Alexei Volkov
Plastic film is lightweight, thin, and flexible, making it useful for packaging goods and preserving food. However, its small size and light weight also make it difficult to recycle. In the US, plastic film is often collected at curbside and taken to a materials recovery facility (MRF) for sorting and recycling. However, plastic film can fly into the air and get stuck in the machinery at MRFs, causing operational disruptions. As a result, some MRFs have implemented optical sorters and RFID testing to improve the automated sorting of plastic film from other materials. In addition, some retailers offer store drop-off programs for plastic film recycling, and subscription services through specialty recyclers are also available in select areas. While recovering plastic film from mixed-waste MRFs can be challenging, studies have shown that it is economically viable, and advancements in technology continue to improve the process.
| Characteristics | Values |
|---|---|
| Plastic film collection | Curbside recycling of flexible plastic packaging is practical and economically feasible |
| Plastic film recycling | Store drop-off programs, subscription services through specialty recyclers, and curbside collection carts |
| Plastic film sorting | Optical sorters, RFID testing, and manual labor |
| Plastic film recovery | Mechanical sorting, disk screens, and optical sorting |
| Plastic film processing | Washing, shredding, and melting |
| Plastic film uses | Fuel products, feedstocks for conversion technologies, and building materials |
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What You'll Learn
Curbside recycling of flexible plastic packaging
However, there are challenges to be addressed. Curbside recycling is taken to Material Recovery Facilities (MRFs), where plastic wrapping can fly into the air and get stuck in the machinery, causing operational disruptions. Flexible packaging is also often made of multiple layers and materials that are difficult to recycle or break down mechanically.
To overcome these challenges, the Materials Recovery for the Future (MRFF) consortium has implemented solutions such as optical sorters and flex/rigid separators to improve the automated sorting of flexible plastics from other materials. Additionally, programs like the Hefty ReNew™ program offer curbside recycling of alternative plastics in select municipalities, and specialty recyclers provide subscription services for a monthly fee.
Furthermore, Store Drop-off programs, managed by the Flexible Film Recycling Alliance (FFRA), allow consumers to collect and recycle plastic films at participating retailers. These programs help divert flexible plastic packaging from landfills, but it's important to verify which types of plastic film are accepted through these initiatives.
While there are obstacles, advancements in recycling technologies, such as advanced, chemical, or molecular recycling, show promise in processing mixed plastics, including flexible packaging. The Flexible Packaging Association (FPA) has also advocated for Extended Producer Responsibility (EPR) laws to accelerate the widespread recycling of flexible plastics, including curbside collection options.
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Overcoming moisture and contamination issues
Moisture and contamination are two of the main challenges when it comes to collecting film plastic in a mixed-waste MRF. Plastic films and wraps are lightweight and thin, which makes them effective packaging materials, but also difficult to handle in the recycling process.
Firstly, plastic films can get stuck in machinery, causing production lines to halt. This is a particular issue with flexible plastic films, which can fly into the air and cause issues. Secondly, plastic films are often contaminated with grit, PVC, and polyurethane foams, which can affect the quality of the recycled material. For example, film processed at WRI contained some moisture and contamination that would not meet the specifications of higher-value film markets.
To overcome these issues, several measures can be taken. Firstly, ensuring all recyclables are covered and processed quickly can help to mitigate the problem of plastic film clinging to wet cardboard. Installing optical sorters on each of the MRF's fiber lines can also help to eject film plastic from fiber. Additionally, a secondary exhaust fan can be placed on the MRF line to remove grit contamination from the collected film.
It is also important to sort plastics by resin type to reduce the risk of contamination and allow for continuous recycling. Consumers can also play a role in overcoming contamination issues by ensuring their plastics are clean and dry before recycling. A light wipe with a dry cloth to remove any residue can help ensure plastics are effectively recycled without contaminating other materials.
Finally, staff training can help ensure that only acceptable levels of contamination are present in the recovered plastic film. This includes training on which plastic films to recover and what levels of contamination are acceptable.
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Sorting and separating plastic film
The next step involves using disk screens to separate wide and flat materials like flattened cardboard boxes from other items like cans, jars, paper, and bottles. Flattened cardboard boxes are separated using the disk screen, while other materials fall below. Paper is then separated from the waste stream using a blower.
To separate the glass and plastic streams, additional disk screens are employed. The glass is crushed into cullet for easier transportation. As for the plastics, they are sorted by polymer type, often utilizing infrared technology (optical sorting). Infrared light reflects differently off various polymer types, allowing a jet of air to direct the plastic into the correct bin. It is important to note that MRFs may only recycle specific polymers of plastic, sending the rest to landfills or incinerators.
