Recycling Product News September/October 2024, Volume 32, Number 6
A C C E N T ® 4 7 0
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Accent W ire Tie is the largest supplier of baling wire and wire tier technology in the recycling and waste industry. Our leading line of bale packaging equipment includes the Accent 470® W ire Tier, featured on balers around the world and the Envirobale® bagging system for solid waste containment. Accent W ire Ties’ sales and service technicians teams have hands-on experience and stay up-to-date on the latest industry trends. Accent W ire Tie has forged the strongest ties in the industry since 1986.
FE A T U RE S & B E N EF IT S
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46 COVER STORY
JOSH HARAF DISCUSSES A NEW ERA IN WASTE FOR INTERSTATE WASTE SERVICES
26 7 SIGNS OF A DECELERATING STAINLESS STEEL MARKET
20 34
LRS FACILITY RESHAPES HOW RECYCLABLES ARE PROCESSED IN THE MIDWEST
6 TIPS FOR MAINTAINING OPTICAL SORTERS
34
38 Feess
42
46
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
just five providers authorized for city-wide containerized
See more on page 46.
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Contact: Editor Slone Fox at sfox@baumpub.com or 604-291-9900 ext. 335
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FROM THE EDITOR
DUMBING DOWN THE SMARTPHONE
For someone who writes for a living, I’m a terrible texter.
I have a solid three- to five-day turnaround on message replies, and an even worse score when it comes to calling people back (sorry, Mom).
While I love the convenience that comes with a smartphone — like being able to have 5,000 photos of my dogs on hand at any given moment — having social media and messaging at our fingertips has created an expectation of perpetual availability. Leaving someone on “read” has become one of the greatest modern-day insults.
This pressure to be available 24/7 is a big change from how things were just a few decades ago — if someone called and you weren’t home, they just had to wait for hours or even days. It was less demanding and didn’t carry the expectation of an instant response.
Recently, the “dumbphone” movement has gained momentum as a way to challenge on-demand availability. These cheaper, featureless phones offer basic functionality and lack features like apps, touchscreens, and internet access. While they’re an affordable way to decrease your screen time, the low price point causes an issue when they reach the end of their life.
Even though these simplified phones can sometimes be easier to recycle compared to the advanced electronics found in smartphones, very few manufacturers prioritize recyclability in their designs to begin with. And since dumbphones lack modern features, they aren’t considered desirable enough for the refurbished market, making them more likely to end up in landfills.
To be good candidates for resale, devices need the functionality (and branding) that people will want to buy several years after the device’s release. Cheaper models don’t fit this criteria, making refurbishing and reselling them not worth the effort. But for anyone who’s been keeping up with the news recently, more e-waste is the last thing we need.
According to the UN’s latest Global E-waste Monitor, the world’s electronic waste is increasing five times faster than recycling efforts. In 2022, less than 23 percent of e-waste was properly collected and recycled, leaving $62 billion worth of materials unaccounted for. E-waste continues to grow by 2.6 million tonnes a year and is expected to hit 82 million tonnes by 2030, marking a 33 percent rise from 2022.
Even
though these simplified phones can sometimes be easier to recycle compared to the advanced electronics found in smartphones, very few manufacturers prioritize recyclability in their designs to begin with.
The report also predicts recycling rates will drop to 20 percent by 2030 due to this growing gap between e-waste generation and recycling efforts. Rapid technological advances, higher consumption, planned obsolescence, and poor e-waste management are some of the main contributing factors to these unfortunate trends.
To tackle this growing challenge, it’s clear that just ramping up recycling efforts won’t cut it. We need a fresh perspective, one that looks at how we use and dispose of our phones, laptops, TVs, and other gadgets. By rethinking our consumption habits before even making a purchase, we can hopefully reduce the amount of e-waste we generate. Embracing longer-lasting products, supporting repairable designs, and opting for sustainable brands will undoubtedly all play a crucial role moving forward.
SLONE FOX Editor sfox@baumpub.com
BALCONES RECYCLING OPENS
$68 MILLION MRF IN TEXAS
Balcones Recycling has opened its newest recycling facility located in San Antonio, Texas. Equipped with a CP Group 50-ton-per-hour system, the San Antonio MRF will have a fully automated container line, making it what Balcones Recycling says is the most automated facility in the U.S. The facility will process both residential and commercial single-stream material for the City of San Antonio and surrounding communities, and recovered recyclable materials will be marketed in North America.
“As we established when we first sought out this project, our goal is to deliver a recycling campus that is without peer anywhere in the country,” said Balcones president Adam Vehik. “This facility is living proof of our commitment to that goal.”
The San Antonio MRF is Balcones’ fourth facility in Texas. Designed and built by KDW, the 145,000-square-foot facility represents a $68 million investment in San Antonio recycling and also includes the latest innovations in recycling technology, amenities dedicated to employee wellness, and community engagement programs. On-site resources include:
• Integrated walking trails, recreational facilities, and a community garden program for employees.
• Viewing gallery and education outreach activities for the community.
• Drop-off options for recyclable materials outside of the city program.
The City of San Antonio awarded Balcones with a 15-year municipal recycling contract in April 2022, which commenced in early August of this year. The facility’s capabilities enable the recycling of a wide range of materials with precision and efficiency. The facility will also be able to sort hard-to-recycle materials like film and flexible plastics.
Balcones has accelerated its growth in the past year after becoming the recycling arm of Circular Services, a developer of circular economy infrastructure. The inauguration of this facility brings Balcones Recycling’s reach to 19 regions across the U.S.
RECYCLABLES WITH 85 TO 90 PERCENT ACCURACY
Bower has launched an AI-powered app enabling anyone with a smartphone to identify everyday items and immediately learn how to recycle them.
The result of a €1.75M contribution and the pro bono support from a team of Google engineers to Bower for a six-month Google.org Fellowship, the new computer vision tool increases the accessibility of recycling and waste disposal.
Currently, the free app lets users log a product by scanning its barcode before being rewarded with money and coupons once that item is recycled. With this latest adaptation of Bower’s technology, anyone can aim a smartphone camera at an object, regardless of barcode, and immediately detect the item’s type, material, size, and product specifics, while also calculating the carbon emissions savings that can be made by recycling the item. They will also learn how to best dispose of it.
The new open-source computer vision model achieves 85 to 90 percent accuracy for manual recycling accuracy in the EU (versus 64 percent previously). Additionally, Bower users will be able to aim their smartphone cameras at any form of recycling station and bin anywhere in the world and be provided with real-time guidance on what can be recycled at said location and how best to do this.
This technology has been trained using Gemini, a family of multimodal large language models developed by Google’s DeepMind, as well as through Bower’s own crowdsourced user data. Bower currently has partnerships with over 600 global and local brands, such as Nestlé and battery manufacturers, where they help them engage users to increase recycling rates.
The technology Bower has built with support from Google.org will be open-source so that other organizations can more easily build innovations to help fight pollution and climate change.
CITY OF LOUISVILLE TO OPERATE FIRST FULLY ELECTRIC COLLECTION FLEET IN U.S.
Republic Services of Denver and the City of Louisville have partnered to replace the city’s residential recycling and waste collection fleet with electric trucks by the end of 2024. This will mark the first time in the U.S. that a municipality has adopted a fully electric residential collection fleet.
“We are so proud that Louisville will be the first city in the nation with a fully electric collection fleet,” said mayor Chris Leh. “These innovative EV collection trucks will fulfill our trash, compost, and recycling needs, reduce noise pollution, and include larger windshields to increase each driver’s field of vision and lower greenhouse gas emissions, making our neighbourhoods quieter, safer, and healthier.”
Adopting an electric fleet will help the city meet the objectives of its Sustainability Action Plan. Republic Services has its own climate goal to reduce greenhouse gas emissions by 35 percent by 2030, and partnering with municipalities on fleet electrification will help the company achieve it.
The fleet serving Louisville will include four McNeilus Volterra EVs. Developed with insights from Republic Services, these trucks prioritize safety in addition to producing zero tailpipe emissions. Key safety features include 360-degree cameras, an enlarged windshield for improved visibility, lane-departure sensors, automated braking, and audible devices that alert nearby drivers and pedestrians to compensate for their quieter operations.
By the end of 2024, Republic Services expects to operate more than 50 EVs as research vehicles or in partnership with other municipalities across the U.S.
FEESS
RETURNS
OVER 90 PERCENT OF ITS C&D WASTE TO THE BUILDING CYCLE.
See more on page 38.
NOVELIS TO DOUBLE USED BEVERAGE CAN RECYCLING CAPACITY
Novelis is investing approximately $90 million to increase the recycling capacity for used beverage cans (UBCs) at its plant in Latchford, UK. The project will increase the facility’s recycling capacity for UBCs by 85 kilotonnes per year.
The investment includes the construction of a new dross house, three new bag houses, and the installation of shredding, sorting, de-coating, and melting technologies, enabling the plant to recycle a larger volume and new types of aluminum scrap. The expansion of recycling capacity and the implementation of advanced technologies will result in an annual carbon emissions reduction of more than 350,000 tonnes.
The project is expected to begin commissioning in December 2026. Once complete, the facility will be able to recycle 100 percent of UBCs to be collected under the future UK deposit return scheme. This will create a local, fully circular system that will avoid the need to export scrap from the UK.
