The City of Lethbridge, Alberta held the grand opening of their new single-stream material recovery facility on May 8. According to Machinex, their sorting system at the facility, commissioned in mid-April, will allow the City to process residential recycling materials generated by a new blue cart program that is currently being set up.
Vilar Guillén: Evolving from a focus on local recycling to world markets
Kadant Paal presses provide dense, uniform bales for lower shipping and handling costs
Only a few years ago the standards for recycled paper and board in China were not high. As a massive importer, China is now known to reject entire container loads based upon one inferior bale. Responding to this reality, Valorizaciones Vilar Guillén SL (V V G) set out to streamline their entire business to deliver against tight specifications, earning respect and repeat business as a result.
Says Tomas Vilar, Co-founder and CEO of the family business started three generations ago, "Some customer pay a considerable premium for VVG bales. We work closely with them to control content and stability, especially because of shipments over long distances. Our bales, made exclusively with Kadant Paal presses, are dense and uniform, so shipping and handling costs are lower."
Continues Vilar, "We evolved from a focus on local recycling to providing premium raw materials to world markets. At our Les Franqueses del Vallès, Barcelona, Spain facility, we make customized compact bales from two robust production lines. We know exactly what each bale contains, documenting precise content. That's why the most demanding Chinese and European paper mills choose our products. Adapting each day is the VVG way, because markets keep changing."
Continuous improvement as a corporate value
Vilar considers it important to educate customers, government officials and all VVG employees about ongoing changes in recycled paper and board content.
"Carton board can be white on one side, for example, and that can be good. Brown paper has a range of colours," he says. "We try to find a balance, being ready from the beginning of any change, always taking the first step without delay."
Frequent inspections from customers and the CCIC (China Certification Inspection Group) in Spain are the new norm. Often the focus in on 120 containers.
Continues Vilar, "We have discussions and review sessions, including opening some bales to guarantee 0.5% or less of unacceptable material. Once they give the OK, we send this notification to the client and prepare the logistics according to the latest rules and specific ports.
After the ocean journey of a few weeks, he says VVG bales arrive for a site inspection. "Having all of our photos from loading, the inspectors verify the quality," says Vilar. "If something is wrong, they reject the whole container. For us this problem has never happened.
"Two years ago, no one could believe this degree of change would happen. Many in our industry are still thinking it's not possible. No one used to sell this way. Inspections up to 3-4 times per month are common.
"China pays a premium, higher than anyone else, because they are buying the best we have to offer. It's not really the same material. There are fewer imperfections. Recycled paperboard and paper has a new standard and a higher price."
High standards at Les Franqueses del Vallès factory
Back in December of 2013, VVG installed Kadant Paal's Konti 600 channel bale press. This fully automatic channel machine has a pressing force of 800kN - 1950kN and bale formats of 75 x 110cm or 110 x 110cm. High pressing force is independent from the cutting and compressing process, and pre-press settings, combined with individual channel adjustments, make for the highest quality baling results.
"High performance, efficiency, and low operating costs played a key role in the decision to acquire a second Kadant Paal press in 2017," explains Vilar.
In early 2017, based on their growth and expansion into the international marketplace, he says they chose Kadant Paal's Likon baler to be an integral part of their new facility. The horizontal-tying Likon baler is a fully-automatic channel baler, known for high loading levels in continuous operation at maximum efficiency.
Robustly constructed, high pressing forces of 1200kN - 1950kN demonstrate the quality and reliability of the Likon baler. The combination of high pressing forces, independent cutting and compression processes, as well as individual channel adjustment, creates bales with maximum compression.
According to Carles Clapes, Kadant Paal's Sales Manager for Norther Spain, "VVG employs our balers to maximum capability, based upon customers seeking more from recycled paperboard and paper."
"VVG defines the change of culture for a new generation in recycling," adds Oriol Juvanet, Kadant Paal Export Area Manager. "They look less at price and more at quality. They don't want to lose time with delays. They expect that critical machines don't stop every three days. They want a supplier they can trust to meet production objectives. They trust us to be part of their planning."
