Firststar recycling 8 tph container processing system

Firststar Recycling’s 8 Tph Container Processing System Highlighted by Green Eye® Hyperspectral Optical Sorters

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!”

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Company leader discusses mixed-plastic sorting plans

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This article originally appeared on the website of industry publication Resource Recycling.
The original article

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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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Midwest facility upgrades plastics sorting capabilities

This article originally appeared on the website of industry publication Resource Recycling.
The original article

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.’”

Earlier changes

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.

PLASTICS RECOVERY FACILITY (PRF) EQUIPMENT

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Optical Sorter Recycling Green Eye®

Equipment Spotlight: Optical sortation ‘down to the molecular level’

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.

Green Eye Optical Sorter

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Green Machine® proven technology is key to your Plastic’s Reuse/Recycling operation

Green Machine® proven technology is key to your Plastic’s Reuse/Recycling operation

Processing recycled plastics can be a lucrative endeavor. Ensuring you can process extremely clean and efficiently sorted plastic material is necessary to ensure recycled plastic streams maintain the highest value for resale as compared to new plastic. PRF’s process recovered scrap or waste plastic and reprocess the material into useful products, often in completely different in form from their original state. Whether you’re mining PET, HDPE or other plastics for your process, the sort can be accomplished using Green Machine Sorting Technology enhanced by Green Machine’s Green Eye Optical Sorters.  Better equipment equals greater profitability for your company.

The process of plastic recycling includes melting down used plastics and uses the material for casting products such as plastic chairs and tables. These recyclables are then re-introduced into the main production operation. This closed-loop operation has taken place since the 1970s and has made the production of some plastic products among st the most efficient operations today.

Compared with lucrative recycling of materials, such as glass and metal, plastic polymers recycling is often more challenging because of low density and low value for particular materials. There are also numerous technical hurdles to overcome when recycling plastic.

For example, when different types of plastics are melted together, they tend to phase separate like oil and water, and set in these layers. This causes structural weakness in the resulting material limiting the application of the polymer blend.

Another barrier to re-use is the widespread use of dye, filler and other additives in plastics. The polymer is generally too viscous to economically remove fillers, and would be damaged by many of the processes that could cheaply remove the added dyes. Additives are less widely used in beverage containers and plastic bags allowing them to be recycled more often. Yet another barrier to removing large quantities of plastic from the waste stream and landfills is the fact that many common but small plastic items lack the universal triangle recycling symbol and accompanying number. Sorting by hand can be difficult or impossible.

This explains why proper sorting using Green Machine® proven technology is key to your Plastic’s Reuse/Recycling operation. Separate what you need for your operation, whether it be polymer, polymer additives, or color or we can efficiently and effectively sort based on your process requirements.

 

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GREEN EYE® OPTICAL SORTER Improves Commercial Waste Processing

GREEN MACHINE® vastly improves existing commercial waste systems with the addition of its patented GREEN EYE® optical sorter.

Watch our GREEN EYE® Commercial Waste Optical Sorter!

Our Hyperspectral vision system successfully sorts both dry and wet cardboard from mixed waste streams. Other technologies have difficulty identifying damp product, wax cardboard, kraft, and box board fibers. In addition we identify and sort all fiber grades producing clean grades of ONP and SOP.

INDUSTRY’S MOST VERSATILE AND EXACTING OPTICAL TECHNOLOGY OVER 10 YEARS developing our hyperspectral identification systems and our artificial intelligence software provides the industry’s fastest and cleanest sort rates of fibers, plastics, woods, textiles, aggregates, ASR, E-Scrap and more!

PATENT ANNOUNCEMENT!!!!!!!
UNITED STATES
US PATENT NO. APPLICATION FILING DATE ISSUANCE DATE
9,950,346 11/18/2008 4/24/2018

CANADA

CA PATENT NO. APPLICATION FILING DATE ISSUANCE DATE
2,688,805 11/17/2009 2/7/2013

GREEN EYE® OPTICAL SORTER Improves Commercial Waste Processing

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Our State of the Art Recycling Equipment

Our new equipment can process 600 tons of recyclable materials per week. Those materials might otherwise have ended up in Seneca Landfill. While landfills are necessary and have many benefits, their space is limited and certain materials do not break down quickly. Recyclable materials linger in landfills, taking up valuable space, for years or longer.

By processing more materials with greater accuracy, we help ensure that plastics, metals, paper and other recyclable materials are able to be reused instead of wasted. This saves space in the landfill as well as conserving natural resources used to make consumer goods.

 

How Does It All Work?

Loading Recyclables into the Green Machine

Here, a front-end loader deposits mixed recyclable materials from both residential and commercial sources into a dual-side feed metering bin system.

TC Recycling facility | Loading Recyclables into the Green Machine

 

 

Elevating and Pre-Sorting

The material is then deposited upon an in-feed system which elevates the materials up to a pre-sort mezzanine area. Sorters manually remove heavy metals, plastic bags and rigid plastics from the stream.

TC Recycling facility | Elevating and Pre-Sorting

Cardboard Removal

The Green Machine OCC Separator system is designed to remove large bulky cardboard from smaller mixed containers and small fibers. The bulky cardboard is then deposited upon a post-sort conveyor where sorters perform a manual post-sort, removing any non-brown, non-cardboard materials. Cardboard is later baled and shipped for processing.