TEREX ACQUIRES ENVIRONMENTAL SOLUTIONS GROUP AND BRANDS
Terex Corporation has agreed to acquire Environmental Solutions Group (ESG) from Dover Corporation in a $2 billion cash transaction. The transaction is anticipated to close in the second half of 2024, subject to the receipt of required regulatory approvals and customary closing conditions.
ESG is comprised of several brands: Heil, Marathon, Curotto-Can, Bayne Thinline, 3rd Eye, and Soft-Pak. ESG’s array of products and services across equipment, digital, and aftermarket offerings complement Terex and will allow the company to expand its customer base.
Terex will create a new environmental solutions segment that includes ESG as well as Terex’s existing utilities business. The segment combines Terex’s positions in utility equipment with ESG’s portfolio of brands. The segment will service the growing waste, recycling, and utility end markets that are expected to benefit from growth themes including electrification, circularity, and energy transition.
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DEBRAND OPENS FIRST U.S.
TEXTILE SORTING PLANT IN OHIO
Debrand has opened its first U.S. facility in Columbus, Ohio. Debrand’s 32,000-square-foot facility has been designed to support brands in integrating sustainability and circularity models that align with impending regulatory compliance using future-proof sortation technology and new machinery.
“The fashion industry is well beyond its tipping point with textile waste. The sheer volume of garments produced each year is becoming insurmountable, and there simply aren’t enough regional solutions to address this issue at the scale
required in North America,” said Amelia Eleiter, CEO and co-founder of Debrand. “By expanding our footprint, we’re making the investments necessary to move the industry toward a more responsible future. Not only will this help us address our current challenges with pre- and post-consumer waste, but we’re also future-proofing so that once regulations pass and our clients are faced with new operational realities, we’re ready to support them in lockstep to create the most impactful systems of sustainability and circularity possible.”
The facility strives to mirror the success of the company’s facility in Canada, housing a fusion of automated textile sortation technology and equipment. This integration empowers scalable textile sortation, increasing capacity and capabilities to meet the growing demands of Debrand’s logistics services and solutions.
The new facility is poised to fuel the company’s ongoing growth trajectory and success within the fashion and apparel sector. In the last 18 months, Debrand has diverted over 4.5 million pounds of textile waste from landfills.
CANADIAN GOVERNMENT
INVESTS $9 MILLION IN LITHIUM BATTERY SUPPLY CHAIN
The Government of Canada is supporting domestic value chains for critical minerals and the clean technologies and energy sources they enable through two investments totalling over $9 million to Saltworks Technologies and NORAM Electrolysis Systems. This funding will support the battery supply chain in B.C. under the Critical Minerals Research, Development, and Demonstration (CMRDD) program.
The $4,937,500 investment to Saltworks will be used to accelerate the concentration and conversion of Canadian lithium brine into lithium battery precursors using two technologies
developed and tested by Saltworks. An additional investment of $4,500,000 to NESI will support the industrial-scale demonstration of membrane electrolysis technology for lithium production at NESI’s new test centre. The project will help commercialize sustainable lithium hydroxide production from a variety of lithium resources.
SWANA JOINS THE CANADA PLASTICS PACT
The Solid Waste Association of North America (SWANA) has joined the Canada Plastics Pact. Launched in 2021, the Canada Plastics Pact is leading Canada’s response to the escalating plastic crisis. It exists to eliminate plastic waste by accelerating and scaling the solutions that will keep plastics in the economy and out of people, animals, and nature.
Through fostering innovation and collaboration, more than 100 partners from across the plastics value chain are taking steps to eliminate unnecessary and problematic plastics, redesign packaging, and increase their use of recycled plastic.
“To eliminate plastic waste and pollution, we need a holistic strategy that includes both upstream and downstream solutions,” says Cher Mereweather, managing director of the Canada Plastics Pact. “These new partnerships allow us to better address unnecessary and problematic plastics by providing reusable or refillable alternatives where it makes sense and designing the plastics we do need to be easily recyclable.”
NWRA AWARDS ACHIEVEMENTS IN WASTE AND RECYCLING
The NWRA Recycling Awards recognize partnerships that implement game-changing initiatives in the industry, as well as recycling equipment designers and manufacturers across North America who successfully challenge and advance recycling sector operations
Republic Services’ Polymer Center in Las Vegas won the 2023 Sustainability Game Changer award for the way the facility approaches plastics circularity. The facility processes sorted and baled plastics from recycling facilities, further separating plastics by type and colour to produce hot-washed recycled PET flake and colour-sorted olefins.
Machinex won the Recycling Equipment Innovator of the Year award for its next-generation MRF at the Sherbourne
Resource Park in Coventry, UK. Machinex designed, manufactured, and installed a sorting system featuring 19 SamurAI sorting robots, 14 optical sorters (including 13 MACH Hyspec optical sorters), a MACH Vision stream composition analyzer, and multiple MACH INTELL platforms facility-wide.
REPUBLIC SERVICES HITS EMISSIONS REDUCTION TARGET EARLY
Republic Services has released its 2023 Sustainability Report, which highlights the company’s sustainability initiatives and progress toward its 2030 goals. As of 2023, Republic Services has reduced operational GHG emissions by 15 percent, versus a 2017 baseline, ahead of its interim target of a 10 percent reduction by 2025.
Prevent your process from coming to a grinding halt
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• Faster and Safer Knife Changes – Adjustments are Made in Jig Outside of Granulator
• Available Force Feeders – Increase Throughput by 50% - 80%, Reducing Power Consumption
The EvoQuip Caiman 150 shredder is ideal for diverse applications such as C&D, asphalt, green waste, wood, and household waste, such as mattresses. It has a compact 1.5-metre twin-shaft shredding unit, which produces up to 80,000Nm of torque per shaft. The ability to quickly change shafts allows the operator to swiftly change from working in one application to another, with the option to operate the shredder with either synced or independent shafts. It includes a robust track sub-frame with bolt-on tracks, catering to both track and track/hooklift versions, and has a robust tracking system and hydraulic chassis for smooth operation and diagnostics.
MDS TROMMEL
The new M518R compact recycling trommel from MDS has a suite of new features for screening a variety of materials, including compost, green waste, biomass, and municipal waste. The M518R is well-suited for small to medium-sized operations and contractors, particularly those with limited space and a need for easy transportation. Featuring a 180-degree radial fines conveyor, the machine offers a radial stockpile capacity of up to 650 cubic metres. Its compact dimensions and efficient folding mechanism of the radial conveyor fit neatly onto a standard 26-foot-long trailer. One standout feature of the M518R is its remote-controlled conveyor swivel, enabling operators to adjust positioning effortlessly during operation.
M&J Recycling SHREDDER
The new M&J F240e is designed to improve energy efficiency and output quality with a unique cutting system. Once the rotor blades and static knives are set, there’s no need for frequent adjustments. This system reduces operating costs and maximizes uptime, ensuring efficient production and high output quality. The M&J F240e leaves waste in uniform sizes with a grain size down to 10 millimetres. The strategic placement of wear parts means maintenance time is significantly reduced, and parts replacement is rapid and hassle-free. Operational energy savings is up to 35 percent.
Compact trommel
Electrical fine shredder
Waste shredder
EvoQuip JAW CRUSHER
The EvoQuip Bison 220R jaw crusher features a large 820 millimetres by 550 millimetres (32 inches by 22 inches) jaw inlet and has 240MPa compressive strength to process a wide range of materials in different applications. Its hydrostatic drive system is fuel efficient and can run the chamber in reverse. It also features an 8- by 4-foot single-deck screen on the R section for efficient screening. Operators have the flexibility to raise and lower the product conveyor, facilitating smooth material handling. Quick setup times, simple intuitive operation, easy maintenance, and transport capabilities make the Bison 220R a versatile and user-friendly solution for various crushing applications.
Sesotec SORTING SYSTEM
Sesotec and KRS Recycling Systems’ SPEKTRUM+ glass sorting system is equipped with a new C-C sensor system that can differentiate better between black glass or dark glass and CSP (ceramic/stone/porcelain). The traditional viewing of cullet using normal transmitted light illumination has been extended with a newly developed, special illumination plus sensor system which identifies glass that is especially impermeable to normal light so it is no longer unintentionally sorted out with impurities such as CSP. This represents an advantage in glass recovery, as the dark fragments, which are particularly valuable due to their material thickness, remain in the material cycle.
Jaw crusher
Glass sorting system
CIRCULARITY
IN CHICAGO
LRS FACILITY RESHAPES HOW RECYCLABLES ARE PROCESSED IN THE MIDWEST
BY MEGHAN BARTON
In the heart of Chicago’s historic Stockyards neighbourhood, a game-changing facility is transforming the future of waste management. The Exchange, LRS’s latest material recovery facility (MRF), is reshaping recycling practices across the Midwest.
With a holistic and innovative approach to single-stream recycling, the Exchange is not just another MRF; it’s a symbol of forward-thinking solutions designed to minimize environmental impact. Operating at a capacity of 25 tons of recyclables per hour — with plans for future expansion to 35 tons per hour — the facility is already making waves in waste diversion efforts.
