Sofia Martinez
The process of recycling plastics involves collecting and processing plastic waste, which would otherwise be discarded, and transforming it into new products. However, the reality of plastic recycling is complex. While plastic bottles are the most commonly recycled plastic product, especially in the US, the effectiveness of plastic recycling has been questioned. Historical documents and investigations reveal that the oil and gas industry promoted plastic recycling despite knowing it would not work on a large scale. The high costs of separating plastics and the low cost of using oil to produce new plastics are significant challenges. Additionally, not all types of plastic are recyclable, and the success of recycling efforts varies across different areas. To address these issues, recycling centers employ various methods, including optical sorters, robotic arms, and manual quality control, to sort and process plastic waste.
| Characteristics | Values |
|---|---|
| Plastic bags, wraps, and films | Not accepted in most curbside or drop-off programs in the US |
| Plastic bags | Should be collected separately and returned to special drop-off locations |
| Plastic films | Can be recycled at some store drop-off locations |
| Plastic bottles | Most commonly recycled plastic product in the US as of 2018 |
| Recycling plastic | Unlikely to happen on a broad scale |
| Recycling plastic | Not economically justifiable due to high costs of separating plastics |
| Recycling | Benefits the community, the economy, and the environment |
| Recycling one ton of office paper | Saves the energy equivalent of consuming 322 gallons of gasoline |
| Recycling 10 plastic bottles | Saves enough energy to power a laptop for more than 25 hours |
| Recycling plastic | Can drive jobs and revenue, reduce natural resource extraction, and help move towards a circular economy |
| Recycling | Most effective when waste is not created in the first place |
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What You'll Learn
Sorting plastics
The first step in sorting plastics is to separate plastic items from other recyclables. Plastic bags, for instance, should not be mixed with other recyclables and need to be returned to specific drop-off locations, often found in grocery or retail stores.
After the initial separation from other recyclables, the plastic items are then fed into an automated sorting system. This system utilizes a combination of conveyor belts, sensors, and optical scanners to identify and categorize plastic items based on attributes like density, color, and behaviour when exposed to specific wavelengths of light. For example, optical sorters may be programmed to identify specific plastics like PET bottles, and once identified, a puff of air moves the item into a separate collection area.
While automated systems have improved accuracy and efficiency, manual intervention is still required in certain cases. Skilled workers are needed to sort irregularly shaped or unusually colored plastic items that may confuse the sensors. Additionally, they play a crucial role in removing contaminants, such as non-recyclable plastics like PVC, which is challenging to recycle due to its chemical composition.
After the initial sorting, the plastics are baled into compressed rectangular blocks and sold to recyclers. However, even at this stage, another round of sorting is conducted to remove any remaining contaminants, such as glass or small metal pieces. This multi-step sorting process ensures that the plastics are adequately prepared for the recycling journey ahead.
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Removing contaminants
There are various methods for removing contaminants from plastic, including manual and automated processes. One common method is to use optical sorters, which are programmed to identify and separate specific types of plastic, such as PET bottles. However, in-person quality control is still necessary to remove contaminants that the optical sorters might miss. Some recycling centres have also started using robotic arms for sorting and quality control.
Another method for removing contaminants from plastic is through a two-part process involving an upstream solvent cleaning system and a downstream carbon dioxide cleaning system. This method is particularly useful for removing residues from containers made of synthetic resin materials, such as motor oil containers. However, it requires the carbon dioxide to be placed under very high pressure, which can be costly.
Other methods for removing contaminants include dry and wet systems. Dry systems include processes such as depackaging, grinding, shredding, extrusion, screening, magnetic removal, centrifugation, and air entrainment. Wet systems, on the other hand, include processes like pulping, filtration, cyclonic classification, flotation, and settling. Water is often used as a separation medium in float/sink tanks to separate lightweight plastics from heavier materials like stones and bricks.
Overall, the process of removing contaminants from plastic is crucial in ensuring the effectiveness and efficiency of the recycling process, as well as maintaining the value of the recycled material.
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Selling bales to recyclers
Once plastic is sorted at a recycling centre, it is baled into compressed 1000-1500 lb rectangular blocks and wrapped with wire. These bales are then sold to reclaimers, who process the material into recycled plastic. The revenue from the sale of bales needs to cover the costs of sorting and processing those materials.
Recycling centres frequently purchase materials from businesses looking to dispose of waste responsibly. Companies that use balers to streamline waste management can sell their recyclable bales to enhance sustainability efforts and generate additional revenue.
Selling bales directly to local businesses can be beneficial, as it provides them with raw materials while offering a convenient sales outlet for recyclables. Local recycling centres are a common destination for selling recyclable bales, as they are equipped to handle large volumes of sorted recyclables.
Businesses can also sell plastic scrap waste directly to a plastic recycling facility, which will recycle and reprocess the plastic into regrinds, compounds, and homogenized materials for circular products. Berry Global, for example, purchases nearly all types of plastic waste and reprocesses them into quality, homogenized materials for circular products.
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Grinding and washing plastic
The grinding and washing of plastic are crucial steps in the recycling process. This process involves taking plastic waste that has been collected from homes, businesses, and recycling centres and giving it a "second life".
Firstly, the plastic waste is sorted and then crushed or shredded into smaller pieces. This is done to simplify the separation of different elements, such as organic materials, paper, and dust, which cannot be manually separated. Grinding also allows for the differentiation of plastics with different densities, ensuring the quality of the final recycled material.
The ground plastic is then washed in a process that can vary depending on the level of contamination. Friction washers, for example, use heat, kinetic energy, and pressure to remove contaminants. Rotary washers, on the other hand, use a heated caustic solution to remove oils and food residue. This washing process also helps dissolve adhesives used to attach labels.
After washing, the plastic may undergo further separation, with some plastics floating and others sinking in a float-sink tank. This process separates plastics with different densities, such as HDPE and PET.
The washed and separated plastic can then be processed into recycled plastic products, giving new life to waste and contributing to a more sustainable future.
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Energy savings
Recycling plastics saves energy and resources (such as water, petroleum, natural gas, and coal) that would otherwise be needed to create new plastics. Manufacturing plastic items from recycled plastics can decrease energy needs by 66%, and up to 75% in some cases.
Recycling plastic also reduces the amount of energy spent on waste management. Recycling diverts waste away from landfills and incinerators, which reduces the harmful effects of pollution and emissions. Recycling just 10 plastic bottles saves enough energy to power a laptop for more than 25 hours. In 2014, over 89 million tons of municipal solid waste (including plastics) were recycled or composted in the United States, saving over 322,000 GWh of energy—enough to provide electricity to 30 million homes.
Recycling plastic also helps to reduce the energy spent on extracting and processing raw resources. For example, recycling steel saves 60-74% of the energy used to produce steel from raw materials. Similarly, recycling aluminum saves a significant amount of energy as aluminum ore needs to be extensively processed to isolate the aluminum metal. Recycling one ton of paper could save enough energy to power the average American home for six months.
Recycling plastic is a proven climate solution, reducing greenhouse gas emissions and supporting a circular economy.
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Frequently asked questions
After plastic is sorted, it is baled into compressed rectangular blocks and sold to recyclers (reclaimers) who process the material into recycled plastic. The recycled plastic is then turned into new products.
Plastic bottles are the most commonly recycled plastic products. However, the types of plastic that can be recycled vary by location. It is important to check with your local recycling provider to see what types of plastic they accept.
It is important to clean plastics before recycling to ensure they can be recycled effectively without contaminating other materials. A light wipe with a dry cloth to remove any residue should be sufficient.
