorters for the county’s existing materials recovery facility.
PLASTICS
PLASTICS EXPANDS OPERATION CLEAN SWEEP TO HELP REDUCE PLASTIC RESIN POLLUTION
T NEW STANDARD AIMS TO GUARANTEE RECYCLED PLASTIC CONTENT IN PRODUCTS MANUFACTURED IN CANADA
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he Bureau de normalisation du Québec has published the standard CAN/BNQ 3840-100 Recycled Plastic Content Products that aims to guarantee recycled plastic content in new products manufactured in Canada and will support positive change throughout the plastic value chain so that plastics continue to be used as part of a circular economy. The new National Standard of Canada aims to meet the needs of industry, consumers, and regulatory authorities. It applies to all organizations performing plastics recycling, plastics sorting, plastics processing, and plastics transforming, as well as brand owners whose products contain plastics. This standard specifies the requirements for determining the content of recycled plastic introduced into the production process of the end product and the procedures for tracing products with recycled plastic content entering the supply chain. It establishes the basic requirements for classifying a product based on its origin and treatment (mechanical or chemical). It has been developed to be used as a reference document as part of certification activities of the applicable products.
he Plastics Industry Association (PLASTICS) and the American Chemistry Council (ACC) have launched Operation Clean Sweep (OCS) Blue Verification, a new program designed to further the plastics industry’s goal of keeping plastic in use and out of the environment. The launch of OCS Blue Verification brings a new level of transparency to the more than 500 facilities in the U.S. under the OCS Blue program through an external, facility-level inspection program. Operation Clean Sweep was founded by the Plastics Industry Association in 1991 and is managed in partnership with the American Chemistry Council’s Plastics Division. The program is dedicated to helping companies move toward zero plastic resin loss and is active in more than 60 countries worldwide. OCS members in the U.S. represent a diversity of the plastics value chain, ranging from companies making and
distributing plastic to transportation companies moving plastic and processors manufacturing final products. To become OCS Blue Verified, a facility must demonstrate that it has successfully implemented 29 required management practices ranging from risk assessments to comprehensive employee training and data reporting. OCS Blue Verification inspections will be conducted by trained and approved OCS Blue Verifiers that meet eligibility requirements. The first verification cycle extends through the end of 2025 and continues every three years moving forward.
CANADA PLASTICS PACT’S FIVEYEAR ROAD MAP FOR FLEXIBLE PLASTICS
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ver 95 companies, governments, institutions, and NGOs that are part of the Canada Plastics Pact (CPP) have released a five-year action plan (2023 to 2027) focused on addressing the challenges and opportunities associated with flexible plastic packaging in Canada. The road map has a clear objective of transitioning the industry toward a circular packaging ecosystem. Despite flexible packaging and films comprising 47 percent of the plastic packaging placed on the Canadian market, the current recycling rate for these materials remains below two percent. This disparity underscores a pressing concern as the demand for flexible plastic packaging continues to grow, driven by its lightweight, durable, versatile, and cost-effective attributes. However, the complex composition of flexible plastics poses significant challenges for recycling. The Flexible Plastic Packaging Roadmap represents a crossvalue-chain collaboration, uniting key players behind a shared vision for a circular economy for flexible plastic packaging in
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Canada and a targeted plan to accelerate and scale solutions by 2027. “Developing a circular economy for flexible plastic packaging and films is critical given the current state and the existing challenges,” says Paul Shorthouse, strategic advisor at the CPP. “This road map presents a unique opportunity for stakeholders across the plastics value chain to come together and drive rapid, unprecedented change and investment.” The CPP seeks to drive the implementation of the road map’s three thematic areas between now and 2027, including: • Upstream innovation and design for circularity. • Collection and consumer communication. • Sorting, recycling, and end-market development.
AMERICAN CIRCULAR TEXTILES WANTS TEXTILE WASTE ADDED TO EPA’S PLASTIC POLLUTION STRATEGY
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merican Circular Textiles (ACT) has submitted a letter to the United States Environmental Protection Agency (EPA) urging the agency to include textile waste in its efforts to prevent plastic pollution. The letter outlines the pressing challenges of textile waste and proposes solutions to combat the environmental and social impacts caused by the industry. The letter commends the EPA’s efforts to address plastic and other waste in waterways and oceans but emphasizes the significant impact of textile waste on environmental health, human well-being, and climate change. With approximately 60 percent of clothing production materials consisting of plastic, including polyester, acrylic, and nylon textiles, the disposal of over 30 billion pounds of textile waste annually in landfills and incinerators is becoming one of the fastest growing waste streams, a major methane emitter, and a major source of microfibre pollution. In its letter responding to the EPA’s Draft National Strategy to Prevent Plastic Pollution docket, ACT proposed amendments to existing extended producer responsibility (EPR) laws to include the reuse and recycling of textiles. The coalition suggests that federal committees collaborate to pass bipartisan legislation providing a unified road map for state textile reuse and recycling solutions, including but not limited to textile-specific EPR laws aligned with the waste hierarchy. This approach aims to harmonize national textile collection targets and the allocation of funds for textile reuse and recycling logistics, infrastructure, market development, and innovation.
