Optical sensor-based automatic sorting systems to promote sustainability and increase profitability

high precision

intelligent

custom made

PRA‘s 2013 Green Packaging Conference 21 November 2013 – Jakarta, Indonesia

Optical Sensor based Automatic Sorting Technologies to Promote Sustainability & Increase Profitability Lee Chee Kiong Sales Director, Asia – Sorting Division

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custom made

PRA‘s 2013 Green Packaging Conference 21 November 2013 – Jakarta, Indonesia

We are privileged to be part of this CSR (Corporate Social Responsibility) initiative from PRA and Tara Media & Communications.

high precision

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custom made

Optical Sensor based Automatic Sorting Technologies to Promote Sustainability & Increase Profitability

Sharing •

Introduction of S+S

•

The Reality

•

The Roles of Automatic Sorting

•

Available Sorting Technologies

•

Application based Sorting Technologies

•

Conclusion

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Company Profile

• Founded in 1976 as S+S

Elektronik KG • Corporate headquarter, R&D and manufacturing facility located in Schoenberg, Germany, about 150 km North East of Munich in Bavaria state

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Company Profile •

•

Wholly owned world wide subsidiaries: - United States of America - France - United Kingdom - Singapore - China - India - Italy - Turkey

350 staffs world wide

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Company Profile

• Asia Pacific Service & Sales Offices: - Singapore (Asia HQ) - Thailand - The Philippines - Indonesia

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Company Profile Approximately 1,300 automatic sorting installations worldwide, in different industries:     

Plastics Recycling Glass Recycling Wood Recycling Metal Scrap Recycling Electronics Scrap Recycling

More than 250 installations in plastics recycling since 2001

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

The Reality

REALITY

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19 November 2011

Source: http://www.thejakartaglobe.com/archive/workers-threaten-strike-over-minimum-wage-rise/

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REALITY

06 February 2013

Source: http://www.aljazeera.com/news/asia-pacific/2013/02/20132675333828387.html/

REALITY

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05 September 2013

Source: http://www.bloomberg.com/news/2013-09-05/indonesian-workers-rally-in-java-to-demand-50-percent-pay-rise.html

REALITY

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29 October 2013

Source: http://www.indonesia-investments.com/news/todays-headlines/demand-for-higher-minimum-wages-hurts-indonesias-investment-climate/item1261

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

REALITY

The Reality

Source: http://www.oecd.org/eco/surveys/2012%20Indonesia%20Overview.pdf

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REALITY

Indonesia is not alone in this reality landscape

According to a report by French bank published on 29 July 2012: China’s labour costs will  match those in the US in 4 years’ time  catch up with Eurozone in 5 years’ time  be similar to Japan in 7 years’ time Source: http://www.news.com.au/business/worklife/china-labour-costs-like-us-withinyears/story-e6frfm9r-1226438065496

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UNSUSTAINABLE!

11/29/2013

Page 5

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UNSUSTAINABLE!

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UNSTOPPABLE! We are very sure you would rather have

Let’s Explore .......

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The Good News!

Innovative technologies are available to promote sustainability and increase profitability

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

A Cruel Fact on Plastic Packaging

Plastic packaging will take up to 450 years to decompose!

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

A Cruel Fact on Plastic Packaging

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custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

A Cruel Fact on Plastic Packaging

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intelligent

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

A Cruel Fact on Plastic Packaging

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Opportunities in Recycling of Rigid Plastics Packaging

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Opportunities in Recycling of Rigid Plastics Packaging

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Opportunities in Plastic Packaging 3R

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Opportunities in Plastic Packaging 3R

o o o o o o

EcoARK in Taiwan

By Far Eastern Group 1.5 million PET bottles 3 stories tall One amphitheater One exhibition hall

Source: http://www.treehugger.com/sustainable-product-design/massive-plastic-bottle-building-unveiled-in-taiwan.html

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Opportunities in Plastic Packaging 3R Weight of Packaging

Year

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Opportunities in Plastic Packaging 3R

o o o o o

2010 World Cup Up to 8 recycled PET bottles ďƒ† 1 shirt About 13 million PET bottles recycled Bottles laid end to end = 3,000 km Enough to cover 29 football fields

Source: http://www.ecouterre.com/nike-outfits-world-cup-teams-in-jerseys-made-from-recycled-bottles/

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Opportunities in Plastic Packaging 3R

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Opportunities in Plastic Packaging 3R Many other opportunities in the recycling of plastics

Recycled PET Punnet

Recycled PP Flower Pots

Recycled HDPE Milk Bottles

high precision

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custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Typical Recycling Process for Plastics