The sustainability picture
"Locally, individuals and companies want raw materials to be resused, and not buried in landfills," concludes Vilas' brother-in-law Octavi Ginjaume. "Our global customers want high value when they employ recovered materials. The VVG team is proud to contribute by constantly adapting and supporting sustainable success."
Key Benefits of Kadant Paal Baling Systems
• Energy saving from latest generation axial piston pumps.
• Higher throughput, combined with lower energy consumption
• Easy to use pre-set recipes with PLC
• Increased lifetime of machine, thanks to changeable bolted wear-plates
• Higher bale weights due to new optimized channel design and hydraulic system pressures.
• Ease of maintenance, ensured by:
o Enhanced accessibility at both sides of the tying unit.
o Larger inspection door, at the rear section of the baler.
o Remote maintenace (SPS), offering the possibility of using remote access and service.
• Advanced user-friendly operation, due to new interactive operator control panel, with higher pixel resolution.
More from Paper Recycling
Machinex attended the official ceremony this week marking the major upgrade of the Sani-Éco material recovery facility located in Granby, Province of Quebec, Canada. The owners of the recycling management company reiterated their trust in Machinex, which provided them their sorting center more than 18 years ago. This modernization will allow an increase of their current sorting capacity in addition to bringing a direct improvement to the quality of the fibers produced.
Bulk Handling Systems (BHS) has launched the Max-AI AQC-C, a solution that is comprised of Max-AI VIS (for Visual Identification System) and at least one collaborative robot (CoBot). CoBots are designed to work safely alongside people which allows the AQC-C to be quickly and easily placed into existing Material Recovery Facilities (MRFs). BHS launched the original Max-AI AQC (Autonomous Quality Control) at WasteExpo in 2017. At this year's show, our next generation AQC will be on display along with the AQC-C.
RePower South (RPS) has begun processing material at the company's new recycling and recovery facility in Berkeley County, South Carolina. The recycling system, provided by Eugene, Oregon-based Bulk Handling Systems (BHS), is one of the most advanced in the world. The highly automated system is capable of processing more than 50-tons-per-hour (tph) of mixed waste to recover recyclables and produce a fuel feedstock.
Machinex recently carried out a full design review of the MACH Hyspec optical sorter. As part of this process, the decision was made to totally revamp the overall appearance of the unit.
Niagara Recycling was incorporated in 1978 as a non-profit social enterprise company. Norm Kraft started with the company in 1989, became CEO in 1993, and has never looked back.
Between summer 2017 and 2018, Dem-Con Materials Recovery in Shakopee, Minnesota retrofitted their single-stream MRF with three new MSS CIRRUS optical sorters for fiber from CP Group. The units increase recovery, improve product quality and reduce sorter headcount on the fiber QC. A fourth MSS CIRRUS sensor is currently in production and will install this summer.
MSS, Inc., the optical sorting division of CP Group, has received a patent for their PrecisionFlow eject hood for optical sorters.
Canada Fibers awarded contracts to design, build and operate two technologically advanced recycling facilities
Canada Fibers Limited (CFL) has been awarded two contracts to design, build and operate advanced single-stream post-consumer Material Recovery Facilities (MRFs) in Winnipeg, Manitoba and Peel, Ontario. The Company is constructing an 80 thousand square foot greenfield facility in Winnipeg and is retrofitting the Region of Peel's existing MRF. Both projects involve advancements to recovery technologies in response to increasingly rigorous quality standards from industries utilizing post-consumer recyclable materials.
Machinex and Canada Fibers partnership to result in two of the most technologically advanced single-stream facilities in North America
Toronto-based Canada Fibers Ltd. (CFL) is building two single-stream recycling facilities in 2019 that will include the most advanced, high-tech fibre and plastics sorting and recovery systems in Canada. In Winnipeg, Manitoba, a completely new 30-tonnes-per-hour facility (approximately 80,000 square feet) is currently under construction and scheduled to open in the fall. In the Region of Peel, Ontario, the existing Peel Integrated Waste Management Facility MRF, owned by the Region, will be retrofitted for 31.5-tonnes-per-hour capacity, with the updated facility (approximately 85,000 square feet) scheduled to open in the first quarter of 2020.
