Chloe Zhang
Paper and plastic are two of the most commonly recycled materials. Paper production accounts for about 35% of felled trees, and worldwide, we produce 300 million tonnes of plastic each year. Recycling these materials is therefore essential to reducing waste and protecting the environment. The recycling process for paper involves separating, pulping, screening, and cleaning the paper before it is formed into rolls of recycled paper. Plastic is collected, sorted, washed, shredded, and melted into pellets, which are then sold to be made into new products.
| Characteristics | Values |
|---|---|
| Paper recycling rate in 2013 | 63% |
| Paper recycling rate in 2018 | 68.2% |
| Paper recycling rate in 2023 | 65-69% |
| Plastic recycling rate in 2018 | 8.7% |
| Plastic generated in the US in 2018 | 35.7 million tons |
| Plastic generated globally to date | 11 billion metric tons |
| Paper recycling process | Collection, sorting, baling, shipping, turning into new products |
| Plastic recycling process | Generation, recycling, composting, combustion with energy recovery, landfilling |
| Issues with recycling | Wishcycling, contamination, injury to operations crew |
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What You'll Learn
- Paper recycling reduces CO2 emissions by 20% compared to incineration
- Paper mills separate, grade, pulp, screen, clean, colour and form paper
- Plastic is sorted by type at Material Recovery Facilities
- Plastic is then washed, shredded, sorted and formed into new products
- Paper is de-inked and bleached before being made into new recycled paper
Paper recycling reduces CO2 emissions by 20% compared to incineration
Recycling paper helps reduce CO2 emissions by 20% compared to incineration. Recycling paper also helps divert waste from landfills, where harmful greenhouse gases are released. The paper recycling process involves separating paper and paper-based packaging from other materials, pulping and screening the paper to remove contaminants, and then cleaning and processing the fibres into new paper products. This process uses less energy and produces fewer emissions than incineration.
After being collected from homes, businesses, and recycling centres, paper is taken to a Materials Recovery Facility (MRF). Here, contaminants are removed, and paper is separated from other recyclables. The paper is then transported to a paper mill, where it is loaded into a pulper and mixed with water and chemicals to separate the fibres. The slurry is screened to remove inks, plastic film, staples, and other contaminants. The cleaned fibres are formed into rolls of recycled paper, which are then cut and dispatched to make new products such as cardboard, newsprint, and office paper.
Plastic recycling also involves several stages, including collection, sorting, and reprocessing. Plastic is collected from users and taken to Material Recovery Facilities (MRF) or Plastic Recovery Facilities (PRF), where it is sorted by type. The plastic is then washed, shredded, and sorted further before being melted and extruded into new recycled plastic pellets, which are used to create new products.
Overall, paper and plastic recycling play a crucial role in reducing CO2 emissions and mitigating climate change. By recycling paper, we can not only reduce emissions but also divert waste from landfills, contributing to a more sustainable future.
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Paper mills separate, grade, pulp, screen, clean, colour and form paper
The process of recycling paper and plastic begins with sorting and cleaning. At a recycling plant, paper is sorted into different types and grades, while plastic is sorted by resin type and sometimes colour. The sorted paper is then washed in a chemical bath to remove inks, plastic film, glue, and staples. It is then mixed with water to create a slurry, which serves as the base for various paper products. Plastic, on the other hand, is shredded into flakes or melt-processed into pellets after sorting and cleaning.
Paper mills play a crucial role in the recycling process by performing several key steps: separating, grading, pulping, screening, cleaning, colouring, and forming paper. Firstly, they separate the fine dirt from the fibre using equipment like centi-cleaners, ensuring a clean pulp suitable for bleaching. The pulp is then graded, with modern screen rooms designed to remove impurities from the chemical pulping process. If the pulp is undercooked, the screening rejects increase, and the screen room may need to be bypassed to avoid plugging.
The pulp is then mixed with dilution water to achieve the required consistency for the screening plant. Pulp screening equipment varies, including Cowan, IMPCO, diaphragm or flat screens, Quiller, bird pulp screens, and more. The choice of screen depends on factors such as the type of fibre, cost, repair, power consumption, efficiency, and space required. After screening, the pulp undergoes further processing, including colouring and forming it into paper sheets.
Finally, the recycled paper is formed into large, thin sheets, dried, and rolled up. These sheets are then cut and sent back to paper suppliers, completing the recycling process. Similarly, the plastic pellets obtained after shredding are used to manufacture new plastic products through moulding or other processes like thermal depolymerization and heat compression.
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Plastic is sorted by type at Material Recovery Facilities
Plastic is one of the most popular and versatile materials of modern times. Sorting plastic by type is an important step in the recycling process, and it is done at Material Recovery Facilities (MRFs). These facilities use a combination of mechanical and manual labour to sort and prepare plastic for further processing, helping to reduce waste sent to landfills. Sorting is mainly done automatically, with a manual sort to ensure all contaminants have been removed.