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AUTOMOTIVE RECYCLING
MOVE OVER, 3RS AUTO RECYCLERS ARE AT THE FOREFRONT OF THE CIRCULAR ECONOMY BY STEVE FLETCHER
The circular economy for vehicles opens up more opportunities for auto recyclers, especially as electrification begins to take hold.
AUTOMOTIVE RECYCLING
W
e all grew up with the 3Rs for turning waste into resources: reduce, reuse, and recycle. Most people think of the Blue Box when they think of the 3Rs, but those programs only focus on the last R. While important, recycling is the last priority in what has become a linear way of thinking: make, use, dispose. A term like “auto recycling” actually encompasses a wide variety of activities. For members of the Automotive Recyclers of Canada (ARC), those main activities (i.e., main revenue sources) are the re-use of auto parts and the recovery of materials that have value (i.e., metals) for recycling. But auto recycling actually encompasses even more than that: managing collection and logistics to move end-of-life vehicles (ELVs); processing ELVs to manage the hazardous wastes that they hold; shredding depolluted hulks to access their metals; sorting those metals into ferrous and non-ferrous streams; moving those metals to be reused in the making of something new; and using the recycled materials in manufacturing. Who is the actual auto recycler in that ecosystem? All of them, to some degree. Like many things in this world, the simplicity of the 3Rs is getting more complex as we learn, innovate, and respond to external signals for efficiency, cost-reduction, and, more im-
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portantly as of late, climate change. Enter the circular economy (CE). The International Standards Organization defines CE as an economic system that uses a systemic approach to maintain a circular flow of resources by regenerating, retaining, or adding to their value while contributing to sustainable development. Climate change and net-zero requirements are driving a lot of activity in the CE world. It used to be that auto recyclers were deemed to be relevant only at the end of life of a vehicle. We used to call these products that we break down into parts and materials “end-oflife vehicles” (and most still do). But, with CE impacting many aspects of commerce and governance, there is no “end of life” anymore. Everyone in the supply chain is at the beginning and end, making upstream and downstream relationships important for CE to work. We witnessed this at the CARI–ARC Convention held this year in Halifax, Nova Scotia. What seems like two industries to outsiders is actually an interwoven ecosystem that has more in common than not. As the CE has taught us, we all need to get along and we all need to interact. It’s now generally agreed that there are 10Rs that provide different approaches to make a product or system more circular.
10RS
GENERAL CE CONCEPT
AUTO RECYCLING IMPLICATIONS
Refuse
Make a product redundant by abandoning its function or by offering the same function with a radically different product.
Mass transit, cycling, walkable cities – all are pointing toward less auto ownership. Not great for auto recyclers, but not all things CE are good for your sector.
Rethink
Make product use more intensive.
Design of a product to be more circular (disassembly, long lasting).
Reduce
Increase efficiency in product manufacture or use by consuming fewer natural resources and materials.
Using recycled materials helps create demand for recycling.
Reuse
Reuse by another consumer of the discarded product which is still in good condition and fulfills its original function.
This is the very heart of auto recycling – reusing parts. Insurers, repairers, OEMs, and consumers need to remove roadblocks to reusing parts and correct misconceptions about used parts.
Repair
Repair and maintenance of a defective product so it can be used with its original function.
More and more parts are having their life extended through simple maintenance. Headlights, mirrors, and wheels are great examples.
Refurbish
Restore an old product and bring it up to date.
Improvement of the working condition, quality, or functionality of a multi-component product to improve/upgrade it or bring it back to its original condition.
Remanufacture
Use parts of discarded product in a new product with the same function.
Auto recyclers are one of the biggest suppliers of “cores” – parts that go through a disassembly process to make them usable again. Engines, transmissions – virtually any mechanical part is remanufactured today.
Repurpose
Use discarded product or its parts in a new product with a different function.
Electric vehicle batteries repurposed for energy storage is a great example of second life usage.
Recycle
Recovery of product materials where the materials do not retain their original structure.
Metal recovery of all kinds has been a huge driver of the scrap car industry as they are forever recyclable and prevent the mining of new materials.
Recover
Incineration of material with energy recovery.