The good news for recovered paper exporters as the calendar flipped to another new year was China's issuance of almost six million short tons worth of import licenses in December. The first batch of permits issued by China's Ministry of the Environment, covering about 5.5 million tons, was more than double the amount of recovered paper allowed by China's first batch a year earlier.
Balcones Resources celebrated its 25th anniversary in business this month, growing from a small Austin-based paper recycler to a comprehensive environmental services company with facilities in Austin, Dallas and Little Rock. Balcones marked the milestone with a reception featuring a presentation of $25,000 in total donations to five Austin-area environmental organizations: EcoRise, Hill Country Conservancy, Keep Austin Beautiful, Shoal Creek Conservancy and Waller Creek Conservancy.
TOMRA Sorting Recycling has announced two additions to their North America product support team. Sean Hyacinth has been added as a field service engineer for TOMRA optical sorting equipment, while Kevin Javier Montalvo assumes the newly created position of customer project manager, recycling. Both team members will work directly with TOMRA dealers and customers to strengthen equipment service and project management throughout North America.
ZenRobotics Ltd. has appointed Wolfgang Schiller as the company's new CEO, effective immediately. Prior to ZenRobotics, Mr. Schiller was the Vice President Electronics Industry at KUKA AG, a leading supplier of intelligent automation solutions. According to ZenRobotics, as CEO, Schiller will be responsible for further developing ZenRobotics' business and accelerating the uptake of intelligent robots in waste management.
In the spring of 2018, Plessisville, Quebec-based Machinex introduced its new SamurAI sorting robot, which, according to the manufacturer, has since generated a lot of industry interest. Nearly six months after its launch, the response of the market has been very positive and nine robots have been sold to date. The first two SamurAI in Canada have just been installed in Quebec while six more robots will be installed by next year in Canadian sorting centers. Moreover, the company says they continue to have regular requests from customers who are greatly interested in this cutting-edge technology.
Greif, Inc., a global provider of industrial packaging products and services, announced December 20 that it has entered into a definitive agreement to acquire Caraustar Industries, Inc., the leading recycled paperboard and packaging solutions company, from an affiliate of H.I.G. Capital, in a cash transaction valued at $1.8 billion. The transaction is expected to close during the first quarter of calendar year 2019, subject to customary closing conditions, including regulatory clearances.
The Institute of Scrap Recycling Industries (ISRI) recently announced the release of its seventh annual Recycling Industry Yearbook, providing the most up-to-date information and statistics about the U.S. recycling industry and global scrap marketplace. With a greater spotlight on the industry in the wake of rising trade protectionism around the globe, the publication provides the most comprehensive analysis of where the industry stands based on the most current data compared to previous years. It will also serves as a baseline for years to come based on the new global market realities.
The purpose of paper recycling is to produce high quality recycled paper, responding to the high-quality specifications required by paper consumers either from the graphic, hygiene or packaging sectors. In consequence, any collection scheme should be designed in a way to provide grades of paper for recycling adapted to the requirements of high value recycling, according to the EN 643 to the paper industry, either directly or after sorting. (EN 643 is the European List of Standard Grades of Paper and Board for Recycling.)
CP Group, the San Diego-based recycling solutions provider and equipment manufacturer, unveiled their Virtual MRF over a year ago. Now for the first time, it will be on display internationally at Residuos Expo 2018 in Guadalajara, Jalisco Mexico.
TOMRA Collection Solutions has become the first reverse vending provider to offer digital vouchers as a payout option for container deposit schemes, where consumers receive refunds when they return their empty bottles and cans for recycling at a reverse vending machine.
Mondi, a global leader in packaging and paper has partnered with One Young World, the global forum for young leaders, on the Lead2030 initiative - a competition to find youth-led practical solutions to drive progress on the United Nations' Sustainable Development Goals (SDGs). Mondi has committed $50,000 to fund a project that will make a tangible contribution to SDG12 ‘Responsible Consumption and Production'.
