Omar Khalid
Plastic is a significant contributor to pollution, with the US alone producing nearly 35.4 million tons of plastic in 2017. Plastic can take up to 700 years to biodegrade, and as it decays, it releases harmful chemicals into the environment. While recycling is one way to address this issue, the process is not as straightforward as it seems. Once plastic items are collected, they are taken to a Material Recovery Facility (MRF), where workers separate non-recyclable items and sort the remaining materials. However, contamination is a significant issue, as non-recyclable items often end up in recycling bins, reducing the value of other materials and causing issues for recycling machinery. Clean recyclables are more valuable, and recycling facilities do not clean items, so it is essential for consumers to ensure their recyclables are empty, clean, and dry.
| Characteristics | Values |
|---|---|
| Plastic bottles are recycled into other useful items | Clothes, furniture, fences, new plastic bottles, bags, and containers |
| Plastic bottles are recycled into | Carpet and clothing, packaging |
| Plastic bottles are recycled by | Melting them into pellets and then into preformed molds |
| Plastic bottles are recycled by | Chemical recycling: turning problem plastics into oil or gas through industrial processes |
| Plastic bottles are recycled by | Using technology to process materials that cannot be recycled |
| Plastic bottles are recycled by | Using technology to melt down polypropylene to create a virgin resin |
| Plastic bottles are recycled by | Using technology to identify waste |
| Plastic bottles are recycled by | Using technology to augment humans in the recycling process |
| Plastic bottles are recycled by | Using technology to remove non-recyclable items |
| Plastic bottles are recycled by | Sorting the contents by type |
| Plastic bottles are recycled by | Separating clean recyclables from soiled ones |
| Plastic bottles are recycled by | Removing liquids and food residue |
| Plastic bottles are recycled by | Removing non-recyclable items that can damage equipment |
| Plastic bottles are recycled by | Using deposit systems to incentivize recycling |
| Plastic bottles are recycled by | Using extended producer responsibility to share responsibility with manufacturers |
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What You'll Learn
Sorting plastic waste
Collection and Sorting
The process typically begins with waste collection, where recyclables are picked up from curbside bins and transported to recycling centers. At these centers, workers manually sort the contents by type, separating different materials such as newspapers, plastics, cans, and so on. They also separate clean recyclables from soiled ones, as contamination can affect the recyclability of certain items.
Sorting Innovations
Modern sorting plants utilize advanced technologies to achieve optimum cost-effective output. These include sensor-based systems that identify specific types of plastic, such as PET, and pneumatic systems that use air jets to divert items into different collection bins. While automation has improved accuracy, skilled workers are still crucial for handling irregularly shaped or unusually colored items that pose a challenge for sensors.
Size and Material Sorting
Plastic waste is then sorted based on size, either manually or through the use of sieves. Foreign materials, such as metal and glass, are removed using methods like gravity in airflow (air classifiers) or water streams (sink-float). Metals can also be separated through magnetic attraction or repulsion.
Plastic Type Identification
Different types of plastic have distinct properties, so accurate identification is vital. Plastics are often labeled with numbers, such as #3, #6, and #7, which correspond to specific materials like Polyvinyl chloride (PVC) and Polystyrene. These labels help recyclers identify and separate the different types of plastic for proper processing.
Pre-treatment and Sorting
Pre-treatment and sorting operations for commingled packaging and other dry recyclable materials can process large quantities of plastic waste, producing sorted waste with high purity levels. This stage involves preparing the plastic for the next steps in the recycling process, ensuring it is clean and free from contaminants.
Consumer Role
Consumers play a crucial role in the sorting process. By correctly separating waste at the point of collection, they can improve the efficiency of the recycling process and increase the quality and quantity of recycled products. Additionally, consumers can reduce plastic waste by adopting habits like using reusable containers and being mindful of the types of plastics they purchase.
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Cleaning the plastic
It is important to clean plastic items before recycling them. Contaminants can ruin the recycling process, and clean containers are more valuable to manufacturers.
The first step in cleaning plastic items for recycling is to empty them of any food, liquid, or other substances. This can be done by rinsing the item with warm water. If there is stuck-on residue, the item can be filled with water and swirled to loosen the debris. Shaking and drying the item will remove most of the remaining water.
Different types of plastic require different washing methods. The washing can be hot or cold, with water or without, depending on the plastic type. Mechanical cleaning methods, such as vibratory plates or puffs of compressed air, may be used to obtain better results.
For plastic bottles, a wash in hot water is usually sufficient to remove label residues and general dirt. However, specific processes may be required to remove other materials such as paper or metal. For detergent bottles, mechanical cleaning is often necessary to remove all contamination. If the recycled plastic will be used for food-safe packaging, additional cleaning stages are typically carried out to ensure a high-quality final product.
It is important to note that some plastic items, such as plastic bags, straws, and some takeout containers, cannot be recycled and should be thrown away.