Plastics from ELVs are oftentimes seen as great candidates for energy recovery, along with shredder residue. Applying technology to waste can squeeze the last value out of an item.
recyclingproductnews.com | SEPTEMBER/OCTOBER 2023
Auto recyclers have embraced the principles of the circular economy for decades.
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2023-01-27 3:44:39 PM
AUTOMOTIVE RECYCLING I would like to add three more Rs. They are not actions; they are concepts that enhance the functionality of a CE system: reward, respect, and responsibility. Reward There needs to be the right financial incentives available to the supply chain to make the right investments and relationships. Once governments get involved in establishing incentives or system design, efficiency (and profitability) is usually sacrificed. And making OEMs solely responsible for the system means they own the system. In our world, OEMs are great at assembling vehicles, but they can’t possibly understand or work with all of the relationships in an entire supply chain. Respect The circular economy has no start or finish, no head or tail. Each segment needs to have all of the other segments involved, consulted, understood, and, in the end, respected. Responsibility Auto dismantlers are experts in how vehicles come apart to recover their parts and materials. Shredders are experts in separating out valuable materials for recovery. Everyone in the CE ecosystem for vehicles has a role to play, and they need to own that space. I use the term “own” in a broad way – they need to be that expert and continuously improve and refine their processes to keep up with and push their suppliers and customers. Auto recyclers are oftentimes called the “original recyclers.” They were recycling before it became a consumer standard. And they figured out how to make an industry out of other people’s discards that has been profitable and remains profitable.
The term “auto recycling” encompasses a wider variety of activities than many people think.
The circular economy for vehicles opens up more opportunities for auto recyclers, and, for the most part, auto recyclers don’t need to adapt to CE – they have embraced the principles and activities for decades. STEVE FLETCHER is the managing director of the Automotive Recyclers of Canada (ARC) association.
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EQUIPMENT
THE RIGHT AND WRONG PLACES FOR BALLISTIC SEPARATORS
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n recent years, there’s been a trend of replacing screens with ballistic separators. Ballistic separators come with a major advantage: They do not have any stars or discs. This means they do not wrap like traditional disk screens and they do not incur wear that requires costly star changes. But ballistics have their optimal place, and trying to employ them at certain junctions in your system could be a mistake. How do you avoid that mistake? First, let’s clarify how ballistic separators work. They have long paddles that undulate at alternate intervals to separate 2-dimensional materials from 3-dimensional materials. 2D materials walk up the paddles and fall over the screen, and 3D items bounce back and off the screen onto a conveyor. Plus, you can separate out fines as well by adding holes to the paddles. Ballistics seem to perform the same function as a starscreen, but without the wrapping and the star replacement. Sounds like a win-win, right?
POTENTIAL RISKS
The catch is that ballistic separators are picky when it comes to their “diet.” They are very sensitive to the composition of the materials they are fed and prefer a mix that contains a high percentage of 3D materials (bottles and cans) and a low percentage of 2D materials (the last bits of fibre and film). They do not perform well with the opposite ratio. When a high percentage of fibre hits a ballistic screen, there is not enough agitation created to properly clean the fibre from prohibitives. For this reason, putting ballistic separators too early in the system is a risk. Big piles of fibre, film, and other lightweight flattened items can overload the screen and compromise its separation ability. To run the system when a ballistic separator is overloaded and struggling like this, the operator has two choices: 1. Slow the system down to lighten the load. 2. Send the 2D fraction that carries over the struggling screen directly to residue, because it’s a jumble of unsellable paper mixed with film, bottles, and cans. Most operators don’t have the time to slow down their systems and lose capacity. So, most will go with option two. It’s tempting to use ballistic separators early in a system or to install multiple ballistics – there’s no wrapping and no stars to change. In efficient system designs, a larger cut of the materials is taken early on in the system with a 440 non-wrapping screen (with larger shafts). Due to its resistance to wrapping, this screen offers the same benefits of less wear and tear, fewer star
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changes, and increased production. Plus, it is specifically built to handle the larger amounts of 2D materials that are present at the front end of a system.