TC Recycling facility | Cardboard Removal

Paper and Fiber Removal

The material which passes through the OCC stream is deposited upon a Green Machine polishing system, which separates fibers (such as paper) from containers. The fibers rise to the top of the stream and are deposited upon a post-sort conveyor, where inspection sorters remove any non-fiber material. Clean paper and fiber materials are later baled and shipped for processing.

TC Recycling facility | Paper and Fiber Removal

Mini Polisher and Glass Breaker

The mini polisher system takes the material which falls off the major polisher for a secondary cleanup, helping to remove the balance of the fibers from the containers. The containers fall off the bottom of the stream, and then travel across a glass-breaker system, where glass is removed and fiber is then also removed from the glass product. Clean glass is deposited outside in a bunker for daily landfill cover or glass recycling.

 

TC Recycling facility | Mini Polisher and Glass Breaker

Ballistic Bounce Separator

Again, containers removed from the bottom of the mini polisher stream are deposited upon a glass breaker, where fines are removed. Those containers are then transported to a Green Machine ballistic bounce belt separator, where fibers and 2-D materials rise to the top of the separator and containers fall off the bottom. Containers and non-conforming fibers are manually removed from the stream.

TC Recycling facility | Ballistic Bounce Separator

PET and HDPE Removal

Then, HDPE sort system removes all of the high-density polyethylene plastic bottles, such as laundry detergent and milk jugs, for post-sort.

TC Recycling facility | PET and HDPE Removal

Aluminum Removal

The eddy-current separator removes all aluminum UBCs (used beverage cans) from the waste stream.

TC Recycling facility | Aluminum Removal

Material Separation and Storage

Bunkers holding sorted, clean materials are automatically discharged, flow to a baler feed conveyor which then flows to a final processing/baling system.

TC Recycling facility | Material Separation and Storage

Baling Materials

The baler makes highly densified bales of product, tying them with wire for transportation via truck. Although this is the last stage in the process at the TC Recycling facility, the materials we process go on to be used by our customers to create new products.

TC Recycling facility | Baling Materials
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PROGRESSIVE WASTE SOLUTIONS OPENS SINGLE STREAM PLANT IN TAMPA AREA

Progressive Waste Solutions Opens Single Stream Plant In Tampa Area

PROGRESSIVE WASTE SOLUTIONS OPENS SINGLE STREAM PLANT IN TAMPA AREA
PROGRESSIVE WASTE SOLUTIONS OPENS SINGLE STREAM PLANT IN TAMPA AREASt. Petersburgh FL, Progressive Waste Solutions has recently opened a new Materials Recovery Facility in the Tampa area. The newly commissioned system is designed to process both Residential Single Stream and Commercial Dry Waste recyclable materials. Progressive Waste Solutions system was designed and manufactured by GREEN MACHINE® a New Hampshire based company which also manufactures in Upstate, New York. The manufacturer’s President, John Green, says, “We are pleased to now have a presence in the fast growing Florida market. We hope that the success we’ve experienced in the Tampa area will open doors for more projects for GREEN MACHINE Contracts with Hillsborough County mandated that our customer start processing within a tight time frame from the award of contract. We are proud to say we met Progressive’s contractual obligations”. Jonathan Abrams, Manager of Waste Diversion Initiatives for Progressive Waste Solutions was pleased with his choice in vendors. Immediately following Green Machines successful throughput acceptance test Mr. Abrams said, “I am happy the performance of the Green Machine System. We estimate that our throughput exceeds the design capacity and the end product quality is very clean.
SINGLE STREAM PLANT IN TAMPA AREASINGLE STREAM PLANT IN TAMPA AREASINGLE STREAM PLANT IN TAMPA AREA

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green machine recycling equipment manufacturer

Components And Systems For Any Recycling Application

Does your sorter see thru outer shrink wrap labels? Can your sorter identify black and white
colors with ease? Can your sorter identify bio plastics, PVC, styrene and barrier bottles? GREEN EYE® CAN DO ALL THIS + MORE!

GREEN EYE CAN DO ALL THIS

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Green Machine Upgrades County Waste Facility in Virginia

Green Machine Upgrades County Waste Facility in Virginia

Green Machine Upgrades County Waste Facility in Virginia

Scott Earl, president of County Waste – stated; County Waste of Virginia purchased an existing recycling facility in Virginia in March 2014. At the time of the acquisition of this recycling facility, we realized that the existing system was inadequate for our long term needs. Our previous company, County Waste (Clifton Park, NY) had selected Green Machine to build a 30+ ton per hour single stream recycling facility located in Albany, New York back in 2010. Based upon our previous great experience with Green Machine, we sole-sourced selected Green Machine to retrofit, modify and build a new single stream recycling system for our newly acquired recycling facility in Virginia.

Now that we have the experience of having our new single stream recycling system up and running in Virginia, we can tell you the following:

  • The new system was up and running 3-4 weeks SOONER than promised
  • The new system came in right ON budget, with no material change orders
  • The new system is producing QUALITY end product baled recycled material
  • The tonnage per hour throughput of the system is DELIVERING as promised

I am a very hard person to please. However, what else can I say about Green Machine other than our Company received equal to or better than we bargained for on every key perimeter of purchasing and operating a new recycling system.
Green Machine got the job done for us and I give them my highest recommendation.

Scott T. Earl,
President and CEO

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Welcome to Green Machine

Green Machine manufacturer and designer of waste recycling equipment specializing in waste recycling processing systems.

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