Check out Green Machine’s latest MRF enhancement featuring the addition of two patented Green Eye® Hyperspectral Optical Sorters, commissioned to upgrade single-stream fibers from a #54 mixed fiber grade to an exportable #58 clean sorted news mix. See the system in action for yourself!
GREEN EYE® Sorting Technology
Brookhaven, NY, home to one of Long Island’s first dual-stream recycling systems, recently invested in upgrades to their existing container processing line under the new ownership of Winters Brothers Waste Systems. Jeff Nella, Winters Bros. GM, commended Green Machine and Winters Bros. tenured employee, Billy Brennan, for executing what he called a “swiss army knife” approach to recycling systems integration.
The Brookhaven system currently processes 30 TPH of commercial and residential single-stream materials. The new container sort line, built on the back-end of the system, processes 10 TPH of unpicked recyclables remaining after front-end fiber sorting.
Pick Containers & Fibers With a Single Optical Sorter
Revolutionary to the recycling industry, is the deployment of a patented Green Eye® Optical Sorter that, with a push of a button, has the ability to pick containers or fibers, and direct each to the appropriate location on the system. Winters Bros. finds it extremely valuable to process their 10 TPH of containers, and then have the ability to enhance fiber-rich material streams missed by the front-end system. Additionally, another Green Eye® Optical Sorter was deployed in sequence to pick remaining OCC and integrate it with the cardboard sorted on the front-end. Future plans include deploying Green Eye® Robotic Sorters to pick remaining valuable plastics.
Ready For Any Material Stream
Jimmy Winters, Owner of Winters Brothers Waste Systems, says, “Communities in our area are collecting their recyclables mixed (single-stream), separated (dual-stream) with or without glass, along with commercial streams of all types. We feel confident that our new processing system is ready for virtually any material stream dropped on our tip floor.”
Halfmoon, N.Y.; Green Machine® is building their most advanced waste processing system for Rose’s Responsible Recycling, LLC to handle 20+ TPH of residential and commercial waste in the greater Albany area. The brand new facility is equipped with all of Green Machine’s latest technological advancements including seven of their re-designed patented Green Eye® Optical Sorters, an array of newly released Green Eye® Robotic Sorters, as well as their new wrap-resistant disc and spacer designs.
John Green, President of Green Machine Sales, LLC, says, “We’re excited to be able to showcase our latest and greatest. For the past few years, we’ve been putting our nose to the grindstone to design and build recycling equipment that can meet high-grade specifications, despite uncertain market trends, as well as have the flexibility to process many types of material streams. This system is designed to handle dual-stream, single stream, commercial & dry waste, baled plastics, and we guarantee that this automated plant will produce the countries cleanest paper grades.”
Rose’s Responsible Recycling, LLC plans to start processing waste and recyclables in June 2020.
Green Machine Sales, LLC is proud to introduce its revamped patented wrap-resistant disc and spacer design for their GREEN SCREENS®. As a result, Green Machine’s screens have increased protection against material wrapping and jam-ups by optimizing the size and geometry of its discs and spacers, all while keeping the preferred two-piece design for easy maintenance and disc spacing modifications.
Larger Spacer Diameter & Reinforced Disc Longevity
Changing Green Machine’s spacer shape from a hexagon to a pentagon made it possible to increase its diameter, while keeping the two-piece rubber finger disks. The larger diameter and decrease in space between shafts both inhibit material wrapping and reduce the possibility of material jams. The discs were also updated with thicker fingers to increase durability, while improving the ability to throw material forward enhancing tonnage capacity.
This new design is being deployed on current and future GREEN SCREENS® and can be implemented in many of Green Machine’s current systems as an upgrade.
MODULAR SORTING SYSTEMS STARTING
AUTOMATED SYSTEMS WITH ROBOTICS
Our modular phased approach requires little to no site work and enables recycler’s low initial start-up costs with the ability to grow.Manual, semi, and fully-automated systems utilizing hyperspectral artificial intelligent optical and robotic technologies.
When Your Integrator Can’t Integrate!