At an MRF, plastic is sorted by type and separated from non-plastic materials. This is done through a variety of techniques, including manual picking, where large items and non-recyclables are removed by hand. Trommels, or cylindrical drums with holes, are also used to separate finer materials. Optical sorters are a more recent innovation that uses cameras or light-emitting near-infrared (NIR) lasers to automatically sort items based on their colour, shape, size, and other characteristics. Symbols on plastic packaging can help explain what type of plastic they are made of and how to recycle them.
Another method used to separate plastic materials is a wet process known as a sink-float separator. A tank is filled with water, and high-density plastic sinks while low-density plastic floats. This process helps to separate plastics by thickness, colour, size, and type. Some plastics are additionally sorted by colour. Magnetic separators are also used to remove any metals that may be present.
After sorting, the plastic materials are shredded into flakes or pellets, which can then be melted and moulded into new products. This process gives plastic a new life and helps reduce the need to create new plastic.
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Plastic is then washed, shredded, sorted and formed into new products
Plastic recycling is a complex and meticulous process. The end goal is a 100% pure plastic product, preferably made from 100% recycled materials. After collection, the plastic is washed, shredded, sorted, and formed into new products.
Firstly, the plastic is washed to remove any remaining impurities, such as labels, glue, dirt, and food scraps. This can be done using friction washers, which are the most common form of washer due to their low operation cost and effectiveness. Friction washers use heat, kinetic energy, and pressure to clean the plastic. Rotary washers can also be used as a pre-wash, employing a heated caustic solution to remove oils and food residue.
Next, the plastic is shredded or ground into smaller flakes. This can be done using Hammer Mills, which pulverize the plastic in a rotary drum using swivelling hammers. The plastic is shredded to different degrees of fineness depending on its classification and the methods of the shredder.
The plastic is then sorted by type and possibly size, colour, and thickness. This is important for ensuring the quality and safety of the new recycled plastic. For example, shampoo bottles should be prevented from mixing with drink cartons. Metals should also be removed from the plastic. Sorting is done both automatically and manually, with infrared technology used to distinguish between different types of plastic.
Finally, the plastic is formed into new products. It is melted and extruded into pellets, which are sold to manufacturers to be used in new products. The plastic can also be processed into granulate, which is cut into granules that are 100% pure and suitable for processing into new plastic recycled products.
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Paper is de-inked and bleached before being made into new recycled paper
The process of recycling paper involves several steps to ensure that the final product is of good quality. One of the key steps in this process is de-inking and bleaching the paper before it is made into new recycled paper.
De-inking is necessary for printed paper materials to be recycled. This process usually occurs after the pulping process, where paper is shredded into small pieces. During de-inking, the pulp is placed inside a flotation tank, where air bubbles help remove inks, dyes, and other impurities, giving the pulp a paper-white appearance. Certain chemicals, such as hydrogen peroxide and surfactants, aid in this process. Surfactants, for example, help release ink particles from the pulp and keep them separate once removed.
After de-inking, the pulp undergoes another round of decontamination. If further de-inking is required, a de-inking agent can be used to separate and remove the ink. This process, known as flotation, involves changing the ink into fine particulates that are then dispersed. The ink particles are adsorbed onto the surfaces of air bubbles in a foam, which is then separated from the pulp. The de-inked pulp is then cleaned and bleached, if necessary, to create recycled pulp, also known as de-inked pulp.
This de-inked pulp is then combined with wood pulp and recycled into various paper products, including newsprint paper, copier paper, and recycled tissue paper. The recycled pulp can also be used to produce new paper products made entirely of recovered fibre or a blend of recovered and virgin fibre.
Recycling paper is an important process that helps reduce energy use, curb greenhouse gas emissions, and preserve natural resources. It is just one aspect of paper's long history, which has been made from a variety of materials such as cotton, wheat straw, sugarcane waste, flax, bamboo, wood, linen rags, and hemp.
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Frequently asked questions
Paper is collected and taken to a Materials Recovery Facility (MRF) where contaminants are removed and paper is separated from other materials. It is then transported to a paper mill where it is pulped with water and chemicals to separate the fibres. Inks, plastic film, paper clips, staples and glue are screened out and the mixture is cleaned. Colouring agents may be added and the mixture is sprayed onto a fast-moving mesh to form sheets. The sheets are pressed and rolled to remove water and achieve the correct thickness. The recycled paper is then cut and sent off to make new products.
Plastic is collected and sent to a Material Recovery Facility (MRF) where it is separated from other materials. It is then sorted into different types of plastic and sent to be reprocessed. The plastic is washed, shredded and sorted further before being heated and extruded into new plastic pellets. These pellets are then sold on to be moulded into new products.
Plastic collected from recycling bins is sent by rail or truck to waste-sorting facilities. Here, plastics are sorted by type and baled. The plastic is then loaded back onto trains, trucks or cargo ships to be transported elsewhere.