The process of sorting plastic film can be challenging due to its lightweight and thin nature. Curbside recycling of flexible plastic packaging has shown potential in pilot programs, but the lack of curbside collection carts remains an infrastructure gap. However, advancements in technology, such as RFID testing and optical sorter tuning, are being explored to improve the automated sorting of flexible plastics from paper.
In conclusion, sorting and separating plastic film in MRFs require a combination of manual labour and advanced technology. While there are challenges, ongoing efforts and innovations aim to improve the efficiency and effectiveness of plastic film recycling.
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The economic viability of film recovery
Recovering plastic film from mixed waste at a Materials Recovery Facility (MRF) can be economically viable. A study conducted at a MRF operated by Willamette Resources, Inc. (WRI) outside of Portland found that the recovery of plastic film was economically feasible, given the price paid by the Boise Cascade market and WRI's cost structure and operating practices. The total operating cost per pound of film recovered at WRI during the sorting period was approximately 4.6 cents.
To improve the economic viability of film recovery, MRFs can implement several measures. Firstly, investing in additional sorting equipment and staff training can help to reduce contamination and meet the specifications of higher-value film markets. For example, WRI installed a secondary exhaust fan to remove grit contamination and provided training to management and staff on the types of plastic films to recover and acceptable levels of contamination. Secondly, partnering with retailers or community centers to offer store drop-off or flexible film collection bins can increase the volume of plastic film recovered. Finally, implementing optical sorters and RFID testing can improve the efficiency of sorting and separation, reducing labor costs.
The film industry has also faced economic challenges in recent years, primarily due to the COVID-19 pandemic and the rise of streaming services, which have significantly impacted revenue streams and consumer behaviors. To adapt to these changes, the industry has explored integrated distribution strategies, hybrid release models, and collaborations between studios, theaters, and streaming platforms. By embracing technological advancements and innovative distribution channels, the film industry can enhance its economic viability and sustain its success in the evolving media landscape.
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Using optical sorters and other technology
Optical sorters have been used in MRFs for years, but the technology is rapidly advancing. Optical sorters can identify material composition and colour, and are increasingly being integrated with artificial intelligence, robotics, and increasingly high-speed conveyors.
There are several optical sorting technologies available, including vision spectroscopy, which sorts by colour, NIR/VIS, which combines to sort by material and colour, and inductive sensors, which recover metals. The latest option is called Profile Detection, which will improve the purity of recovered fractions in negative sorting by detecting black plastic films in a paper stream or sorting carbon black contaminants in a PET or PE fraction. Optical sorters can also be used in conjunction with robotics, such as BHS' Max-AI AQC (autonomous quality control) unit, which can identify and sort PET trays, aluminium, HDPE, PP, mixed plastics, and residue, leaving a clean PET product.
The addition of AI technology within optical units can enhance recovery and purity rates, while a more user-friendly HMI interface can increase the adjustment flexibility of the technology for customers and lead to more autonomy in their operations. A new dashboard can also be integrated, consisting of a platform that will collect and exchange data within a specific piece of equipment and a full system.
When considering the integration of optical sorters, a MRF operator should outline what the business's goals are and how new equipment might help achieve these goals. It is also important to plan for future equipment and choose equipment and a site that allows flexibility, as the incoming material composition and output demands are ever-changing.
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Frequently asked questions
MRF stands for Materials Recovery Facility, Materials Reclamation Facility, Materials Recycling Facility or Multi-Reuse Facility. It is a specialised waste sorting and recycling system that receives, separates and prepares recyclable materials for marketing to end-user manufacturers.
The main recyclable materials include ferrous metal, non-ferrous metal, plastics, paper, and glass.
MRFs use a combination of manual and mechanical sorting methods. Human workers remove non-recyclable items, potential hazards, and materials that can tangle machinery, such as plastic bags and hoses. Then, conveyor belts transport the materials to disk screens, which separate wide and flat materials like flattened cardboard boxes from other items. Further screens separate newspapers and magazines from mixed materials. Disk screens are also used to separate glass and plastic streams, and plastics are separated by polymer type using infrared technology.
Film plastic tends to travel with all material streams and needs careful monitoring. It can be removed during the pre-sorting stage, along with other residual waste materials, using automated technology. Optical sorters are used to recover plastic film from paper and other materials.
Film plastic can be challenging to collect due to its small, thin, and lightweight nature. It can fly into the air and get stuck in machinery, causing disruptions. Additionally, some flexible packaging is made of multiple layers that are difficult to recycle or break down. Moisture is another challenge, as film plastic can cling to wet cardboard.