PROPER PLACEMENT
Once the 440 screen removes a high percentage of the 2D materials, operators should examine the amount of fibre still left in the back and under the remaining 3D stream. Is the volume of remaining fibre small enough for a ballistic to handle, or would fibre be more effectively removed by an intelligent device such as an optical sorter, robot, or human? At this stage, most MRFs need an intelligent separation device (in this case an optical sorter) to recover the remaining fibre. This is where a screen’s limitations start affecting the sort line. Sure, recent developments in screening technology like ellipticals and non-wrapping screens have alleviated some of the worst problems related to contamination. However, think about everything a starscreen or ballistic separator still cannot do. A ballistic cannot tell the difference between a milk jug or a 3D box. It cannot tell the difference between a piece of fibre and a super thin-walled PET water bottle that has been flattened. And, it definitely cannot tell the difference between a piece of newspaper and a film grocery bag. Anything flat is going over the screen, and anything 3D is bouncing off. Placing a ballistic at this juncture in the system will likely result in two very imperfect streams: the overs being, yet again, a mix of fibre, flat PET, flat aluminum, and film, and the unders being a mix of containers and 3D fibre. Little is accomplished here. The materials will not be in any better of a position than before, and will need significant cleanup on both sides to achieve optimum recovery of all materials. On the other hand, an intelligent separation device placed at this juncture in the system can make significant progress
If the placement choice is the wrong one, it will greatly affect the entire plant throughput, the quality of your fibre, the fibre capture rate, and the quality of the 3D containers passing to the container sort.
Elliptical setup with optical sorter.
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EQUIPMENT
Carrying the last scraps of paper and film out of the container stream.
in sorting these materials. Because optical sorters have the capability to recognize items by shape, colour, or specific material composition, they are essential in dealing with the highly variant and problematic materials in today’s stream. An optical sorter placed directly after a 440 screen can strategically eject the fibre that has made it into the container stream without letting film and flattened containers go with it. Opticals can identify and eject all types of fibre at this point and send it to a quality control line. After the optical sorter ejects the fibre remaining in the container stream is where the elliptical screen comes in to do what it is good at: “polishing” up your container line by removing the last bit of remaining film and fines. This screen is perfectly designed to walk any remaining film up and over its paddles while simultaneously screening out 2-inch minus materials via holes in those paddles. Remember, it needs a higher percentage of 3D materials to function properly. When it is in the right place, it’s wonderfully efficient. Those 3D items will bounce back and off the screen onto a conveyor headed for container separation. Now you will have a container stream with homogeneous materials that are able to spread out on the belt, unencumbered by floating paper and boxes. You’ll get more accurate performance from your optical sorters, robots, and manual sorters, and you will see fewer valuable containers and fibre lost to residue.
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THE BOTTOM LINE
The importance of the placement of new equipment cannot be stressed enough. You cannot simply drop a new piece of equipment wherever you think is most convenient and expect it to work seamlessly. If the placement choice is the wrong one, it will greatly affect the entire plant throughput, the quality of your fibre, the fibre capture rate, and the quality of the 3D containers passing to the container sort. Make sure you physically audit your inbound material stream constantly. Be specific: Take pictures, note sizes and shapes, and study the trends and changes that could affect your equipment placement. If you decide to upgrade from outdated screens and are enticed by the ballistic design, make sure your supplier knows the best strategy for applying the latest screening technology. Sometimes what sounds too good to be true is exactly that. Your supplier should be realistic in assessing the inbound materials that you have and honest about the retrofit layout you need to accomplish your goals. Otherwise, you could end up spending money on a retrofit that solves one problem but perpetuates another. VAN DYK RECYCLING SOLUTIONS is a turnkey systems supplier that offers recycling solutions for facility owners and operators.
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SHEARCORE FS145 GENESIS XT
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ShearCore’s FS145 mobile shear is the largest in the company’s line of attachments for the demolition and scrap recycling industries. A new shark fin rear lug design transfers stress better than previous designs, which allows higher forces to be distributed over a greater mass. The FS145R rotating shear model has a shear weight of 28,000 pounds with a jaw opening of 46 inches and jaw depth of 47 inches, along with a reach of 14 feet 9 inches. The minimum excavator boom mount is 145,000 pounds with a minimum excavator stick mount of 250,000 pounds.
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The Genesis XT is a lighter-weight mobile scrap shear that features a centre of gravity closer to the carrier, enabling models to mount on machines that could previously only carry smaller, less powerful shears. The mobile shear features improved jaw geometry and reduced ground contact wear, as well as a reverse-mounted hydraulic cylinder that shortens shear length and reduces weight. A weld-on, replaceable steel rhino horn protects the front of the upper jaw, reducing welding buildup.
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ROTAR RSS SERIES
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Rotar’s RSS Series of shears is fitted with replaceable cutting knives and completely encased nose knives. The jaw design forces material deep into the jaws where cutting power is at its maximum. The hydraulic motor and the gearbox in the upper head generate a high torque, allowing the shears to be moved in every possible position, and the hydraulic cylinder with integrated speed valve allows the jaws to close quickly. The RSS can also switch from speed to power mode when more cutting power is needed.