This year's 19th edition of the Paper & Plastics Recycling Conference North America, held in Chicago from October 17 through 19th and produced by the Recycling Today Media Group, was a very informative, well organized and well attended event, and a good reflection of the mixed feelings currently being expressed by the industry with respect to the state of paper and plastics recycling. On the technology side of the industry, things are largely positive. Business is good. From the latest plastics additive and stabilizing technologies designed to enhance the physical properties and thereby the quality of recycled plastics for compounders and other reprocessors, to the significant advances in sorting, screening and other equipment being put forward by leading manufacturers, it is clear that there is solid demand, and excellent solutions available to help profitably create better quality recycled materials from challenging input streams. The advances in this sector are in fact rapid and ongoing. The latest robotic and optical sorting, coupled with artificially intelligent (AI) "learning" technologies, are particularly impressive - making it difficult for anyone to deny that high-tech materials sorting has a huge role to play in the future of this industry.
The ReWall Company, which turns recycled food and beverage cartons into environmentally friendly building materials, is set to open a new facility in Colorado that will expand end markets for recycled cartons in the western United States. ReWall makes high-performance, sustainable building and construction materials out of recycled food and beverage cartons through a proprietary process that uses no chemicals or water. It takes about 400 cartons to produce one sheet of ReWall's hail-resistant roof cover board.
This past summer, Van Dyk Recycling Solutions sponsored and hosted a webinar titled "MRFs in Crisis! Where do we go from here?" During the webinar, Van Dyk's sales manager and process Engineer, Adam Lovewell, along with colleague Mark Neitzey, focused on the topic of how recycling businesses have been struggling to deal with China's changes in import policy. According to Lovewell and Neitzey, the so-called "China crisis" has exposed serious issues throughout the recycling industry and "we have hit a critical point where owners and operators need to take a hard look at their equipment's ability to handle changes in the stream."
Recycling Today Media Group's 2018 Paper & Recycling Conference North America, the 19th edition, opened officially Wednesday, October 17 in Chicago, following the third annual day-long MRF Operations Forum dedicated to best practices at material recovery facilities. Jim Keefe, RT's Publisher opened the 2018 MRF Operations Forum Tuesday morning by welcoming approximately 100 attendees and introducing the first session: "Dynamic MRF Operations". The title is an appropriate one -- reflecting the overall theme for the day: with changing incoming recycling streams combined with changing global end markets, MRF operations need to be dynamic - adapting to changes and changing the way they operate - to maintain profitability.
Epax Systems, a specialist in waste management with more than 30 years of experience, recently developed a new method to control industrial compactors and balers called Axxess controls. According to the company, over the last decade, safety and security have become concerns for multi-use property managers who are seeking to meet Occupational Safety and Health Administration's requirements for controlling balers and compactors in their facilities. Since 2017, clients of Epax Systems, inc. have increasingly communicated the need to improve on their traditional key switch systems, which requires employees to use an on/off key switch to control their compactor or cardboard baler.
CP Group has introduced the CP Anti-Wrap Screen, the California-based recycling equipment manufacturer's second new screen of 2018. The new CP Anti-Wrap Screen accurately separates newsprint and large fiber from material streams by using high-amplitude elliptical discs to agitate material.
TOMRA Sorting Recycling has published a new e-book providing advice for businesses who sort paper and cardboard for deinking and recycling. The new online publication addresses the intensifying commercial and regulatory pressures for higher recovery rates of deinked pulp and the fact that meeting these demands will require new technical solutions. The e-book introduces an exceptionally effective new solution.
National Recovery Technologies (NRT) has integrated the company's NRT SpydIR® optical sorter with Max-AI® technology, creating a revolutionary new sorter with detection abilities unmatched in today's optical sorter market, according to the company. NRT's SpydIR technology uses near infrared light (NIR) detection to identify plastics, paper, wood and other materials by material type. Max-AI technology uses artificial intelligence (AI) to identify materials using a camera and neural network algorithm (NN). The NRT SpydIR with Max-AI optical sorter employs both detection technologies to create an optical sorter that is able to combine the information from each technology to deliver a unique sorting capability.