LRS stands as North America’s fifth-largest privately held waste and recycling company, playing a crucial role in advancing sustainable waste management practices. Since 2013, LRS has delivered comprehensive, fully integrated waste diversion and recycling services to thousands of residential, commercial, and construction customers across eight states. With a service portfolio that includes roll-off container rentals, construction and demolition (C&D) recycling, portable restrooms, street sweeping, and more, LRS has rapidly expanded its reach and impact.
ment with critical capital support from trusted stakeholders expedited the opening of the facility in 2023.
The recycling process at the Exchange begins when trucks arrive and are weighed at the scale house to determine the incoming material’s tonnage. The recyclables are then unloaded onto the tipping floor, where a fully electric material handler transfers them onto a conveyor belt. The material first encounters an auger screen that sorts items based on size, allowing larger items to pass over while smaller items, such as bottles and jars, fall through. These smaller items hit a glass breaker, with glass separated using a cyclone separator. The larger materials are directed to a post-sort area, where employees remove contaminants and bulky items.
Subsequent sorting involves screens that differentiate between two-dimensional and three-dimensional objects, with optical sorters and a giant drum magnet that captures ferrous metals. An EverestLabs AI robot monitors the last chance line to recover any aluminum cans and plastic bottles that may have been missed.
Finally, sorted materials are compacted by balers and stored before being shipped to factories and mills for recycling, with an average of 80 percent of materials being recycled successfully.
INNOVATION BY DESIGN
The Exchange facility’s design and equipment choices were driven by a thoughtful and deliberate intent to streamline the recycling process.
We work really hard to educate our communities on the fact that aluminum is infinitely recyclable and in under 90 days that beverage can can be back on your shelf with a new beverage inside it.
Joy Rifkin Sustainability Manager, LRS
THE VISION
The Exchange was conceptualized when a merger between Recycling Systems Incorporated and Lakeshore Waste Services sparked the idea for a state-of-the-art materials recovery facility in Chicago. The vision was clear from the beginning: to build a high-tech, high-capacity single-stream facility that could handle the growing volume of recyclables in the Chicagoland area. By 2021, the project gained significant momentum when the company secured the City of Chicago’s Blue Cart recycling contract.
Construction of the facility began in the Stockyards, close to the company’s existing truck yard to reduce traffic and emissions. This strategic location optimized operational efficiency, with trucks now able to tip materials and park nearby, decreasing fuel use and environmental impact. A $50 million invest-
“We were evaluating for efficiency, safety, and lead time,” says Mark Molitor, VP of post-collection with LRS. “CP Manufacturing hit all those marks with their innovative CP auger screen.”
This piece of equipment streamlines the sorting process by allowing only larger materials to move to the first sorting line, significantly improving safety and efficiency for workers. The same strategic thinking was used when choosing to purchase Harris balers to incorporate full redundancy; having two balers ensures continuous operation even if one malfunctions.
With the increased use and disposal of lithium-ion batteries, fire safety was another key factor in choosing equipment for the new facility. The team at LRS opted to install three Fire Rover systems. These systems utilize thermal imaging and smoke detection cameras to monitor high-risk areas, provide early alerts for potential fires, and activate on-site fire suppression measures. By integrating these high-tech solutions, the facility enhances its operational efficiency and safeguards the health and safety of its workers and the environment.
A HOLISTIC APPROACH
In 2024, LRS’s dedication to reshaping the recycling industry earned it the Recycling Facility of the Year Award from the National Waste & Recycling Association (NWRA). This award recognizes organizations that have profoundly impacted waste diversion efforts, celebrating their achievements and commitment while inspiring others in the industry.
The Exchange MRF was honoured for groundbreaking advancements in sustainability and innovation. But, perhaps more significantly, the award reflects LRS’s holistic approach to
An auger screen sorts items based on size, allowing larger items to pass over while smaller items fall through.
The facility currently operates at a capacity of 25 tons of recyclables per hour with plans to expand to 35 tons per hour.
The
that aluminum is infinitely recyclable and in under 90 days that
ing circularity within the recycling industry. Circularity shifts away from the traditional linear model of resource use — where materials are mined, made into products, and ultimately discarded as waste — toward a system that emphasizes reducing material use and recapturing waste to manufacture new products. LRS recycles materials efficiently and redesigns processes to make recycling more accessible and effective.
“LRS was founded with the DNA of recycling,” says Joy Rifkin, sustainability manager at LRS. “We ask: How can we recycle anything that can be recycled, and how can we connect with our communities to make sure that sustainability and customer satisfaction are foundational in what we do?”
This comprehensive approach to advancing recycling innovation means LRS is dedicated to stringent quality control measures and rigorous contamination management. The Exchange MRF employs a post-sort system, where team members are carefully trained to identify and manually remove contaminants, ensuring the cleanest possible end product for manufacturers.
“We have such good relationships with the mills and factories where we send this material because we deliver such a clean, uncontaminated product,” Rifkin says.
These relationships are crucial in keeping the circular economy running efficiently, as uncontaminated recyclables are more easily converted into new products. LRS’s carefully sorted and baled materials — known as recycling cubes — are stored, weighed, and sent to North American mills, where they are processed into new items, continuing the cycle of reuse and reducing the need to extract raw materials.
LRS has also partnered with the American Beverage Institute and the Can Manufacturers Institute (CMI) to improve beverage
EDUCATION IS KEY
Ongoing education (both internal and public) and innovation are at the heart of LRS’s operations. Team members attend industry conferences and collaborate with leading manufacturers and mills, ensuring they remain at the forefront of recycling innovation.
In this spirit, LRS has partnered with EverestLabs to test AI-driven robotic technology in the Exchange facility. By working with strategic partners to assess potential improvements in sorting accuracy and efficiency, LRS can remain on the cutting edge when implementing new technologies to optimize operations and help educate others in the industry.
As new trends in recyclability emerge — such as the ability to recycle paper cups — LRS works closely with mills to stay ahead of the curve and incorporate these materials into the recycling program.
As part of its front-facing educational initiatives, the team at LRS has designed a custom online tool at chicagorecycles.org, which provides transparency into the recycling process for Chicago residents. As Rifkin explains, “This is a super cool education tool and interactive map that really showcases our commitment to the city.”
The tool allows users to zoom in on specific neighbourhoods, homes, or schools and see how recycling works at the local level. It outlines the city’s recycling zones and the roles LRS plays in collecting recyclables from four out of six collection areas. The interactive platform also illustrates where different materials go after collection, showcasing the circular journey of recyclables. With updated data, LRS ensures that
container recycling through its Every Bottle Back initiative.
A $50 million investment lead to the expedited opening of the facility in 2023.
residents are informed and engaged in the city’s recycling efforts, fostering a deeper understanding of and participation in sustainability initiatives.
Another community education effort involves welcoming the public to its facilities, showcasing the inner workings of an advanced recycling process. With an open-door policy, LRS has hosted hundreds of visitors from academia, government, industry, and community groups. In 2023, over 800 visitors toured the Exchange MRF, gaining first-hand insight into the complex operations behind modern green recycling.
“So many people don’t realize in addition to machines and equipment that are maintained to ensure we can sort at a high level, there are actual human beings who have to deal with these materials,” says Rifkin. By lifting the veil on recycling operations, LRS educates visitors and builds advocates for sustainability within communities.
LRS also plays a crucial educational role by providing annual recycling audits for the City of Chicago. By isolating each zone and breaking down the types of materials processed, LRS helps the city and its residents understand the recycling stream better. These audits offer a detailed view of contamination levels and material percentages, enabling the city to improve its educational outreach and refine its waste diversion strategies. This open exchange of information showcases LRS’s commitment to creating a circular economy while building strong relationships with the communities it serves.
Through these multifaceted efforts — facility tours, annual audits, and interactive online tools — LRS exemplifies how transparency and education can drive better recycling out-
• Complies with DOT regulations
• Disposable
• Economical
• In
comes and inspire a more informed and engaged community as it aims to drive the continued evolution of recycling practices.
THE FUTURE OF RECYCLING
LRS has established ambitious long-term sustainability goals, focused on achieving net-zero operations by 2040.
“We have a board-approved, net-zero plan,” says Rifkin. Key strategies to meet these goals include route optimization to improve efficiency, boost operational effectiveness, and reduce fuel consumption and emissions. LRS is investing in equipment electrification, incorporating technologies like fully electric material handlers and exploring alternative fuels such as compressed natural gas (CNG) and higher biodiesel blends for its fleet. These initiatives are complemented by ongoing education efforts aimed at engaging and informing the community about sustainability practices and the importance of recycling.
“The future of LRS is continuing this mission toward sustainable business operations,” says Rifkin. “That means profitability. That means safety and protecting our people. That means our commitment to the environment. Growing the company across the Midwest in a sustainable and community-centred way is the future for LRS.”
Plans for growth include expanding beyond the Chicagoland area and bringing expertise in high-tech facilities, impeccable customer service, and commitment to the communities where it operates.
MEGHAN BARTON is a freelance copywriter who specializes in crafting engaging B2B content.
7 SIGNS OF A DECELERATING STAINLESS STEEL MARKET
RECYCLED STAINLESS STEEL IS ON THE DECLINE AS MANUFACTURERS AND PROCESSORS DOWNPLAY THE SECTOR’S PERFORMANCE
BY SHOHINI NATH
The stainless steel sector has been slow over the past two years, with subdued global demand. Manufacturers like Aperam continue to see headwinds in the EU steel sector, offset by more shipments from Brazil.
However, the United States’ high-performance alloys market was stable, as per Acerinox, underlining strong performance in North America during the first half of 2024.