CATERPILLAR S2000/S3000 SERIES
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The Cat S2000/S3000 Series of mobile shears is designed for hydraulic excavators working in scrap and demolition applications and features optimum force-to-weight ratios that yield faster cycle times and more cuts per hour compared to predecessor models. Built with added strength and jaw protection features, the models can be boom- or stick-mounted and are available in both straight and 360-degree rotating configurations. The rotating feature allows the shear to be positioned in optimum cutting positions without moving the carrier.
SEPTEMBER/OCTOBER 2023 | recyclingproductnews.com
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ROBOTIC SORTING
Through machine learning algorithms, robots can differentiate between various recyclable materials with precision.
HOW ROBOTIC SORTERS ARE REDEFINING RECYCLING THE PROS, CONS & INNER WORKINGS OF SORTING ROBOTS BY SLONE FOX, EDITOR
T
he recycling industry has always grappled with a persistent challenge: how to efficiently sort and process vast amounts of recyclable materials with both accuracy and speed. As material volumes continue to surge, traditional sorting methods have struggled to keep up, leading to inefficiencies and contamination issues. In an era of rapid technological advancement, robotic sorters have established their presence as a viable solution to these issues. Utilizing a blend of artificial intelligence (AI), computer vision, and automation, these systems have already begun to revolutionize the way we manage waste. From enhancing recycling and purity rates, to reducing contamination and manual labour, autonomous sorting systems are redefining the recycling process and paving the way for a more circular economy.
HOW DO ROBOTIC SORTERS WORK?
At the heart of robotic sorting machines lies artificial intelligence, a vital component that gives the robots cognitive capa-
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bilities. Through machine learning algorithms, these AI-powered robots can recognize and differentiate between various recyclable materials with precision. Computer vision technology acts as the eyes of the robotic sorter, allowing it to “see” and interpret information from objects on a conveyor belt. Equipped with cameras and sensors, robotic sorters capture real-time images of the recyclables which are then processed by AI algorithms. The AI algorithm is then able to identify the materials based on features such as shape, colour, and texture. “AI models and frameworks need to be specifically optimized for the recycling environment because they need to be able to make inferences and command robotics within several milliseconds,” says JD Ambati, CEO of EverestLabs. “For example, in addition to RecycleOS’ robots, EverestLabs puts 3D depth-sensing cameras on recycling conveyor lines. The cameras can identify up to 200 items in each frame. Within 12 milliseconds, the AI software can tell what the objects are, what types of
packaging they contain, and communicate with the robot to recover the item immediately.” The integration of sensors further enhances the robotic sorter’s ability to evaluate recyclable materials beyond their visual features. The sorters are equipped with mechanical arms that pick items from a conveyor belt and sort them into different chutes based on the information provided by the AI and computer vision systems. The sensors can also measure features like size, density, and weight, enabling the robotic sorter to make more accurate sorting decisions. One of the most significant advantages offered by robotic sorters is their adaptability. Deep learning, found on many robotic sorters, involves training neural networks to analyze data from the sensors and cameras, enabling the robots to make precise sorting decisions based on the object. Deep learning robots continuously learn and improve their sorting capabilities as they process numerous materials, leading to increased recycling rates and reduced contamination. “With these considerations, AI data sets will continue to grow and become increasingly accurate, enabling a recycling facility to be able to identify many details about an object including the material, type of packaging, shape, volume, mass estimate, and more,” says Ambati. “This operational data captured with AI is immensely helpful for facilities as they look to optimize their processes to comply with the ever-increasing accepted material list, government regulations, and achieve their overall sustainability goals.”
THE BENEFITS AND CHALLENGES OF ROBOTIC SORTING
The most noteworthy benefit of robotic sorting machines lies in their ability to automate and optimize the sorting process. With robotic sorting machines, recycling facilities
can handle increasing volumes of waste more effectively. Traditional sorting methods rely heavily on manual labour, leading to challenges such as human error and higher processing costs. Robotic sorting systems, on the other hand, offer precision and speed, ensuring that recyclable materials are correctly identified and separated, significantly increasing recycling rates and purity. According to Ambati, robots can increase material recovery rates by up to 40 percent, therefore lowering labour and disposal costs by 40 to 60 percent. “Hiring challenges, rising costs, a lack of operational data, and pending government regulations are paramount issues. AI and robotic solutions alleviate these challenges and help recyclers meet higher recovery and purity standards by optimizing a facility’s recycling program and immediately improving recovery rates to achieve their circularity goals.” Beyond this, the integration of robotic sorting technology also minimizes the physical strain on workers. By automating physically demanding or hazardous tasks, robotic sorters help create a safer working environment for employees, minimizing the risk of injuries associated with repetitive motions and sharp or harmful materials. While human involvement remains necessary for certain tasks, automating the sorting process means that employees can focus on more specialized roles. Another advantage is that robotic sorters can operate 24/7 without fatigue, resulting in continuous sorting. Robotic sorters handle larger volumes of materials at a faster pace compared to manual sorting, and generate vast amounts of data while doing it. This information provides valuable insights into recycling patterns and waste stream composition that can then be used to optimize operations and make informed business decisions. However, like any innovation, robotic sorting also faces challenges. Robotic sorting technology requires a substantial upfront investment, including the cost of purchasing and
Artificial intelligence is a vital component that gives the robots cognitive capabilities.
