Alexei Volkov
Plastic is everywhere, and it's cheap to produce and profitable. Unfortunately, it's not designed to be recycled and is, in fact, difficult to recycle. It's also challenging to recycle many types of plastic more than once without causing the material to acquire defects and contaminants. The process of recycling plastic involves grinding it up, melting it down, and reforming it. This process is energy-intensive and expensive, and the resulting recycled plastic is often of inferior quality and more toxic than the original. However, recycling plastic is still important for the environment as it reduces the need for drilling for oil and processing it. Once recycled, plastic can be used to make new products such as bottles, auto parts, carpets, clothing, or even new containers.
| Characteristics | Values |
|---|---|
| Plastic is recycled into | carpets, clothing, plastic bottles, plastic auto parts, soap bottles, picnic tables, road fillers, playground equipment, plastic crates, etc. |
| Plastic containers are sorted at | MRF (Materials Recovery Facility) |
| Plastic containers are then shipped to | an intermediate processing facility |
| Plastic is then | processed into flakes or pellets, cleaned, melted, and pressed into new consumer products |
| Plastic is a | stubborn substance that resists decomposition and has a presumed life span of over 500 years |
| Plastic bottles are | ground into cornflake-sized pieces, washed, dried, and heated to eliminate contaminants |
| Plastic bottles are then | shipped to manufacturers in the US, China, and other countries |
| Plastic bottles are used to make | carpets, polyester fabric, teddy-bear stuffing, food containers, etc. |
| Plastic bottles are | melted, extruded as ribbons of liquid plastic, and shaped into smooth rice-grain-sized pieces |
| Plastic pellets are | sold to manufacturers as raw materials |
| Plastic is | cheap to make and profitable |
| Plastic is | not designed to be recycled |
| Plastic is | rarely recycled |
| Plastic is | difficult to recycle more than once without causing defects and contaminants |
| Plastic is | vulnerable to the ups and downs of the commodities market |
| Plastic is | expensive to recycle |
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What You'll Learn
Sorting and collection
At the MRF, the plastic items are sorted by type. This process involves mechanical separation, optic sorters, and hand sorting. Plastic containers are sorted by resin type, such as polypropylene or polyethylene terephthalate (PET). It is important to ensure that your plastic containers are clean and free of contaminants before placing them in the recycling bin, as contaminated items cannot be recycled and will be disposed of as waste.
Some facilities may have specific guidelines regarding the caps or lids of plastic containers. It is recommended to check with your local facility to determine whether they prefer to have the caps on or removed. Additionally, some plastic materials, such as plastic bags, flexible packaging, and clamshells, may not be accepted by all curbside recyclers due to the challenges they pose to the recycling process.
After sorting, the plastic containers are baled, or squashed into easily transportable cubes. They are then loaded onto trains, trucks, or cargo ships and transported to the next stage of the recycling process, which involves processing the plastic into a usable form for manufacturing new products.
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Processing into pellets
Once plastic containers are sorted at a materials recovery facility (MRF), they are shipped to an intermediate processing facility. Here, the plastic is processed into small plastic pellets or flakes, which are then cleaned to remove contaminants. The process of creating these pellets involves several steps.
Firstly, the plastic waste is shredded to reduce its size. This step is crucial, as it enables easier drying and separation of the plastic. The shredded plastic is then washed to remove dirt, grease, and other impurities. The washing process also helps reduce the humidity of the waste to an acceptable level of 3-5%.
After washing, the plastic is dried to further decrease its moisture content. This can be achieved through sun drying or the use of mechanical dryers. Once the plastic is sufficiently dry, it is ready for the next step: melting and re-plasticization. The dried plastic is heated and compressed, causing it to reach a viscous flow state.
At this stage, the molten plastic is pushed through an extruder using centrifugal force. It then undergoes pelletizing, where it is cut into small plastic pellets by a cutter. These pellets are still hot, so they are cooled through a cooling system. The final product is a set of processed plastic pellets ready for use in various applications.
The creation of these pellets is advantageous as they can be used as raw materials in manufacturing processes. They can be melted and moulded into new consumer products, such as soap bottles, auto parts, or fibres for carpets. Additionally, they can be utilised in production processes involving Blown Film Machines, Injection Machines, and Plastic Molding Machines.
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Cleaning and contaminating
Plastic waste needs to be cleaned and washed to remove impurities and contaminants before it can move on to the next stage of the recycling process. The specific washing method depends on the quality of the material and the product that will be created from the recycled plastic. For example, plastic bottles are typically washed in hot water to remove label residues and general dirt, and they may undergo additional processes to remove paper or metals. Detergent bottles, on the other hand, usually require mechanical cleaning to eliminate all contamination.
In some cases, detergents or specific substances may be necessary to address particular contamination. After washing, the material is thoroughly rinsed. This cleaning process is especially important when the objective is to manufacture food-safe packaging, as the final material must be of high quality.