Stainless steel prices in the United States have extended the downtrend in the second half of the year from the first half of 2024. Finland’s Outokumpu highlighted subdued market conditions during the second quarter in Europe and the Americas owing to limited supply. Moreover, imports into Mexico are disrupting the regional supply and demand balance.
The primary and recycled stainless steel sector’s near-term outlook remains bearish due to several factors. Here are the top seven signs impacting this market and arresting its growth.
1WEAK GLOBAL ECONOMY
Correlating the slowdown of the stainless steel sector with that of the global economy is easy. The latter is undoubtedly an essential factor influencing every other sector. As economic data inflows show weak numbers since last year, the stainless steel market has been vulnerable to macroeconomic challenges.
The World Bank places the 2024 global GDP growth forecast at 2.4 percent, down from 2023’s 2.6 percent. Last year was marked by geopolitical conflicts leading to problems in ocean freights that continue to hinder any recovery.
Conflicts in the Middle East and Eastern Europe have had ripple effects worldwide,
2exacerbated by the ongoing Red Sea crisis. Stabilization is forecasted to be slower; however, the stainless steel market remains under the undesirable effect of a beaten global economy. Lagging industrial production also affects demand for stainless steel to a significant degree.
HIGH INTEREST RATES
A major highlight of last year was surging interest rates worldwide set to tackle elevating inflation. There was an impetus to tighten monetary policies, which proved counterproductive for stainless steel businesses, stalling growth and affecting scale and profit margin across the supply chain.
Small-scale manufacturers have felt the full brunt of high interest rates. Several trading companies worldwide have stepped back from purchases, grappling with high interest rates, which is painful for the economies.
Several manufacturers feel that Western economies are expected to recover gradually due to the impact of aggressive interest rate hikes. The underlying growth expectations in steel-using sectors were weak in the first half of 2024.
Downstream stainless steel buyers remain exposed to the stiff headwinds of high interest rates. Purchases are still being postponed as sales weaken further and the supply and demand equations falter. The industry is caught in a vicious cycle, with interest rate cuts seen as a quick fix.
SOFT CONSUMER DEMAND
Most large downstream consumers of stainless steel face a harsh business environment. As per S&P Global’s August 2024 report, real estate, metals, mining, automobiles, parts, construction material, machinery, equipment, and household and personal use sectors are all outside the growth territory.
However, the pharmaceuticals, telecommunication, food, and healthcare industries fared slightly better by staying in the growth territory. The latter sectors use stainless steel for equipment and storage.
The oil and gas sector is projected to gain strength in 2024 and 2025 as per OPEC’s July report, which cites increasing air travel in the holiday season to bolster demand for fuel and its production. Aerospace is also expected to be a strong driver during the year and could strengthen nickel alloy demand.
Hydrogen projection and Ni 201 needs for electrolysis are strengthening, with upward forecasts for 2024 and 2025. The Davis Index for 201 solids climbed by 18 percent annually in September.
Another sector that has boosted the demand for stainless steel is shipbuilding. The industry
is anticipated to reach new highs until 2026 as shipyards thrive.
Stainless steel mills have initiated production cuts, which can be traced back to low demand from the automotive and construction sectors. Automobile sales, especially in the United States, have lagged during most of 2024, mainly because of rising costs and inflation concerns. This has contributed to low stainless steel consumption.
Moreover, consumer spending has been hurt, and car sales have taken the back seat this year.
The United States’ monthly purchase manager index (manufacturing PMI) slipped 1.7 basis points to 46.8 in July, according to a recent report from the Institute of Supply Management (ISM).
Construction companies are the most significant users of stainless steel; however, the United States Census Bureau’s July report indicates that housing starts and completions are lower. Consumers are not confident about their future, citing the credit crunch amid limited lending, which has deterred infrastructure and automobile manufacturing growth.
4
BOTTLENECKS IN SHIPPING LINES
Shipping line problems multiplied after disruptions on the Red Sea route escalated, adding further tensions in the Middle East. The fallout on the Suez Canal affected nearly 30 percent of global container traffic and raised inflation rates worldwide. The situation is far from eased as energy supplies have also stalled in regions that import along deep-sea routes.
Containerized freight prices from China’s ports have more than doubled in a year. The Containerized Freight Index is 164 percent higher than in September last year, while the Baltic Dry Index is 70 percent higher in the same timeframe.
In June, several exporters and importers of recycled stainless steel noted a shortage of containers and port congestion in the Far East. This hindered trade and softened the United States’ recycled stainless demand. Rising shipping costs amid container shortages made shipping to and from Asia highly unfavourable.
The market has only started readjusting, and freight prices have stabilized after shipping container production seems to recover gradually. Exports of recycled stainless steel have improved, giving domestic prices a much-needed reprieve. Toward the end of each year, the metals and recycled material market has been known to lose momentum ahead of the holiday season. Looking at these factors, recycled material prices are likely to be rangebound in Q4 of 2024, if not slightly weaker than the current levels.
5
INFERIOR IMPORTS
Despite the bottlenecks in shipping routes and container shortages, the United States sits on a large warehouse of subsidized imports of specific stainless steel grades from China and Southeast Asia.
Overcapacity in those regions has been the main reason for several Asian countries targeting export destinations. Cold rolled overcapacity could exceed 4 million metric tonnes this year in China and 12 million metric tonnes globally, increasing by 2 million metric tonnes compared to 2023.
The latest petition filed in September by United States manufacturing companies has defined a few products, including flat-rolled stainless steel, for assessment. The companies have urged the Department of Commerce and the U.S. International Trade Commission to impose antidumping duties on the listed products from 10 countries: Australia, Brazil, Canada, Mexico, the Netherlands, South Africa, Taiwan, Turkey (Turkiye), UAE, and Vietnam.
In August, Commerce issued a preliminary antidumping duty on Vietnamese exports of welded stainless steel pressure pipe for the review period from July 1, 2022, to June 30, 2023. While countervailing and antidumping duties are levied to protect domestic producers and encourage near-shoring or friend-shoring, a few economists believe this postpones an expected rebound.
Trade restrictions rose substantially in 2023, contributing to economic downside compared with 2015, according to World Bank data. Glob-
Exports of recycled stainless steel have improved, giving domestic prices a reprieve.
al trade growth in 2023 is less than 1 percent compared to an average of 5 percent from 2010 to 2019. However, World Bank data indicates over 2 percent growth in trade in 2024 and a little over 3 percent in 2025.
MOUNTING RAW MATERIAL INVENTORIES
Stainless steel processors and mills were overstocked in Q2 and Q3, reiterating the tangible effects of the global economic slowdown. While businesses want to insulate their company’s performance from sharp market movements, stainless steel markets are vulnerable to volatile nickel, chrome, and molybdenum raw material prices.
Recycled stainless steel processor buying prices for highly traded grades were almost 5 to 8 percent higher in Q1 this year compared with the latest price levels. Furthermore, stainless steel mills have reduced pricing for their raw material intake and have cut purchases in the event of weak downstream sales. For example, Acerinox’s global melting shop production totalled 405,000 metric tonnes in Q2 2024, down 12 percent from Q1 2024 and 17 percent lower than Q2 2023.
Processors are at an impasse as margins continue to shrink while finished inventories mount, and most are now buying at price dips while volumes have waned and buying frequency seems erratic. Most have been keen on lowering prices to counter the high cost paid for buying material in the first half of this year.
Recycled Inconel prices are down almost 10 to 20 percent this year in September, which is in line with nickel compared with the same month a year ago, even though demand from the aerospace sector is firm. Notably, this sector is expected to do well this year and next.
The Davis Index for SS 304 solids is trending at its 2024 low in September, while 316 solids bottomed out from its lowest this year in August. Mounting inventories remains a crucial problem in this industry, affecting both upstream and downstream businesses.
RAW MATERIALS MILL PRICING
Stainless steel alloy surcharges have dropped by 5 to 20 percent annually depending on the grades. Compared with June (end of Q2), the alloy surcharges of September (end of Q3) are down between 2 to 15 percent. Annual and quarterly surcharge cuts have been more noticeable for the 300 series grades than the 200 and 400 series. Mills are keen to expand downstream sales while nursing losses and downstream consumers are unable to meet the expected demand.
Ferrous scrap prices like HMS1&2 cost and freight to Turkey started firmly in 2024, trading around $405 to $415USD per metric tonne as per the Davis Index. Steelmakers were slow to ramp up operations to support prices amid subdued finished steel demand. Despite relatively lower surcharges in September, sales have struggled, and upstream businesses have also faced the brunt.
GLOBAL ECONOMIC RECOVERY IS NEEDED
The solution to these interlinked problems is directly proportional to a recovery in the global economy. Moreover, geopolitical conflicts have hurt energy and commodities markets. Improvement has been slow, and stainless steel consumption is unlikely to grow considerably in the second half of 2024. There is uncertainty about China’s recovery and the direction of high interest rates in Europe and the United States.
The overcapacity situation in China will mostly be met by weaker-than-expected demand globally. Lower inventory levels are improbable this year, thus keeping the global stainless value chain and trade flows under pressure.
The slowdown in the stainless steel market and the lack of visibility remain for the third quarter.