Green Machine’s recycling systems integration capabilities are unmatched. Our in-house 508-A UL listed panel building shop, design engineers, and installation/field wiring crews coupled with 100% control over our American-made component manufacturing ensures every project’s timely success. With over 35 years of retrofit experience, Green Machine can foresee obstacles and simplify your project for the most economical approach. One party having control over every aspect of your project is our key to success. Eliminate costly finger pointing and call on the experience Green Machine offers.
Retrofitting Your System with Patented GREEN EYE® Automation
The GREEN EYE® Product Testing Facility located in Hampstead, N.H., is prepared to provide exhaustive testing of your difficult-to-sort products, ensuring success prior to deployment.
Tim Houlden, project manager, and Mike Bachman, plant manager, with FirstStar Recycling, Omaha, Nebraska, visited with suppliers of virtually every brand of optical sorting technology available in the U.S. and chose Green Machine’s Green Eye® Optical Sorters.
Tim and Mike were impressed with Green Machine’s economical approach to meeting every system design parameter. They say, “Green Machine designed a sortation system to meet our specific quality and production goals. The system has delivered.”
FirstStar was sold when they witnessed the amazing volumes of clean plastics produced by the Green Eyes they visited at TC Recycling in Mars, Pennsylvania.
Peter Mendre, Green Machine’s systems engineer and inventor of Green Eye® technology, says, “Our patented hyperspectral vision systems coupled with our Ai software produces the world’s fastest and cleanest multi-material optical sorter. For instance, on plastics alone our technology can sort every grade of plastic by polymer and color. Additionally, we are able to identify subset commodities like barrier bottles, thermoform food containers, and bio-plastics. We are able to program mixed groups, isolate unwanted rejects, and produce clean material streams for any market. We programmed FirstStar’s first Green Eye to pick PET and their second Green Eye to pick #2 natural HDPE and #3, #4, #5, #6 and #7 plastic grades together, while leaving #2 colored HDPE and residue to pass through to manual post-sorters. Mike Bachman says “Our post-sorters could not keep up with picking all the #3-#7 plastics. This Green Eye programming eliminated downstream sorters and maintained our highly marketable material streams. We would need an army of people to sort what our two Green Eyes can”.
FirstStar was also impressed with Green Machine’s turn-key project approach. Green Machine designs, manufactures, and installs every system and component totally in-house exclusively using American-made components. John Green, owner of Green Machine, says, “It’s both patriotic and smart. Customers appreciate local parts availability and American durability. Processors choose Green Machine for our equipment durability, economical costing, and innovation. Get ready for the introduction of our affordable hyperspectral robotics!”
A Utah recycling facility plans to sort 500 to 600 tons per month of mixed plastics, selling the resulting bales into domestic markets.
Alex Bearnson, president and CEO of Logan, Utah company Revolve Recycling, recently spoke with Resource Recycling to provide more details on his company’s plans to boost consumption of mixed-plastic bales.
Plastics Recycling Update, sister publication to Resource Recycling, in late September reported the company is upgrading its MRF with additional sorting equipment. First opened in summer 2017, Revolve Recycling will take in bales of plastics Nos. 1-7 from across the Western U.S. The company will create PET, HDPE, rigid LDPE and PP bales.
Bearnson said Revolve Recycling is installing a Green Eye optical sorter from Green Machine, adding to an existing one the MRF is currently using to eject PET. It’s also installing a metering bin, screens and conveyors. The improvements will allow the company to significantly boost mixed plastics output, which Bearnson said is currently about 200 tons a month.
Revolve Recycling was founded by members of materials brokerage ACP Solutions Group, which is co-located on the site and manages material acquisition and logistics for Revolve. Bearnson explained that ACP used to have Chinese markets for 1-7 bales, and after those dried up, company leaders realized they could make domestic sorting pencil out if they were efficient enough.
“Everybody thinks that we’re nuts,” he said. “I think it’s just how we’re operating – I think we’re operating pretty efficiently. We’re not raking in billions of dollars, but we’re doing OK, you know what I mean?”
If there’s one thing that he’s learned, it’s that “we’ve got to adapt,” he said. “We can’t be complacent.”