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Melting the plastic
At the recycling facility, plastics are further sorted based on their type and condition. Clean plastics are more valuable and recyclable than soiled ones. Sorting ensures that the plastic is free from contaminants, as non-recyclable materials can ruin the value of the plastic and render it unusable for manufacturers.
After sorting, the plastic is processed. This can involve melting the plastic and reshaping it into pellets, which can then be sold to manufacturers. These pellets are then melted again and injected into moulds to create new products, such as plastic bottles, which are then filled and shipped to stores.
Some companies have fully embraced recycled plastic, with Nestlé using 100% rPET for its natural spring water, and PepsiCo purchasing almost half of the bottle-grade rPET sold in the United States. However, it is important to note that not all plastics are recyclable, and the fate of many plastic items is often landfills or incineration.
The process of melting plastic for recycling is an important step in reducing pollution, saving energy, and conserving natural resources. It is a complex process that involves multiple steps and careful sorting to ensure the final product is of value and can be reused.
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Creating new products
Recycling centres play a crucial role in diverting plastic waste from landfills and incinerators, and in creating new products from recycled plastic. The process typically involves sorting, cleaning, and processing plastic waste into raw materials that can be used to manufacture a variety of items.
Once plastic waste is collected and transported to a recycling centre, workers sort the materials by type, separating different types of plastics and removing non-recyclable items. This step is crucial as contamination can render a batch of recyclables unrecyclable. The sorted plastics are then cleaned and prepared for further processing.
At this stage, the plastics are typically shredded or melted down into pellets, which can then be purchased by manufacturers to create new products. For example, these plastic pellets can be melted and injected into moulds to create new plastic bottles, containers, or other products.
Some companies have embraced recycled plastic in their manufacturing processes. For instance, Nestlé started using 100% recycled PET (rPET) for its natural spring water, and PepsiCo purchases a significant amount of bottle-grade rPET for its beverage bottles.
There are also innovative technologies being developed to process hard-to-recycle plastics. For example, PureCycle Technologies is working on a technology that melts down polypropylene-based materials to create a virgin resin, expanding the possibilities for recycling.
The creation of new products from recycled plastic not only reduces the demand for virgin plastic production but also helps conserve resources, reduce pollution, and support local jobs and businesses. It is important to note that the recyclability of plastics can vary depending on the region, with some places accepting all kinds of plastic while others have more limited capabilities.
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Selling to manufacturers
Recycling centres sell plastic to manufacturers to be broken down into raw materials for new products. However, this is not always the case, as different countries have different regulations, and it can be difficult to find a place for all the recycling to go. Manufacturers will pay more for clean containers.
In the past, China was the world's largest market for recycled waste, but in 2018, the country prohibited 24 types of waste from entering, citing contamination as the reason. This policy shift was partly attributed to the impact of a documentary, Plastic China, which went viral before being censored and erased from the Chinese internet. The film followed a family working in the recycling industry, shredding and melting salvageable plastic into pellets that could be sold to manufacturers.
Following China's decision, the global waste crisis has worsened, with other countries' recycling ending up in foreign landfills or incinerated. Despite this, there is exciting technology being developed that can process materials that cannot be recycled. For example, PureCycle Technologies is building a technology that melts down materials made with polypropylene to create a virgin resin, allowing for a broader way of recycling waste. Chemical recycling, which turns problem plastics into oil or gas through industrial processes, is another promising development.
In the United States, there are a few facilities that recycle used plastic bottles, such as CarbonLite in Riverside, California. CarbonLite is one of the country's largest facilities, recycling more than 2 billion bottles a year. The plastic pellets produced at CarbonLite are sold to beverage companies, where they are melted, injected into preformed moulds, stretched, and blown into plastic bottles, which are then filled and shipped to stores.
To improve the effectiveness of recycling programs, some states have implemented deposit systems, where consumers are charged an additional price on each recyclable item, which can be recovered only after the item is returned to a designated recycling station. These systems have been shown to increase recycling rates, as seen in California, which has a legislated deposit system and a 65 to 70 percent recycling rate, compared to Texas, which recycles less than 5 percent without a bottle deposit.
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Frequently asked questions
Plastic can be recycled and broken down into raw materials for new products. However, this is not always the case, and some plastics are sent to landfills or incinerated.
Plastic bags can cause problems at recycling centers as they can get tangled in the machinery. Therefore, bagged recyclables are often sent straight to landfills.
Plastic bottles can be recycled and turned into other useful items, including new bottles, clothes, furniture, fences, bags, and containers.
After collection, recyclables are taken to a material recovery facility (MRF) where they are sorted by type. Workers separate clean recyclables from soiled ones, and non-recyclable items are removed. The remaining materials are then sorted mechanically.
Plastic that cannot be recycled is often sent to landfills or incinerated. There is also technology in development that can process non-recyclable materials, such as PureCycle Technologies, which melts down polypropylene to create a virgin resin.