In the United States, softening inflation and lower unemployment are key contributors to the potential rate cuts. The awaited interest rate cut could pave the way toward recovery. However, a 25 basis points cut would be a step toward the 50 basis points cut that economists expect later in the year. The way to return to normalcy is by overcoming these challenges.
SHOHINI NATH is a U.S. stainless steel analyst and editor at Davis Index, a market intelligence platform for the ferrous and non-ferrous metals and recycling industry. She can be reached at shohini.nath@davisindex.com.
PLASTICS NEWS ROOM
REPORT SHOWS 10 COUNTRIES EXPORT OVER 4.4 MILLION TONNES OF PLASTIC WASTE
Anew research report from CleanHub ranks the top 10 countries that export and import the most plastic waste annually.
With many governments reluctant to release official figures, highlighting the complicated nature of global plastic waste disposal, the research has been compiled from various key industry and scientific reports for a definitive ranking.
Some countries export and import an enormous amount of plastic waste per year, simultaneously getting rid of the plastic they can’t process while taking in plastic they can turn into material to manufacture new goods.
Key report findings include:
• The top 10 countries export more than 4.4 million tonnes of plastic waste per year, accounting for 71 percent of all plastic waste exports.
• The top 10 exporting countries are all high-income, developed nations, and seven of them are in Europe.
• Germany, Japan, and the UK are the top three plastic waste exporting countries.
• The Netherlands, Turkey, and Germany are the top three importers of plastic waste.
• Many nations have reduced plastic waste exports over the past year — notably the U.S. by 28 percent and Germany by six percent.
• In the last year, Japan’s exports have increased by seven percent, Canada’s have grown by 10 percent, and the
Netherlands’ have shot up by 69 percent in the past four years.
• Around five million tonnes of used plastic are exported each year, 55 percent of which are discarded.
Exporting plastic waste has become a cheaper way for some of the wealthiest countries to avoid having to recycle, reuse, or properly process millions of tonnes of their own garbage, says CleanHub. It keeps their carbon footprints and plastic footprints low and maintains the impression that they’re progressing toward their net-zero targets.
Instead, they send it to other nations for recycling — aware that vast quantities of the exported waste are mismanaged through dumping in landfills and/or burning.
The CleanHub report looks at the ongoing legislation around plastic waste, as well as detailing the way plastic waste exports impact the environment through:
Polluting oceans Five percent of ocean plastic pollution is from waste exports, a total of approximately 635,000 tonnes of bottles, bags, plates, and other waste.
Polluting countries Exported plastic waste is routinely burned illegally, which sends toxic chemical pollutants into the air, or dumped illegally, causing toxins to seep into ground and water supplies.
Polluting the atmosphere The five million tonnes of plastic exports are mainly shipped abroad, which emits 320,900 tonnes of carbon dioxide annually.
PARTNERSHIP TO TURN TIRES INTO
NEW CAR PARTS
Neste, Borealis, and Covestro have signed a project agreement to enable the recycling of discarded tires into high-quality plastics for automotive applications. The collaboration aims to drive circularity in plastics value chains and the automotive industry. When no longer fit for use, tires are liquefied using chemical recycling and then processed into base chemicals and further into polycarbonates of high purity. These can then be used in various automotive applications, from parts of headlamps to radiator grilles.
“Circularity requires cooperation, and this cooperation with our partners Neste and Borealis is a testament to the possibilities at our disposal,” says Guido Naberfeld, senior vice president and head of sales and market development mobility at Covestro. “We are creating options to turn old tires into new car parts again. With that, we are supporting our automotive customers and addressing an increasingly prominent question discussed across the value chain: how to match high-performance materials with recycled content. Projects like this can be the answer.”
As part of the collaboration, Neste will turn liquefied discarded tires into raw material for polymers and chemicals manufacturing and supply it to Borealis. Borealis will then process the Neste-produced raw material into base chemicals phenol and acetone, which are then supplied to Covestro. Covestro can use these materials to make polycarbonate. The share of recycled content is attributed to the mass balancing approach to the final products using ISCC Plus certification.
The first products based on the collaboration are already
available as each party has manufactured the first batch of their contribution to the project. Aside from polycarbonates, the project partners may also consider polyurethanes as a possible end product, which could also find its way into parts of the interior of a car. The companies emphasize that the potential to scale up these types of developments should be considered when setting ambitious targets for future EU regulations, such as the End of Life Vehicles Regulation.
“We are demonstrating the importance of value chain cooperation to give new value to waste,” says Thomas Van De Velde, senior vice president of base chemicals at Borealis. “We are proud that Borealis, in collaboration with Neste, is able to play a role in this project, providing more sustainable solutions for polymer applications for Covestro and its customers.”
PARTNERSHIP AIMS TO IMPROVE HEALTHCARE PLASTICS RECYCLABILITY
Brightmark has formed a strategic partnership with Lewis Salvage, an independently owned recycling company based in Warsaw, Indiana, a location with the world’s highest concentration of orthopedic
design and manufacturing companies. By participating in Lewis Salvage’s Minimized Landfill Recycling Program, the Brightmark Circularity Center in Ashley, Indiana, will receive plastics for recycling from medical
device companies, orthopedic implant manufacturers, and packaging companies originally bound for landfills and incinerators. Brightmark has been able to recycle approximately 400,000 pounds of plastic waste because of this partnership.
“We’re proud to play an important role in reducing the amount of healthcare plastic waste going to landfills, and our strategic partnership with Lewis Salvage is a significant step toward achieving this goal,” said Bob Powell, founder and CEO of Brightmark. “Our Plastics Renewal technology provides a crucial solution for recycling essential plastics at the end of their useful life cycle, which assists vital sectors such as the healthcare, agriculture, manufacturing, and transportation industries by providing a viable recycling solution that helps them
achieve their sustainability goals and reduce their environmental footprints.”
The U.S. produces 6 million tons of medical waste annually, with plastics accounting for about 25 percent of this total. The vast majority of this waste ends up in landfills or natural environments without adequate infrastructure to recycle it. Nevertheless, plastic plays a vital role in the healthcare industry.
“Plastic is crucial for patient safety, but the sheer volume of single-use medical waste is a growing environmental concern,” says Peylina Chu, executive director of the Healthcare Plastics Recycling Council. “The amount of healthcare plastic produced annually is projected to increase to 48 billion pounds by 2025. It’s imperative that we find sustainable solutions to manage and recycle this valuable resource.”
PLASTICS
U.S. PLASTICS PACT’S ROADMAP 2.0
TARGETS INCREASED REUSE AND CIRCULARITY GOALS
The U.S. Plastics Pact has released its latest strategic plan to help companies change how they design, use, and reuse plastics in their packaging. The U.S. Plastics Pact designed “Roadmap 2.0” to focus on practical steps to create a circular economy where plastic packaging is reused, recycled, composted, and kept within the economy instead of becoming waste. This plan builds on the initial “Roadmap to 2025”, setting forth updated targets to address plastic waste and drive change across the entire plastics value chain.
The original “Roadmap to 2025” was created to catalyze immediate action in the absence of a federal strategy. Over the past four years, the U.S. Plastics Pact has seen significant progress in plastics circularity:
Reduction of problematic materials Through the creation of a problematic and unnecessary materials list, the use of problematic or unnecessary plastics decreased from 14 percent to 8 percent.
Increased recyclability The amount of reusable, recyclable, or compostable plastic packaging increased from 37 percent to 47.7 percent.
Recycled content Post-consumer recycled or responsibly sourced biobased content in packaging increased from 7 percent to 9.4 percent.
Community growth The U.S. Plastic Pact expanded from 62 to over 130 activators.
Resource development The “PCR Procurement Toolkit,” “PCR Certification Principles,” and the “Design for Circularity Playbook” will be published summer of 2024.
Building on these advancements, the changing landscape requires companies to continue pushing boundaries. “Roadmap 2.0” is designed to carry forward the unfinished targets from the original plan and introduce new objectives based on the experiences of U.S. Plastic Pact activators:
Reuse innovations Making reuse a core target can significantly reduce single-use plastics. Practical examples include returnable cup systems at events, which help reduce waste.
Design for circularity All plastic packaging will be designed and manufactured to be reusable, recyclable, or compostable.
Elimination of problematic plastics By 2030, all items on the expanded problematic and unnecessary materials list will be eliminated, and virgin plastic will be reduced by 30 percent. This approach ensures that only essential plastics are produced and used in ways that support sustainability.
Effective recycling The plan aims to recycle 50 percent of plastic packaging and establish the necessary infrastructure
to achieve this at scale. In comparison, plastic packaging will achieve an average of 30 percent post-consumer recycled or responsibly sourced biobased content.
Health and community impact The plan also addresses the social impacts and disparities related to plastic production and use.
The U.S. Plastics Pact continues to work as part of the Ellen MacArthur Foundation’s Plastics Pact Network and other global initiatives to harmonize efforts and share best practices. “Roadmap 2.0” emphasizes cross-sector collaboration and innovation to achieve these goals and begins on January 1, 2026.
6 TIPS FOR MAINTAINING OPTICAL SORTERS
METHODS TO MINIMIZE CONTAMINATION AND ACHIEVE CLEANER OUTPUT
Optical sorters are finely tuned machines. Their software and hardware components work together to deliver high-purity recycled products from complex feedstock at high throughput rates. If even one of the components is out of tune, the entire circuit’s productivity and final product purity suffer.