Industrial Waste

Extrusion Extrusion

Commercial Waste

Pelletizing Blown Film

Collection / Baling

Sorting / Separation

Size Reduction

Pipes, sheet Tube Bags, film

Cleaning / Washing

Agricultural Waste

Injection Molding

Various Items

Municipal Waste

Blow Molding

Bottles Containers

Pelletizing

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intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Typical Recycling Process for Plastics

Industrial Waste

Extrusion Extrusion

Commercial Waste

Pelletizing Blown Film

Collection / Baling

Sorting / Separation

Size Reduction

Pipes, sheet Tube Bags, film

Cleaning / Washing

Agricultural Waste

Injection Molding

Various Items

Municipal Waste

Blow Molding

Bottles Containers

Sorting / Separation

high precision

intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Manual Sorting

 Increasing Labour Costs  Difficulties to Employ Workers  Inconsistent Quality

Low Sustainability!

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

The Roles of Automatic Sorting  To improve quality  To increase output  To reduce costs

 Higher Profits

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

The Roles of Automatic Sorting

Automatic PET Bottle Sorting

ďƒź Higher Profits

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custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

The Roles of Automatic Sorting

Automatic PET Flake Sorting

ďƒź Higher Profits

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custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Available Automatic Sorting Technologies – PET Bottles

High Resolution CCD Colour Sensor Separation of coloured and nontransparent bottles from clear PET bottle stream Near Infra-Red Sensor Separation of non-PET plastics (e.g. PLA, PVC and PET-G) from the PET bottle stream

High Frequency Electromagnetic Sensor Removal of ferrous and non-ferrous metal contamination from the PET stream Metal Cans

Metal Parts

Metal Caps

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intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Available Automatic Sorting Technologies – PET Bottles

High Resolution CCD Colour Sensor Separation of coloured and nontransparent bottles from clear PET bottle stream

High Frequency Electromagnetic Sensor Removal of ferrous and non-ferrous metal contamination from the PET stream

Near Infra-Red Sensor Separation of non-PET plastics (e.g.

PLA, PVC and PET-G) from the PET bottle stream

The selection of the sensor type depends on the incoming materials and sorting objectives. It can be a single sensor, or a combination of two or all three sensors

high precision

intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Available Automatic Sorting Technologies – PET Bottles

Digital signal processing

CCD camera

Valve control

Air blast ejection system Illumination unit

Diverter shield Multispectral NIR sensor incl.

Illumination unit Conveyor belt Metal detection coil Output fraction 3, e.g.

Colored PET bottles

Output fraction 2, e.g. clear PET bottles

Output fraction 1, e.g. offpolymers like PVC & metal

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custom made

Application Based Automatic Optical Sensor Sorting for the PET Recycling Industry

Available Automatic Sorting Technologies – PET Bottles

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intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Available Automatic Sorting Technologies – PET Flakes

High Resolution CCD Colour Sensor Separation of coloured and nontransparent flakes from clear PET flakes stream

PVC

PET Near Infra-Red Sensor Separation of non-PET (e.g. PLA, PVC and PET-G) flakes from the PET flakes stream

High Frequency Electromagnetic Sensor Removal of ferrous and non-ferrous metal contamination from the PET stream

high precision

intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Available Automatic Sorting Technologies – PET Flakes

High Resolution CCD Colour Sensor Separation of coloured and nontransparent flakes from clear PET flakes stream

High Frequency Electromagnetic Sensor Removal of ferrous and non-ferrous metal contamination from the PET stream

Near Infra-Red Sensor Separation of non-PET (e.g.

PLA, PVC and PET-G) flakes from the PET flakes stream

The selection of the sensor type depends on the incoming materials and sorting objectives. It can be a single sensor, or a combination of two or all three sensors

high precision

intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Available Automatic Sorting Technologies – PET Flakes

Flake infeed

Multi-spectral NIR sensor CCD camera

Illumination unit

Metal detection coil Air blast ejection system Diverter shield Ejected impurity material Cleaned accept material

high precision

intelligent

custom made

Application Based Automatic Optical Sensor Sorting for the PET Recycling Industry

Available Automatic Sorting Technologies – PET Flakes

high precision

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custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Application Based Sorting Technologies

PET Recycling – from Bottles to Flakes

Long Fiber

Strapping Band PSF

Food Packaging

Bottle to Bottle

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intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Application Based Sorting Technologies

PET Recycling – from Bottles to Flakes

Long Fiber

Strapping Band PSF

Food Packaging

Bottle to Bottle

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intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Application Based Sorting Technologies