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ROBOTIC SORTING
The integration of sensors enhances the robotic sorter’s ability to evaluate recyclable materials beyond their visual features.
integrating the robotic systems, sensors, and AI software, along with training workers to operate them. This can be a significant barrier for some recycling facilities, particularly smaller ones with limited budgets. The complexity of robotic sorters also requires specialized technical expertise for setup and maintenance, adding to the overall operating costs. Rapid advancements in technology have also led to concerns about the obsolescence of robotic sorters, potentially requiring costly upgrades or replacements in the future. While robotic sorters excel at recognizing common recyclable materials, they may also struggle with unconventional items, leading to the need for manual sorting in certain cases. Rapid shifts in the recycling stream or the introduction of new materials may challenge the adaptability of these sorters, so striking a balance between automated sorting and human involvement remains crucial to ensure optimal efficiency and adaptability in the face of ever-changing waste streams. Despite these challenges, the promise of robotic sorting technology in improving the recycling industry is undeniable. As advancements continue and costs decrease, it’s increasingly likely that these sorting systems will become a staple in recycling facilities worldwide, ushering in a new era of sustainability.
WILL ROBOTS REPLACE HUMAN WORKERS?
The introduction of robotic sorters for recycling has a significant impact on human workers in recycling facilities. While these technologies bring a myriad of benefits, they also raise concerns about potential job displacement and changes in the work environment. The fear of job displacement is not just unique to the recycling industry, as concerns continue to grow regarding the broader impact of technological advancements and AI on employment.
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This operational data captured with AI is immensely helpful for facilities as they look to optimize their processes to comply with the ever-increasing accepted material list, government regulations, and achieve their overall sustainability goals. JD Ambati CEO, EverestLabs Notably, the integration of robotic sorters can create new job roles and opportunities for human workers, in addition to being a helpful tool in addressing the current labour shortage. As these automated systems handle repetitive tasks, human workers can pivot to focus on more specialized and complex responsibilities that require creativity, problem-solving skills, and critical thinking – things that are not easily accomplished by most robots. For instance, workers can be trained to operate and maintain robotic sorters, oversee the sorting process, and conduct quality control checks to ensure the accuracy of the sorting process. Upskilling programs can also equip workers with the technical expertise required to work alongside robotic sorters, enhancing their career prospects and employability.
The integration of robotic sorters – and artificial intelligence in general – continues to raise ethical considerations surrounding job security. Policymakers will need to address concerns about potential job losses as a result of these types of technologies by developing policies that prioritize worker welfare and protect their rights. However, one undeniable benefit of robotic sorters is their contribution to occupational safety. By automating physically demanding and potentially hazardous tasks, the risk of injuries associated with repetitive motions and exposure to harmful materials is significantly reduced. This shift toward a safer working environment ensures the well-being and health of employees for years to come. “The adoption of robotics systems by recycling facilities will not eliminate jobs, rather it enables human workers to move up to less dangerous and more valuable positions to manage operations support and analyze the data and insights that are generated to help make more informed decisions,” explains Ambati. “There are several areas in a facility, like residue lines, where it’s just too difficult to place human sorters. Robotics addresses this problem.” While concerns about job displacement are valid, the collaborative integration of robotic sorters and human workers presents opportunities for upskilling, improved job satisfaction, and a safer working environment. By embracing this technology and addressing the associated challenges, the recycling industry can optimize the potential of robotic sorters while ensuring the well-being of its human workforce. RPN
Robotic sorting systems ensure that recyclable materials are correctly identified and separated, increasing recycling rates.
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SEPTEMBER/OCTOBER 2023 | recyclingproductnews.com
SAFETY
Q&A RYAN FOGELMAN ON SAFETY HAZARDS, INDUSTRY CHALLENGES & FIRE PREVENTION SYSTEMS IN ACTION In an industry where the convergence of combustible materials and recycling processes can create countless potential hazards, fire safety is a paramount concern for recyclers. The recycling industry, with its complex blend of materials and equipment, is particularly vulnerable to fire outbreaks, especially as electronic waste continues to find its way into waste streams. I caught up with Ryan Fogelman, vice president of strategic partnerships for Fire Rover, to discuss the hazards inherent in recycling operations, the innovative strategies aimed at preventing and managing these incidents, and how advanced fire detection and prevention systems – like those pioneered by Fire Rover – have made strides in protecting recycling facilities.