Selecting the right piece of equipment with the right technology supplier is just the first step in delivering the desired performance. Every day, week, and month, the machine’s operator must keep a careful eye on and maintain the components to ensure they work at peak performance to optimize profitability.
SORTER CALIBRATION IS KEY
Optical sorters found in the typical MRF or MSW sorting plant process what the human eye can see but at much higher rates. While optional technologies are available to meet specific application needs, two standard technologies are often employed by most sorters: visual spectroscopy (VIS) and near-infrared (NIR).
To see the material correctly, it is crucial that the sorter’s illumination unit is calibrated so the software detects colour and material properties properly. Any environmental change — bulb wear/aging, temperature variations, etc. — can alter how the sorter sees material.
Calibrating the sorter on a daily or weekly basis helps to optimize sorting performance but can cut into the production schedule. When working with your technology supplier, ask how quickly and how often calibration should be performed. Some optical sorters, like the TOMRA AUTOSORT, offer continuous sensor calibration, which constantly computes and maintains the VIS and NIR signals to tolerance.
KEEP VALVES CLEAN AND CLEAR
All sorters use the same mechanical process to sort material. Air valves produce jet pulses of air at precisely timed intervals to eject either the desired material or impurities in a touchless sorting process. The valve blocks on these sorters can have hundreds of individual valves, depending on belt width. To work properly, these valves must remain clean and clear of debris. Just the operating environment or oil/water in the air lines can clog or completely block a valve, leading to recycled product purity suffering.
Workers must perform a valve check for high and low pressure to make sure each valve is working properly. This is a critical maintenance step since a broken or clogged valve leads to lost output or contaminated final product.
In the past, this required the technician to go to each machine separately to manually perform the valve check. This frequently led to human error when assessing and documenting valve performance.
Some, but not all, optical sorters offer
A TOMRA AUTOSORT optical sorter.
auto testing and cleaning of the valves to ensure optimal sorting performance and purity. The testing/cleaning process occurs automatically when the circuit stops, removing the chance of human error. Detected damaged valves are reported on the machine’s control panel, or, in the case of a connected machine, to the control room or machine app.
CHECK FOR THE CORRECT BELT SPEED
Paramount to the optical sorter’s success is belt speed. The correct belt speed is the difference between high product purity and increased material contamination.
With every optical sorter, the software calculates the material’s distance by dividing belt speed to compute the proper air valve firing time and location. This is the key to optimizing the product sort.
Multiple factors can contribute to changes to belt speed — belt wear, bearings, gears, and debris buildup. A belt running faster or slower than the established belt speed leads to a valve firing too early or late, resulting in product losses or contamination.
It is essential to check for correct belt speed multiple times throughout each shift. If the sorter’s material feeder is not equipped with sensors, then the worker must manually check speed with a tachometer and make any necessary adjustments. Automation can assist with this process. For example, AUTOSORT’s feeder belt has sensors that continuously monitor its speed. Upon detecting a change, the operator is alerted for corrective action. If a sensor
fails, the system also provides an immediate and automatic alert.
A CLEAN SORTER IS A HAPPY SORTER
While intuitive and apparent, keeping a clean sorter is an important component of an accurate sorting process. They require consistent light intensity to properly detect the material but work in an inherently dirty environment. More importantly, debris allowed to build up on externally mounted illumination units can pose a fire hazard. Workers must wipe down the encasement glass, so the sensor’s field of view is not obstructed. While cleaning, inspect for any damage resulting from flying debris. For external lamps, verify they are in correct alignment, as flying debris can easily strike them. If realignment is necessary, then the worker should recalibrate the machine to optimize performance.
Any type of cleaning requires the circuit to be shut down, cutting into production. Cleaning efforts are reduced when operating sensor-based sorters with illumination units mounted inside the scanner box. Sorters offering quick-access panels to the scanner and valve block will help to minimize downtime for cleaning.
MAXIMIZE UPTIME BY KEEPING SPARE PARTS IN STOCK
Another tip to minimize downtime is keeping enough critical and high attrition parts on hand for quick replacement. Parts such as air filters for the air machine, lamps, and
An operator works to optimize an optical sorter.
parts on hand. For example, a bulb is a 10 minute replacement if it is in stock. If not, it will require one to two days to replace, plus the cost of overnight shipping and circuit downtime.
LEVERAGE TECHNOLOGY TO MINIMIZE DOWNTIME
More manufacturers now offer remote support and connectivity programs for optical sorters. With a connected asset, manufacturers can resolve many machine sorting issues remotely through a virtual private network (VPN). With a call, text, or email, users can connect with the manufacturer to resolve performance issues quicker than with a site visit.
More advanced production information harvesting programs, such as TOMRA Insight, are designed to provide actionable data on sorting performance. At the same time, they also can alert management and service technicians to machine issues as they occur, allowing small service items to be addressed before becoming bigger problems to minimize circuit disruption.
Work with the technology supplier to develop a service contract to ensure long-term maximum circuit performance. Regardless of the level of support needed, sorter manufacturers are there to partner with recyclers, so they can optimize throughput with high purity levels and maximize profitability.
Many manufacturers offer remote support and connectivity programs for optical sorters.
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NEW MODEL
Feess repurposes over 90 percent of C &D waste using Kleemann crusher
OLD CONSTRUCTION MATERIALS ARE RECYCLED ON-SITE FOR COST-EFFECTIVE, SUSTAINABLE NEW BUILDINGS
BY STEPHANIE MACDONALD, EDITOR
In Baden-Württemberg, Germany, an old district administration building had reached the end of its useful life and was being demolished. Instead of trucking the demolition material away to a landfill, Heinrich Feess GmbH & Co. returned over 90 percent of it to the building cycle.
Feess — whose core business is earthworks, demolition, and recycling — utilized a Kleemann MOBIREX MR 130i PRO mobile impact crusher to complete the majority of the recycling processes on-site. Feess tested the plant for Kleemann at the end of its development phase and was so impressed they decided to keep it.
Upgraded to serial production standards, the plant now plays an important role in the company’s overall operations and contributes to its environmentally friendly operations.
A DEDICATION TO SUSTAINABILITY
A commitment to recycling building materials is more than just a business strategy for CEO Walter Feess: an important part of the company culture is dedication to protecting the environment through eco-friendly demolition and waste-to-resource conversion.
“Construction and demolition wastes are a huge factor in the overall volume of waste generated — they make
up over 50 percent of the total waste produced in Germany,” says Feess. “At present, high-quality mineral construc tion resources are dumped in landfill sites every day or are at most utilized as materials for sub-bases or filling. This is an incredible waste of valuable resources that we are making every effort to prevent. We return large amounts of construction materials to the cycle.”
TECHNOLOGY FOR ECOFRIENDLY DEMOLITION AND RECYCLING
“For us, the [mobile impact crusher] is an extremely important component in the concrete demolition rubble processing chain. Up to now, we had one Kleemann impact crusher in operation,” says Feess. “We used the smaller MOBIREX MR 130i EVO2 together with a separate screening plant. We still use the MR 130i EVO2, sometimes on the actual project sites. The compatibility of the parts is a practical aspect that makes it easier for us to store and organize the spare and wear parts we need.”
The MOBIREX MR 130i PRO mobile impact crusher processes concrete demolition material and mixed rubble to produce materials such as mineral aggregates for recycled concrete.
“This meant that the aggregate for the [recycled] concrete for the new
district administration office was produced from the construction materials reclaimed from the old building. In other words, we turned old into new,” says Feess. “The largest proportion of the mineral construction materials was crushed directly on the construction site or at our recycling depots at a rate of up to 1,800 tons a day. The experience we gathered here is something I’d like to pass on, including to our competitors.”
Using the MOBIREX MR 130i PRO was also cost-effective, according to Feess. Consolidation of crushing and screening functions into one machine reduces the need for multiple units, saving on fuel and maintenance.
According to Feess, the low fuel consumption, the high output, and the extremely efficient double-deck post-screening unit are key to cost efficiencies, as well as space saving.
“Space is at a premium here, and with this plant, we get two machines in one. We used to use a crushing plant followed by a separate screening plant — now, thanks to the high performance and the ability to discharge two classi-
fied final products, the MR 130i PRO is just what we need. It also means that we now only have to operate, service, and refuel one machine in our daily routine,” says Feess.
In terms of fuel, it makes a clear difference to the bottom line. “The
another 14 to 16 litres of fuel. Today, we no longer need this extra fuel. And that’s not all: the MR 130i PRO brings us up to 20 percent higher output, which is pretty amazing when you consider its fuel consumption.”
Fuel and material prices will con
At present, highquality mineral construction resources are dumped in landfill sites every day or are at most utilized as materials for sub-bases or filling. This is an incredible waste of valuable resources that we are making every effort to prevent.
Walter Feess CEO, Feess
not be able to achieve our environmental goals without a narrower focus on the establishment of strong recycling management.”
THE FUTURE IS ELECTRIC
The company is working toward
The company utilized the MOBIREX MR 130i PRO mobile impact crusher to complete the majority of recycling processes on-site.
The MOBIREX MR 130i PRO mobile impact crusher is ideal for processing concrete demolition materials and mixed rubble.
ide. The option of operating the plant with electric power was a decisive factor for us. However, for this purpose, we have to expand our transformer station, that is, the power supply. We are already discussing a number of ideas for the realization of this. We are also considering expanding the overall area of our photovoltaic power generation systems. It would be great if we could run the plant at least to some extent with electricity from our own renewable energy sources.”
