Pictured from left, Tim Dohner; Jim and son Jerry
Casual Living Unlimited’s newly commissioned baled plastics processing plant began accepting mixed bales this January. James Allgyer, owner of Casual Living, needed a cheaper, more reliable source of clean feed stock for his highqualityplasticwood furniture company.
Mr. Allgyer says, “My furniture company depends on high-quality resins to produce the exotic color schemes that separate us from the competition. Green Machine designed and manufactured a system that delivered us the clean product we needed to feed our grinders, wash tanks and ourplastic extruders.”
John Green, President of Green Machine, says, “It was a pleasure working with Jim and his two sons, Justin (furniture plant manager) and Jerry (recycling production supervisor). We all worked closely in determining a final design that would be capable of automatically processing highly contaminated bales of plastics.”
The Green Machine system design begins with an infeed system with a bale
breaker. Mixed plastic bales with fiber, fines and residue contamination are then fed to our rubber disc inclined polishing screen, where the agitation provided by our high speed rotating discs helps to declump bale fragments, while the waste fiber climbs to the top and declumped plastics with fines fall off the bottom. A 2” minus fines screen then removes all small particulates, and a cross belt magnetic separator collects metals. Three patent-pending GREEN EYE® optical sorting systems remove PET plastic, natural HDPE and finally colored HDPE. Each commodity
is blown to huge holding bunkers with live floor conveyors that automatically feed downstream processing equipment.
Mr. Allgyer says, “Our Green Eyes sort cleaner than any other system I visited. We are able to sort with little or no manual postsorting. We are ready to accept mixed plastics bales with plenty of contaminants and sort that material by grade at a rate of 10 tons per hour and produce the cleanest end product. We are now looking to buy mixed bales of plastics from recyclers all over the East Coast and use that material to produce our high-quality furniture products. Our company is truly a full-circle recycler now.”
Plastics Processing Plant