Incoming Material Composition

Mechanical & Washing Processes

Sensor Based Auto Sorting

The selection and configuration of the sorting systems depend on the incoming material and the output flake quality requirements

Output Material Quality

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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Application Based Sorting Technologies – Example 1 Sample Input Material Type: Compacted Bottles Input: 2,000 kg/hr - PET Clear: 98% - PVC: 2% (20,000ppm)

Solution One unit of Varisort N 1920 (2 outlet chutes) with re-sort tracks

Sorting Objectives: To remove PVC to below 150ppm

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custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Application Based Sorting Technologies – Example 2 Sample Input Material Type: Compacted Bottles Input: 2,000 kg/hr - PET Clear: 98% - PVC: 2% (20,000ppm)

Solution One unit of Varisort N 1920 (2 outlet chutes) with re-sort tracks And one unit of Flake Purifier N 1024 (2 outlet chutes

Sorting Objectives: To remove PVC to below 25ppm

high precision

intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Case Study – Reduction of Manual Sorting Possibility 1 – Sorting of non PET Plastics such as PVC Bottles Bottles ① ③ ⑤ ⑦ ⑨ ⑪ De-Bale

Manual Sorting Station

① ③ Pre-Washing

① ③ ⑤

Manual

Label

Manual

Sorting

Stripper

Sorting

① ③ Crusher

② ④ ⑥ ⑧ ⑩ ⑫

② ④

② ④ ⑥

12 workers per shift

4 workers per shift

6 workers per shift

Flakes

Flakes

Washing

Drying

Zig Zag Shifter

Manual Sorting

Flakes Packing

② ④ Flakes

4 workers per shift

Bottles ① ③ ⑤ De-Bale

Label

Vibratory

Sorter # 1

Sorter # 2

Manual

Stripper

Feeder

Varisort N 1536

Varisort N 1536

Sorting

① ③ Crusher

Flakes

Flakes

Washing

Drying

② ④ ⑥ 6 workers per shift

Zig Zag Shifter

Manual Sorting

Flakes Packing

② ④ Flakes

4 workers per shift

high precision

intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Case Study – Reduction of Manual Sorting Possibility 1 – Sorting of non PET Plastics such as PVC Bottles Bottles ① ③ ⑤ ⑦ ⑨ ⑪ De-Bale

Manual Sorting Station

① ③ Pre-Washing

① ③ ⑤

Manual

Label

Manual

Sorting

Stripper

Sorting

① ③ Crusher

② ④ ⑥ ⑧ ⑩ ⑫

② ④

② ④ ⑥

12 workers per shift

4 workers per shift

6 workers per shift

Flakes

Flakes

Washing

Drying

Zig Zag Shifter

Manual Sorting

Flakes Packing

② ④ Flakes

4 workers per shift

Bottles ① ③ ⑤ De-Bale

Label

Vibratory

Sorter # 1

Sorter # 2

Manual

Stripper

Feeder

Varisort N 1536

Varisort N 1536

Sorting

① ③ Crusher

Flakes

Flakes

Washing

Drying

② ④ ⑥ 6 workers per shift

Zig Zag Shifter

Manual Sorting

Flakes Packing

② ④ Flakes

Saving of 48 workers / day

4 workers per shift

high precision

intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Case Study – Reduction of Manual Sorting Possibility 2 – Sorting of non PET Plastics such as PVC and Coloured PET Bottles Bottles ① ③ ⑤ ⑦ ⑨ ⑪ De-Bale

Manual Sorting Station

① ③ Pre-Washing

① ③ ⑤

Manual

Label

Manual

Sorting

Stripper

Sorting

① ③ Crusher

② ④ ⑥ ⑧ ⑩ ⑫

② ④

② ④ ⑥

12 workers per shift

4 workers per shift

6 workers per shift

Flakes

Flakes

Washing

Drying

Zig Zag Shifter

Manual Sorting

Flakes Packing

② ④ Flakes

4 workers per shift

Bottles ① ③ De-Bale

Label

Vibratory

Sorter # 1

Sorter # 2

Manual

Stripper

Feeder

Varisort CN 1536

Varisort CN 1536

Sorting

① ③ Crusher

Flakes

Flakes

Washing

Drying

② ④ 4 workers per shift

Zig Zag Shifter

Manual Sorting

Flakes Packing

② ④ Flakes

4 workers per shift

high precision

intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Case Study – Reduction of Manual Sorting Possibility 2 – Sorting of non PET Plastics such as PVC and Coloured PET Bottles Bottles ① ③ ⑤ ⑦ ⑨ ⑪ De-Bale