According to Kleemann, fully electric plants are the future of the industry as they provide medium-term cost benefits in addition to practical and environmental benefits.
With electric mobile plants, end users can position themselves on the market as future-oriented providers. Although the initial investment costs are higher, the company says they are quickly balanced out due to the fuel savings. A sample calculation for the German market showed that it’s possible after around six years — if the plant can be supplied with energy via the customer’s
own photovoltaic system, it can pay off after around four years.
Electrification advocates understand that careful planning is required to maximize the benefits of using electric machines. Tobias Möß from Wolff & Müller GmbH says, “First of all, the actual energy requirements of the plant and that of all already existing consumers should be determined. How much power is needed on the entire company premises? The load profile must also be taken into account. When are the power peaks, when are the times with lower consumption? The individual load profile can be obtained from the power supplier or network operator.”
Tobias Böckle, head of product management at Kleemann, lays out one practical application.
“Our mobile plant train in the sample calculation consists of a jaw crusher MOBICAT MC 120 PRO, cone crusher MOBICONE MCO 110 PRO as a secondary crushing plant, and a downstream screen machine MOBISCREEN MSC 953 EVO. The plant train consumes an average of approximately 77 litres of
diesel fuel per operating hour. In the electrified version, it has an average fuel consumption of 302 kilowatts per operating hour. The maximum power requirement is 542 kilowatts. The energy requirement must first be met by the infrastructure and, ideally, by electricity from renewable energy sources. The power supply from the company’s own photovoltaic system is sustainable and a very fast cost-efficient solution.”
At the end of the day for Feess, it all comes back around to educating people about the possibilities, and he believes in the importance of his mission.
“It’s clear that we have to act now. There is no point in merely talking about having to get a grip on carbon dioxide emissions. We owe it to our children and grandchildren to take action now and create corresponding legal and normative bases. But the great thing is that we already have the capabilities, the technology, and the expertise — all we have to do is use them. I will never tire of appealing not only to architects and engineers but also to local authorities and administrative bodies.” RPN
ADVANCING EDUCATION IN WASTE MANAGEMENT
The show where sectors of the waste, recycling and public works industries come together for three days of education, networking, and business development. Explore the exciting schedule of events and show features.
What’s in store:
Expert Panels & Workshops
Innovative Technologies
Educational Sessions
Conference: November 5 – 6, 2024
Exhibition: November 6 – 7, 2024
Follow us online: cwre.ca
A commitment to recycling building materials is more than just a business strategy for Walter Feess and his company.
WEAR PART INNOVATIONS FOR MOBILE WASTE SHREDDERS
ADAPTING TO DIVERSE MATERIAL STREAMS REQUIRES CUSTOMIZATION AND MODULARITY
BY SLONE FOX, EDITOR
Modular rotor and tool systems have revolutionized mobile shredders, allowing operators to tailor machines for the specific materials they process. This customization not only enhances machine performance but also extends the lifespan of components.
Mobile shredders, known for their versatility, are critical in processing materials ranging from construction debris and
plastics to metals and green waste. Their adaptability has made them indispensable for applications like waste-to-energy plants, municipal recycling facilities, and scrapyards.
Whether they’re reducing bulky items for easier transport or preparing waste for further processing, mobile shredders are an adaptable solution for the ever-evolving demands of recycling operations.
OPERATIONAL CHALLENGES
Despite their benefits, mobile shredders can face significant operational challenges. The constant shredding of abrasive and hard materials takes its toll on critical components like rotors, cutting teeth, and screens. Wear and tear are inevitable, and without efficient maintenance, repair costs can quickly skyrocket.
Traditionally, these issues have been a persistent struggle for operators. Replacing entire rotors or drums when teeth or knives wear down is a common but costly and time-consuming process that can lead to extended downtime. To address these concerns, manufacturers are placing greater emphasis on aftermarket solutions that extend the lifespan of mobile shredders. From modular designs that allow for the quick replacement of wear parts to smart technology that proactively monitors equipment health, manufacturers are paving the way for a new era of more resilient and versatile mobile shredders.
INNOVATIONS IN WEAR PARTS
Wear on critical components like teeth and rotors is one of the biggest challenges in mobile shredding operations. Tradi-
Komptech’s Terminator 6000 S solid waste shredder.
tionally, machines required full rotor or drum replacements when these components wore down, leading to extended downtime and expensive repairs.
Manufacturers like Terex Ecotec and TANA have made advancements to combat this issue, focusing on replaceable parts that extend machine life and minimize operational disruption. Terex Ecotec’s replaceable, bolt-on shredding teeth allow operators to replace only the worn teeth instead of the entire rotor. TANA’s shredders feature individually replaceable rotor teeth and counter knives which similarly reduces the need for full overhauls, helping operators save on maintenance
costs and improve overall efficiency.
Manufacturers like Viably (formerly Komptech) and Eggersmann have developed innovative ways to reduce wear. Viably’s slow-running drums produce less friction and heat which reduces wear on critical parts, and their quick-change systems allow for screen baskets and tools to be replaced easily.
Eggersmann, on the other hand, offers slow-running shredders that avoid the need for the protective measures often required by high-speed machines. Their shredders reverse automatically when an obstruction is detected, protecting wear parts from damage. If larger obstacles
are encountered, the shredding process halts automatically, signaling the operator to address the issue. This proactive maintenance system extends the overall lifespan of their machines.
MODULAR SYSTEMS FOR SHREDDING EFFICIENCY
Modular systems are transforming mobile shredders by providing flexibility and customization, allowing operators to configure machines based on the materials being processed. Viably’s modular design allows operators to adjust settings depending on the type of material,
Eggersmann’s Z 60 single-shaft shredder.
Terex Ecotec’s TBG 530T highspeed mobile shredder.
reducing unnecessary wear on parts that don’t need to work as hard. This customization helps the machine perform more efficiently across a variety of materials, improving its longevity.
Eggersmann’s shredders also benefit from a modular setup with customizable cutting gaps and screen baskets, which enhance precision and reduce the need for secondary shredding. Their machines feature automatic rotor reversal when obstructions are detected, adding a layer of operational safety while extending part life.
PROACTIVE MAINTENANCE WITH TECHNOLOGY
In an era where efficiency and reliability are paramount, the integration of smart technology into mobile shredders is an obvious choice. The TANA ProTrack monitoring system provides real-time data on rotor performance and alerts operators when parts require replacement, preventing unexpected failures that could lead to extended downtime.
Similarly, Terex Ecotec’s T-Link telematics system monitors machine performance, location, and operational data, allowing operators to track metrics such as fuel consumption, operating hours, and maintenance schedules. The system also facilitates remote diagnostics, ensuring that any issues can be addressed quickly and efficiently.
Viably also utilizes predictive mainte-
nance algorithms in its Connect! system which streamlines administration, optimizes deployment planning, and facilitates remote machine monitoring. This system allows for targeted service when issues arise and provides real-time analysis for enhanced operational insight. This trend of implementing monitoring systems is gaining traction across the industry, allowing shredding operations to reduce downtime and improve operational efficiency, which ultimately results in lower operating costs and increased profitability. The intuitive control systems from various manufacturers empower operators to monitor wear part usage and machine performance, make informed decisions, schedule maintenance at optimal times, and avoid costly breakdowns, ensuring smooth operation over extended periods.
THE FUTURE OF MOBILE SHREDDERS
As the recycling industry works to meet ambitious sustainability targets while processing an ever-expanding range of materials, the aftermarket for mobile shredders will be key to driving more efficient waste management.
With technology advancing rapidly and the need for higher throughput growing, the future will see mobile shredders equipped with even smarter, more resilient systems that improve performance, extend the lifespan of critical components, and minimize downtime.
In an era where efficiency and reliability are paramount, the integration of smart technology into mobile shredders is an obvious choice.
The integration of predictive maintenance and smart technology will give operators real-time insights into machine health, allowing them to make data-driven decisions that keep operations running smoothly. These technologies will make shredders more reliable and better suited to handle the increasing complexity of recycling applications. Modular wear parts will become more commonplace, simplifying repairs and enabling operators to tailor their machines to specific materials, reducing costs and boosting productivity. As manufacturers continue to innovate, mobile shredders will evolve into more adaptable and efficient tools, ensuring the recycling industry can keep pace with growing demands. RPN
A TANA rotor with 44 knives boosts process capacity.
A LONG WAY TOGETHER
EARTHMAX SR 41
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Back in 2019, New York City overhauled its waste management system by introducing the Commercial Waste Zones (CWZ) initiative. By dividing the city into zones — each served by a limited number of haulers — the initiative streamlines collection routes, lowers costs, and creates a safer system overall. Operating across New York, New Jersey, Pennsylvania, Connecticut, and Ohio, Interstate Waste Services (IWS) recently secured 14 out of 20 zones in NYC — more than any other hauler — and is one of just five providers authorized for city-wide containerized waste collection.
What do you see as the biggest challenges facing the waste management industry today?
We are constantly challenging ourselves to operate more sustainably: finding cutting-edge technology, staying agile with best practices, and keeping people’s safety at the forefront of what we do every day. We embrace the challenge to continue evolving along with the needs of future generations — that’s our responsibility in this industry. We’re always asking ourselves hard questions: “How can we adapt this process to reduce emissions? How can we integrate new technologies like AI to increase recycling rates at our facilities?”