Photo credit: Katerina Morozova/Shutterstock
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A $2 million below-market loan from the Closed Loop Fund is helping a Nebraska company retrofit its materials recovery facility to better target PET and HDPE. The project is the latest such equipment improvement for First Star Recycling.
The Closed Loop Fund announced in January that it has invested in the Omaha-based company, which runs a single-stream MRF in the city.
In an interview, First Star Recycling CEO Dale Gubbels told Resource Recycling the project will address the “bottleneck” in the Omaha MRF, the container line. “It’s really bringing us into the 21st century in terms of our capabilities,” he said.
Container sorting improvements
The retrofit involves installing two optical sorters and bunkers that feed directly to an in-ground conveyor. New Hampshire-based Green Machine is supplying equipment for the project.
The optical sorters will target clear HDPE and PET. The in-ground conveyor will carry sorted recyclables directly to the baler, replacing the use of cages that have to be moved by forklift. Equipment installations will occur in March and April.
The project will yield both quantity and quality benefits on the container line. The line was first installed in 2005 and has relied mostly on hand sorting for plastics. Gubbels noted that the 2007 addition of plastics Nos. 3-7 overwhelmed the MRF container line, resulting in frequent stoppages. Currently capable of sorting about 1 ton per hour, the upgraded container line will tackle about 3 tons per hour, Gubbels said.
Gubbels noted the facility is still accepting 3-7 plastics, and although the market is “not terribly robust,” it’s sending mixed-plastic bales to the recently reopened ReVital Polymers plastics recycling facility (PRF) in Sarnia, Ontario.
Gubbels estimates the company is investing a total of about $2.4 million. That number includes the current retrofit and the installation of a ballistic separator last fall.
First Star Recycling’s bank was prepared to lend money for the project, but when Gubbels explained Closed Loop Fund’s loan terms, the banker “barely let me finish the sentence and said ‘If you don’t do it, you’re crazy.’”
Last fall, Fiber Star Recycling replaced a star screen with a ballistic screen for the separation of two-dimensional materials from three-dimensional ones. That project was separate from the Closed Loop Fund loan.
“The ballistic screen has proven to be a much better approach for us to deal with separating the containers from the two-dimensional fiber,” he said. “It’s doing a great job on that.”
The company knew it needed to improve the fiber-container separation before it installed the optical sorters on the container line, Gubbels said. Otherwise, too much fiber would have been left on the belt at the optical sorters.
The Omaha MRF was also one of the first U.S. facilities to install a robot with artificial intelligence. In Nov. 2016, First Star Recycling installed a robot from Denver-based AMP Robotics. It was only the second U.S. MRF to introduce the advanced technology, after the Alpine Waste and Recycling Altogether Recycling MRF in the Denver area.
In Omaha, the robot is sorting clear HDPE. Gubbels suggested that after the retrofit is finished this spring, the robot might be moved to a quality-control function or a different location where it’s handling lower volumes.
Green Machine has released an optical sorter that incorporates newly patented technology.
The Green Eye Optical Sorting Recycling System provides an automated sorting process that incorporates artificial intelligence, according to its manufacturer. Its learning ability gives it “the flexibility to sort multiple commodities with the ability to evolve with each market challenge in real time,” according to Green Machine.
The optical sorter can handle a conveyor operating at up to 900 feet per minute. The optical unit collects three-dimensional information about each item that travels through its field of view. It collects details “down to the molecular level,” according to Green Machine.
“This lets the Green Eye system remove or block undesired materials from the air ejector miss-hits,” the company says. It can achieve a clean pick rate that operates with at least 95 percent accuracy.
According to its patent, the optical sorter uses a hyperspectral camera that observes infrared and visible light that gives it information about the target material. A single sensor identifies items by composition and color with a higher degree of positive identification.
“In most cases, this optical sorting system removes any need for post sorting,” the company stated.
The Green Eye equipment is designed for plastics recovery facilities (PRFs) and other standard residential recyclables processing plants.
The patent was filed for in April 2014 and issued in April 2018.