BY SLONE FOX, EDITOR Slone Fox
What are the most common fire hazards specific to the recycling industry, and how does Fire Rover address them?
Ryan Fogelman
I typically break the fire hazards into two types. The first is traditional hazards, which are hazards that have been in our waste and recycling streams since the beginning of time with the risk of being the cause of or accelerant to fires and explosions. Those hazards include propane tanks, fireworks, pool chemicals, paint thinner, aerosol cans, and more. The second is electronics, which are personal storage and/or personal electronics with batteries in them, including but not limited to lithium-ion batteries.
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SF
Can you share an example of how Fire Rover’s fire detection and prevention systems have prevented or minimized fire incidents in recycling facilities?
RF
At Fire Rover, we have prevented or minimized thousands of fire incidents at our clients’ facilities since we installed our first solution in 2015. The graph [Figure 1] shows our scorecard for 2022. During that year, we had about 300 to 350 facilities protected with one of our solutions: the Fire Rover box, OnWatch solution, or Continuous Flow solutions. Of the hundreds of thousands of alarms, we saw 2,880 confirmed fires or hot spots. Of those confirmed events, we pressurized our system
Fire Rover has prevented and minimized thousands of fire incidents since the company’s first installation in 2015.
for 12 percent of the incidents and called first responders and/or actively suppressed the fire with our remotely operated solutions. The fact is we have not had a catastrophic loss that has started in an area that we protect. We also have never had a false alarm. I don’t want to say that what we do is easy, because there are a ton of moving parts to our solution, but with our track record of currently protecting more than 500 waste and recycling facilities, we can make a pretty good case to our clients’ insurance companies that having a Fire Rover solution is far better than the alternatives to achieve good results. Personally, I follow the Volvo school of thought where safety knows no competition. That said, some of our customers allow us to share their videos to help educate other operators about the hazards they are seeing on the front lines. We have a Fire Rover YouTube channel where we share the videos that we can share.
Figure 1.
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SAFETY
Recyclers need proper equipment and training to safely respond to fire hazards.
SF
RF
In your experience, what are the key challenges in promoting fire safety awareness among recycling facility operators and workers? Promoting any solution that solves a safety problem inherently gets a lack of internal attention because it is not revenue-generating. Even solutions like the Fire Rover that are about cost avoidance and have other savings, including “fire watch” replacement, lower insurance premiums, and mitigating the risk of a major loss and operation downtime, have an uphill battle in proving to the industry that the juice is worth the squeeze.
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SF
What are the most important measures recycling facilities should take to minimize the risk of fire outbreaks?
RF
First, we need to educate the public on the dangers of improperly disposing of items that cause fire hazards in the waste and recycling streams. However, you can only educate your way out of the curbside recycling side of the equation. Construction and demolition, scrap metal, hazardous materials, and electronic recycling facilities are dealing with the risk of fires first-hand. They need back-end training for their employees on how to properly remove these hazards from the stream, how to deal with a potential fire hazard, and
how to properly fight these fires when one occurs. Fire professionals also need proper equipment and training to safely respond to these types of fire hazards when one occurs. The reality is these fires happen quickly and are powerful. For example, one bike battery can have the power of three grenades and release toxic gases that no one without the proper equipment should be fighting. They should only be evacuating as fast as possible. This is why the Fire Rover solution has been so successful. We not only detect fires early, but we get professionals to the scene quickly, and we fight the fire during the critical first minutes of an event targeted to the hazard and response needed.
SF
RF
How do you envision the future of fire safety in the recycling industry, and what improvements can still be made? We need to do audits of incoming material and presort the potential hazards out of the recycling stream. The key is that it needs to be as fast or faster than auditing or sorting is done today. I am sure there will come a day when we will be able to scan at the curbside or before processing to ensure potential fire risks are removed prior to processing the material. We are currently seeing some progress on robotic sorting lines, and I am sure technology will catch up to this at some point in the next few decades. But until then, we need to ensure we all do what we can to protect the waste and recycling operators by doing our part to be part of the solution and properly recycling and disposing of our potential fire hazards. RPN
RYAN FOGELMAN, JD/MBA, is vice president of strategic partnerships for Fire Rover. He compiles and publishes Reported Waste & Recycling Facility Fires In The US/CAN as well as the Waste & Recycling Facility Fires Annual Report.