This constant improvement mindset has allowed us to really uplevel our sustainability ambitions over the past few years. In 2022, we prevented 1.2 million metric tons of carbon dioxide emissions through recycling,
JOSH HARAF DISCUSSES A NEW ERA IN WASTE FOR INTERSTATE WASTE SERVICES
BY SLONE FOX, EDITOR
Adding to this momentum, IWS recently built a $30 million MRF in New Jersey capable of processing up to 350,400 tons of recyclables annually. Notably, the facility features a glass-cleaning system that separates glass into three sizes for better recovery and is the only one of its kind in the region.
I caught up with Josh Haraf, market vice president of New York City for IWS, to discuss the new MRF, sustainability, and how the CWZ initiative is reshaping the future of waste management in one of the world’s busiest cities.
generating renewable energy, and capturing landfill gas. The methane we capture from our Apex landfill in Ohio produces enough natural gas to power 30,000 homes a year! And by leading initiatives like Commercial Waste Zoning in New York City, we’re further reducing truck traffic and cutting emissions. There’s still a lot of work to be done, but we’re proud of the progress we’ve made and will keep working with partners to make our industry as sustainable as possible.
Can you explain the significance of the CWZ initiative for NYC’s waste management system? What are the anticipated benefits and challenges?
New York City generates nearly 3 million tons of commercial waste annually and that
Slone Fox
Josh Haraf
volume has historically been managed by over 90 different haulers. Within such a dense market, our industry has been challenged by traffic jams, pollution, de-segmented service, and ample room for improvement when it comes to overall service efficiency. This is the city that never sleeps and New Yorkers deserve an alert waste management system to keep them safe, clean, and proud of their communities.
In 2019, the NYC Council passed Local Law 199 to mold a new system to meet New York’s unique needs. The historic legislation creates 20 Commercial Waste Zones across the five boroughs and allows only three companies to operate in each zone. This intends to make commercial waste management safer and more efficient by
streamlining routes, cutting commercial waste truck traffic in half, and setting high safety and sustainability standards across haulers, all while providing customers fair, transparent pricing with elite customer service standards. This transformation is revolutionizing NYC’s commercial waste management and will foster a safer, cleaner, and less congested city.
After a two-year selection process, the New York Department of Sanitation (DSNY) awarded our New York City subsidiary, Action Carting, licenses to operate in 14 of the 20 zones — the most of any hauler. We’re excited and proud to be a leading partner in this new approach and look forward to building on our 25year legacy of serving the people of New York City.
IWS recently secured 14 out of 20 zones in NYC, more than any other hauler.
How does IWS plan to manage the zones it has been awarded, and what strategies will be employed to ensure efficiency and safety?
We’ll do what we’ve always done: deliver excellent service to New York City customers with safety, efficiency, and sustainability at the forefront. Our experience operating in all of the Commercial Waste Zones has built an invaluable arsenal of expertise that we’ll use to integrate new customers while continuing to serve existing ones. Our day-to-day operations won’t change. We’ve built deep relationships with our customers and understand their specific needs and challenges. We’re proud to keep supporting them as always, and now we can do it even more efficiently because we’re serving more customers in the same area.
Safety remains our number one priority at IWS, and we’re continuing to meet
and exceed the safety standards established under the CWZ program. We’ve equipped all our trucks with Samsara AI-powered in-cab safety systems, the gold standard of fleet safety hardware, featuring GPS, dashcams to detect distracted driving, and real-time data dashboards for continuous improvement. We’ve also installed protective side guards across our entire fleet years before they were required in NYC. Our safety-focused investments in people, equipment, technology, training, and processes are a hallmark of our business, and we won’t stop; our goal across our entire organization is zero — zero incidents, zero accidents, and zero injuries.
To ensure a smooth transition, we launched a new website, actioncarting. com, and continue to update our corporate IWS website with CWZ-related information so that customers can find their zone and get answers to frequently asked questions. We are also launching an online portal where customers can view recycling rates, pay bills, and submit service requests. Clear communication is key to a successful transition, and IWS will remain the go-to source for up-to-date CWZ information for our customers.
IWS is one of just five providers authorized for citywide containerized waste collection in NYC.
What lessons from New York City’s experience with CWZ would you highlight for other municipalities looking to implement similar initiatives?
I think in many big cities around the country, streamlining waste and recycling collection is key to achieving a variety of goals, whether that’s improving public safety, boosting recycling rates, cutting emissions, reducing traffic, or generally enhancing the quality of life.
DSNY has already learned from other cities’ experiences. For example, DSNY is taking a progressively collaborative approach, partnering with awardees to improve communication, learning, and a thoughtful implementation timeline. We’re
still in the early stages of implementation, but I’m optimistic that transitioning New York City to a CWZ model will cultivate transferrable lessons that could benefit many cities.
In terms of advice to take from New York’s experience, I think the most important factor is choosing haulers who have a deep-rooted understanding of their communities and customers. Here’s a good example: We service several entertainment venues and stadiums where the amount of trash and recycling fluctuates widely depending on event or game attendance. Being able to adjust service to meet those needs on short notice is crucial to prevent trash pile-ups. We’ve built the capacity to do that over the years by building a relationship with them, just like we build relationships with all our clients, all over the city. We’ve proven we can handle the diverse needs of our customer base, and I believe that’s why we were awarded the most zones of any company.
SF
JH Can you give me an overview of the new MRF in New Jersey and its key features? How does this facility compare to other MRFs in the region in terms of technology and capacity?
We’re really excited about this! Our new MRF in North Arlington, NJ, is a $30 million investment to boost recycling rates across the tri-state area. Stepping into this facility feels like jumping five years into the future in terms of the technology we’re using — it’s the most advanced recycling facility in the region, bar none.
The MRF revolves around a Machinex system with two feed lines that can process up to 350,400 tons of recyclables annually. That translates to saving 3 million trees, 108,000 gallons of oil, and over a billion kilowatt-hours of energy every year.
It has it all — presort areas, OCC screens, ballistic separators, optical sorters to recover plastics and fibres, and magnetic and eddy current separators to grab metals. There’s even an AI-powered SamurAI sorting robot that uses advanced cameras and a vacuum arm to make sure that every recyclable gets recycled. But the real showstopper is the glass-cleaning system — the only one of its kind in the re-
gion – that separates glass into three sizes for better recovery and marketability. It’s no exaggeration to say this is some of the most advanced recycling infrastructure in the country, and it’s going to play a major role in helping us recover more recyclable materials from New York and the rest of the region.
In your opinion, what are the biggest opportunities for growth and innovation in waste management in the next decade?
Circling back to what I mentioned earlier, sustainability isn’t just a responsibility, it’s also a huge opportunity for our industry.
I mentioned how we’re generating clean energy by capturing methane gas from our Apex landfill — well, we actually have plans to double that capacity by 2025. Capturing these landfill emissions is crucial for reaching climate goals, and it’s an area where we’re continuing to invest heavily. I think AI plays a big role here, too. From optimizing collection routes to reduce truck traffic to AI-powered sorting like what we have at our North Arlington facility, this technology has the potential to make waste management and recycling more sustainable than ever before. It’s an exciting time for the industry, and I’m proud to be a part of a company that’s leading the charge. RPN
The new MRF in North Arlington, NJ.
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EVENTS CALENDAR
CONNECT WITH THE INDUSTRY
PAPER AND PLASTICS RECYCLING CONFERENCE
CHICAGO,
IL | OCTOBER 23 – 24
The Paper and Plastics Recycling Conference runs back-to-back with the MRF Operations Forum. These two events coincide to emphasize the importance of optimizing MRF processes to advance the recycling of paper and plastic materials and drive progress across the recycling industry. paperplasticsna.recyclingtodayevents.com
COMING SOON
WORLD RECYCLING CONVENTION 2024 ROME, ITALY |
OCTOBER 28 – 30
The World Recycling Convention 2024 gathers experts and professionals from various fields, including recycling, environmental engineering, and climate science to address the latest developments and challenges in waste management and recycling. The convention will feature keynote talks, B2B meetings, discussion panels, and exhibitions focused on enhancing knowledge and fostering collaboration. recycling.thepeopleevents.com
AWMI 2024 ANNUAL CONFERENCE NASHVILLE, TN
| NOVEMBER 6 – 8
Hosted by the Association of Women in the Metal Industries, the AWMI 2024 Annual Conference provides attendees with a place to network and connect with other professionals. Highlights include educational tours, leadership development, networking receptions, keynote speeches, panels on leadership and economics, and social events. awmi.org/events/2024-annual-conference
ON | NOVEMBER 5 – 7 WASTE-RECYCLING-EXPO-CANADA. US.MESSEFRANKFURT.COM/CANADA/EN.HTML
C&D WORLD
DALLAS, TX | MARCH 11 – 14, 2025 CDRACONFERENCE.COM
• See the latest equipment
• Learn best practices and techniques
• Improve your jobsite and business March 25-27, 2025 | St. Louis, MO
PERFORMANCE DELIVERED
AC H IE V IN G RESU LTS
19 optical sorters performing 35 sorting tasks
AI deployed in optical sorters performing 12 sorting tasks that conventional sorters can not perform