Manual Sorting Station

① ③ Pre-Washing

① ③ ⑤

Manual

Label

Manual

Sorting

Stripper

Sorting

① ③ Crusher

② ④ ⑥ ⑧ ⑩ ⑫

② ④

② ④ ⑥

12 workers per shift

4 workers per shift

6 workers per shift

Flakes

Flakes

Washing

Drying

Zig Zag Shifter

Manual Sorting

Flakes Packing

② ④ Flakes

4 workers per shift

Bottles ① ③ De-Bale

Label

Vibratory

Sorter # 1

Sorter # 2

Manual

Stripper

Feeder

Varisort CN 1536

Varisort CN 1536

Sorting

① ③ Crusher

Flakes

Flakes

Washing

Drying

② ④ 4 workers per shift

Zig Zag Shifter

Manual Sorting

Flakes Packing

② ④ Flakes

Saving of 54 workers / day

4 workers per shift

high precision

intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Case Study – Reduction of Manual Sorting Possibility 3 – Sorting of non PET Plastics such as PVC and Coloured PET Bottles and Sorting of PET Flakes Bottles ① ③ ⑤ ⑦ ⑨ ⑪ De-Bale

Manual Sorting Station

① ③ Pre-Washing

① ③ ⑤

Manual

Label

Manual

Sorting

Stripper

Sorting

① ③ Crusher

② ④ ⑥ ⑧ ⑩ ⑫

② ④

② ④ ⑥

12 workers per shift

4 workers per shift

6 workers per shift

Flakes

Flakes

Washing

Drying

Zig Zag Shifter

Manual Sorting

Flakes Packing

② ④ Flakes

4 workers per shift

Bottles ① ③ De-Bale

Label

Vibratory

Sorter # 1

Sorter # 2

Manual

Stripper

Feeder

Varisort CN 1536

Varisort CN 1536

Sorting

Crusher

Flakes

Flakes

Washing

Drying

② ④ 4 workers per shift

Flakes

Zig Zag Shifter

Flake Purifier

Flakes Packing

high precision

intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Case Study – Reduction of Manual Sorting Possibility 3 – Sorting of non PET Plastics such as PVC and Coloured PET Bottles and Sorting of PET Flakes Bottles ① ③ ⑤ ⑦ ⑨ ⑪ De-Bale

Manual Sorting Station

① ③ Pre-Washing

① ③ ⑤

Manual

Label

Manual

Sorting

Stripper

Sorting

① ③ Crusher

② ④ ⑥ ⑧ ⑩ ⑫

② ④

② ④ ⑥

12 workers per shift

4 workers per shift

6 workers per shift

Flakes

Flakes

Washing

Drying

Zig Zag Shifter

Manual Sorting

Flakes Packing

② ④ Flakes

4 workers per shift

Bottles ① ③ De-Bale

Label

Vibratory

Sorter # 1

Sorter # 2

Manual

Stripper

Feeder

Varisort CN 1536

Varisort CN 1536

Sorting

Crusher

Flakes

Flakes

Washing

Drying

② ④ 4 workers per shift

Flakes

Saving of 66 workers / day

Zig Zag Shifter

Flake Purifier

Flakes Packing

high precision

intelligent

custom made

8th China International Recycled Polyester Conference 13 ~ 14 September 2012

Sorting is NOT Magic

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custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Conclusion

Automatic Sorting is Magical but NOT Magic

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custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Conclusion It is possible to move from labour intensive manual sorting‌.

To highly efficient automatic sorting with - Improved quality - Increased processing output - Lower costs - Better efficiency

- Higher Profit Margin with Sustainability

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intelligent

custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Conclusion – 3R’s

Rethink

• Future Rising Labour Costs • Approach to Sorting

Retool

• Technologies are available • Work with Partners

Recover

• Valuable Recyclables • Eroding Profits

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custom made

Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry

Conclusion – 3R’s

Rest

• You DESERVE It!

Relax

• You DESERVE It!

Rejoice

• You DESERVE It!

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intelligent

custom made

PRA‘s 2013 Green Packaging Conference 21 November 2013 – Jakarta, Indonesia

Thank You Very Much!

Contact: Mr. Dharmawan Putra - Indonesia +62-811-816-342 dharmawan.putra@sesotec.com.sg

Mr. Lee Chee Kiong – Asia Pacific +65-9088-3758 cheekiong.lee@sesotec.com.sg

www.sesotec.com & www.pet-recycling.com