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THE AUTO IMPACT THE OUTLOOK FOR AMERICA’S RECYCLED ALUMINUM INDUSTRY IS MUTED IN THE SHORT TERM, THOUGH EXPORTS SHINE BY GEORGE DCRUZE
M
embers of the United Auto Workers (UAW) decided to go on strike against the Big Three automakers of the U.S. (General Motors, Stellantis, and Ford) on September 14. This meant that 13,000 workers across three auto assembly lines would walk away from their roles. Since then, the UAW has reached an understanding with Ford. However, it chose to expand the strike a week later to include 38 aftersales and service locations at GM and Stellantis, which meant another 5,600 additional workers off the job. Market participants in aluminum and other base metal industries, along with steel, are mulling over the impact of this strike on demand and prices in the days ahead. In the steel sector, U.S. Steel has already idled its Blast Furnace-B at Granite City Works, Illinois – a site capable of producing 1.4 million mt of steel per year. Many fear that other steel and aluminum plants across the country are looking at similar consequences
Market participants in aluminum and other base metal industries, along with steel, are mulling the impact of the UAW strike on demand and prices.
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in the near term. Economists, however, have indicated that the impact may not be as hard as feared. In a recent Institute of Scrap Recycling Industries (ISRI) webinar, Jason Schenker, president of Prestige Economics, noted that non-ferrous metals have already been on a downtrend since the first quarter, and the potential for further downside is limited. Simultaneously, Joseph Pickard, chief economist and director of commodities at ISRI, pointed out that the Big Three’s market share in auto production has gradually decreased from 68 percent in 1999 to 40 percent in 2022. At the remaining 60 percent of auto companies, production remains unhampered and they will continue to consume aluminum at the same pace as they did before the strike. Still, the strike isn’t the only factor that has disrupted the aluminum industry this year.
LOOKING BEYOND AUTO
Recent surveys at aluminum smelters have revealed that die casters, the supply chain link between smelters and the automakers, have not changed their purchase behaviour at all since the strike began. In fact, a handful of smelters have noted that sales have improved slightly as die casters believe the strike will not impact business as much as initially estimated. Die casters have also sought to ensure an unhindered supply chain once production is resumed and are building inventories of components to ensure this. Looking ahead at the rest of the year, the situation at rolling mills and secondary aluminum smelters is almost the same. Both are sitting on large inventories of recyclable materials and do not need to purchase big lots to meet consumption needs. Hence, recycled aluminum prices are expected to trend sideways until December. For finished products, smelters expect secondary alloy sales to pick up around February of 2024, with rolling mills also expecting a similar rebound in new orders. Recycled aluminum prices peaked in Q1 2023 amid rising tensions due to Russia’s war on Ukraine. However, since then, demand has tapered steadily, leading to annual lows in July. In some cases, the bottom price level has been maintained to date. In the secondary aluminum space, demand for secondary alloys has consistently declined since Q1. The Davis Index for A380.1 settled at $1.342/pound delivered on September 22, down by 10.1¢/pound or 7 percent from $1.443/pound on March 24. This is largely due to weaker demand from consumers, especially outside the automotive sector, who are undergoing a destocking phase. Similarly, in the mill-grade aluminum space, spreads for recycled aluminum have widened consistently this year with the Davis Index spread for EC wire at 19.9¢/pound under the Midwest Transaction Price on September 19, wider by 6.5¢/pound or 48 percent compared with 13.4¢/pound under Midwest on March 21. Most rolling mills and secondary smelters placed large orders for recycled material in Q2 2023, with a large number of them filling up their inventories for the remainder of the year. Reportedly, some buyers are deferring volumes committed for Q4 2023 to Q1 2024, signaling slower recycled materials consumption than anticipated. At present, trading is muted, and buyers are selectively buying items that they need for immediate consumption, albeit in smaller quantities. Many companies have already curtailed production slightly to reflect lower demand levels and weak order books, even into Q1 2024.
THE BRIGHT SPOT
However, the recycled aluminum exports market has seen robust demand across items since mid-July. The lower Midwest premium made mill-grade items more affordable, and weak secondary material competition from domestic smelters meant exporters could set their rates. Importers in Asia believe that this is their time to grab material while it is still easily available. This optimism – and speculation for higher prices in Q1 2024 – has seen bids from Asia grow steadily despite a volatile LME. Finally, the industry remains bullish about the recycled aluminum industry’s long-term trends, and all participants believe that this short-term pain is likely to lead to many long-term gains starting in mid-2024. GEORGE DCRUZE is the U.S. aluminum analyst for Davis Index. He can be reached at george.dcruze@davisindex. com.
The world's only price publication dedicated to scrap and recycled materials markets. www.davisindex.com
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