According to Austria-based Binder+Co, due to China's recently imposed scrap import restrictions, concerns are growing in Europe and in North America about how to cope with plastic waste. The industry is sceptical about reuse, because the required quality of secondary raw material is, for the most part, not ensured, and the use of plastic waste as alternate fuel in incinerators makes too little use of plastic as a valuable secondary raw material.
Canada Fibers Ltd. (CFL) has announced that it has filed a statement of claim with the Superior Court of Ontario asserting damages arising from breach of contract by the City of Hamilton. CFL's decision to file the claim follows over 12 months of negotiations with Hamilton staff that culminated in a recommendation by the City's staff proposing measures to resolve the breach and end the dispute. Unfortunately, Hamilton City Council has rejected the compromise recommended by staff and made it necessary for CFL to seek a remedy in the courts.
Norway's largest waste management company first to implement BHS Max-AI VIS to monitor outbound product quality
Norsk Gjenvinning (NG), Norways largest waste management company, has selected Oregon-based Bulk Handling Systems (BHS) to supply NG's new state of the art paper recycling system in Oslo. Operational in Q1 2019, the system will process 20 tonnes per hour (tph) and run three shifts to process approximately 120,000 tonnes annually. Noteworthy to this process is the inclusion of Max-AI VIS (Visual Identification System) units to monitor the quality of outbound paper.
International Baler Corp. (IBC) has begun production of their new ATX Auto-Tie baler series, a high-volume, "European style" baler for MRF and MSW applications. IBC is the first manufacturer to offer this class of machine in the USA. Built entirely in their plant in Jacksonville, Florida, IBC offers US customers a domestic alternative to the high cost and extended lead time of overseas shipping, parts, and service.
The Institute of Scrap Recycling Industries (ISRI), has released the following statement in response to China's announcement that it will impose a retaliatory tariff on the import of all scrap commodities from the U.S.: "ISRI is already hearing from contacts in China that the announcement has caused consternation among Chinese consumers of U.S. scrap commodities. Although these tariffs will not be levied on imports from other countries, it is our understanding that other regions may not be able to fulfill all of China's demand. This is in line with other reports that the trade war has had an impact on the Chinese economy across many sectors.
American Baler's latest model horizontal single-ram combines quickness and high force for up to 30 tph capacity
According to American Baler Company, the 8043 horizontal single-ram model has proven itself as a workhorse in hundreds of recycling centres around the world.
Paperboard to replace plastic for Swedish card manufacturer and others, including products from IKEA and Apple
According to a press release from Iggesund Paperboard, part of the Swedish forest industry group Holmen, a number of global companies have replaced, or are doing trials to replace, the material in their gift cards - from plastic to paperboard. Sweden's largest cinema chain, SF Bio, has taken the plunge and is now replacing all its cards.
As part of L'Oréal USA's annual Volunteer Day, held June 12th, Garnier USA recently sponsored an opportunity with TerraCycle and GrowNYC where employees worked to install a community garden at the El Gallo Social Club in Harlem, New York City.
Swedish waste management company, Lundstams, invests in robotic sorting to increase resource recovery
The Swedish waste management company Lundstams Återvinning AB and Mared AB have agreed on the delivery of ZenRobotics waste sorting robots to one of their facilities in Northern Sweden. The new sorting line will allow Lundstams to process waste more efficiently and closer to the source. The robotic sorting line is expected to be operational in the first quarter of 2019.
Future looks bright for recovered polycoated aseptic and gable top commodity prices according to Carton Council
Polycoated cartons, both aseptic (shelf-stable) and gable top (refrigerated) were given their own ISRI Paper Stock Industry (PSI) classification - PSI Grade #52 - in 2011. According to Isabelle Faucher, managing director of the Carton Council of Canada (CCC) this was a milestone for the industry.
Tightening global purity targets have the industry searching for new markets and high-tech equipment solutions
The recycling industry is in the midst of a seismic market shift. The world's largest importer of recycled material, and arguably the world's dumping ground for material with impurities, China, has said "enough" as it grapples with domestic environmental issues.