Contamination in plastic recycling can lead to increased pollution, which is detrimental to the planet and its inhabitants. The main cause of contamination is a lack of awareness among the public. For instance, plastic bags are the number one contaminant in the recycling industry, often clogging equipment and even shutting down entire facilities. Plastic lids can also be problematic, as they are small enough to slip through the sorting process and end up contaminating other materials, such as paper.
Additionally, certain types of plastic containers, like clamshells, may be more challenging to recycle due to the way they are molded, which affects the structure of the plastic. Flexible packaging, such as potato chip bags, made from layers of different plastics and lined with aluminum, pose similar difficulties in separating the various materials.
To address contamination, it is essential to educate yourself about your local recycling guidelines and follow their instructions for cleaning and sorting recyclables. This may include tasks such as rinsing out containers, removing labels, and separating different types of materials. By taking the time to properly prepare your recyclables, you can help ensure that your plastic waste can be effectively recycled and contribute to a more sustainable future.
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Selling and shipping
Once your plastic container has been sorted at the MRF, it is shipped to an intermediate processing facility. Here, the plastic is processed into flakes or pellets, which are then cleaned to remove any contaminants. These flakes or pellets are known as "feedstock" and are sold to companies to be used as a substitute for "virgin plastic". This is because virgin plastic is derived from oil, which requires drilling, whereas recycled plastic does not, making it a more environmentally friendly option.
The companies that buy this recycled plastic become known as "remanufacturing facilities" as they melt and press the plastic into new consumer products. These products can include soap bottles, plastic auto parts, fibres for carpets, or even new plastic containers.
The process of selling and shipping recycled plastic is a global business, with plastic being shipped all over the world to be made into new products. This process is made possible by the fact that plastic does not decompose and can, therefore, be reused multiple times. However, it is important to note that not all plastic that is placed into recycling is actually recycled. In fact, according to Tom Szaky, CEO of TerraCycle, a recycling company, "50% of what you put in your recycling bin is never recycled. It's sorted and thrown out". This can be due to user error, with people placing unrecyclable materials into recycling bins, or because it is cheaper for companies to use raw, virgin plastic than it is to buy recycled plastic.
The selling and shipping of recycled plastic are also impacted by local policies and guidelines. For example, in Maine and Oregon, where there has been investment in recycling programs, up to 80% of bottles made from PET (polyethylene terephthalate) are recycled. However, in some states in the South of the US, this percentage is in the single digits. It is also important to follow local guidelines on how to sort and prepare your recyclables, as this can impact whether they are actually recycled or not.
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Melting and reforming
Once a plastic container is placed in a recycling bin, it enters a complex global system where it is sold, shipped, melted, resold, and shipped again, sometimes crisscrossing the globe before being transformed into a new product. This process is made possible by plastic's resistance to decomposition, which gives it a presumed lifespan of over 500 years.
The recycling process typically begins with the collection of plastic containers and other recyclables from residential, commercial, and industrial locations. Collectors then transport the materials to a Materials Recovery Facility (MRF), where they are sorted by resin type using mechanical separation, optic sorters, and hand sorting. It is important to note that not all plastic containers are recyclable, and those that are contaminated or made from certain types of plastic may be discarded as waste.
After sorting, the plastic containers are processed into flakes or pellets, which are then cleaned to remove contaminants. These recycled plastic flakes or pellets, known as "feedstock," are sold to companies that utilize them as a substitute for virgin plastic in manufacturing. This step involves melting and reforming the plastic into new products.
The melting and reforming process involves heating the plastic flakes or pellets to a high temperature until they become a molten state. This liquid plastic is then injected into preformed molds, where it takes on the desired shape. Once cooled, the plastic emerges as a newly formed product, such as a soap bottle, plastic auto part, or fiber for carpets.
It is important to recognize that the melting and reforming process is just one aspect of the larger recycling journey. The specific steps and outcomes can vary depending on geographic location, the type of plastic, and the capabilities of the recycling facilities. Additionally, it is worth noting that not all plastic can be recycled, and even when it is, the quality of the plastic may diminish, and it can become more toxic with each recycling attempt.
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Frequently asked questions
After being collected, plastic containers are taken to a materials recovery facility (MRF) where they are sorted by type and baled. They are then sent to an intermediate processing facility, where they are processed into flakes or pellets, cleaned, and sold to companies that reuse the material for manufacturing other goods.
Plastic bottles, jars, round containers, buckets, and nursery pots can be recycled at home. Containers with a threaded neck or a neck narrower than the base are also recyclable. This includes milk jugs, peanut butter jars, and bottles that held personal care and cleaning products.
Plastic bags, plastic cups, lids, straws, plastic wrap, containers smaller than 6 ounces, and containers made of multiple types of plastic, such as clamshells, are often not recyclable.
Check your local municipality's guidelines for specific instructions. In general, it is important to rinse and clean your containers before placing them in the recycling bin.
