Recycling Systems Solutions Archive | Green Machine LLC

Giordano Cos., Newark, N.J.

Giordano Cos., Newark, N.J.,
“Mills love our Material”

Pictured from left, Mike Zakrewskim, Giordano Co.’s operations manager, and Pat Giordano, owner of Giordano Cos.

Pictured from left, Mike Zakrewskim, Giordano Co.’s operations manager, and Pat Giordano, owner of Giordano Cos.

Giordano Cos., Newark, N.J., installed its GREEN MACHINE single-stream/dry waste recycling system this spring and a GREEN EYE optical sorting system with glass breaker last summer.

Mike Zakrewskim, Giordano Cos. operations manager, says, “Our new GREEN MACHINE sort line is conservatively processing 22 TPH of both single-stream and dry waste materials and running that tonnage with only nine sorters.”

He adds, “Mills love our material.”

Pat Giordano, owner of Giordano Cos., says, “We’re very pleased with the GREEN MACHINE equipment and the startup process. It is a wonder working with John, Peter, Omar and the rest of the crew. They are extremely professional and customer oriented—that’s what puts them ahead of other recycling machinery companies.”

Giordano adds, “I’m pleased to be able to pick up the phone and call the owner of the company to get answers ASAP.”

GREEN MACHINE President John Green says of the Giordano Cos. installation, “It was a challenge to design a system which would suit their dual waste processing needs and fit into the existing building footprint without interfering with their current business. Pat and Mike were very involved in the final system design, and that really paid off.” He adds, “We hope that news of our success at Giordano Cos. will help foster more business for Green Machine.”

GREEN MACHINE single-stream/dry waste recycling system

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Systems With Robotics


AT $500,000.00


AT $1,500,000.00

We at Green Machine have focused our efforts to design a complete single stream recycling system that requires the least amount of upfront capital, labor, and building space. The complete system is capable of processing 6-12 TPH of traditional single stream material within a 17,000 sq. ft. building space with 20 ft. ceilings, and can be operated with only 5-10 employees!

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.

GREEN EYE® Robotic Sorter

GREEN EYE® Robotic Sorter

Hyperspectral Technology

Hyperspectral Technology

GREEN EYE® Optical Sorter

GREEN EYE® Optical Sorter

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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

Green Machine’s patented hyperspectral technology produces the industry’s most versatile and exacting automated sorting platform. GREEN EYE® optical and robotic sorting technologies have revolutionized the recycling industry. Since our first deployment in 2007, Green Machine engineers have continued to perfect our patented 3D artificial intelligence high-speed full-spectral collection systems, driving a wide variety of optical and robotic sorting platforms. High-speed sorting of difficult to identify materials such as all paper grades, polymers,
C&D products, textiles, e-scrap, ASR, organics and much more. Both positive, negative and mixed sorts are achieved through simple training methods. Each system can be trained to sort any commodity without exception. Singularly focused sorters are a thing of the past.

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.

GREEN EYE® Robotic SorterHyperspectral TechnologyGREEN EYE® Optical Sorter

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Trigon Plastics’ Baled Plastics Recovery Facility in Newmanstown, Pennsylvania

Trigon Plastics opened its plastic recovery and recycling facility one year ago and is now processing in excess of 35 million pounds of post-consumer scrap plastic annually. Owner James Allgyer has developed a full service approach which includes Optical Container, Flake sorting, shredding and wet granulation producing profile extrusions, pelletizing, Gaylord and super sack fill stations along with bulk truck silo loading. We’ve been successful thus far but see two areas for advancement: One, upgrading our 3-7 plastics through additional optical sorting,
and two, generate a source of high-volume low-cost, mixed-plastics to satisfy our growing business.

trigon plastics logo

We are upgrading our low-grade 3-7 plastics through additional optical sorting. Our GREEN EYE®Optical sorting systems are capable of sorting any commodity we train them to. We are adding a wider 84” higher volume GREEN EYE unit on the front of our system to increase our PET production allowing our existing (three) 60” wide GREEN EYE’s to then sort higher volumes of HDPE, Colored HDPE and now utilizing our last unit to sort #5 plastics. The remaining plastics are blown into a holding bunker where we could run those low-value plastics through the same GREEN EYE’s to further sort out 3,4,6,7’s. Low-grade mixed plastics are difficult to monetize, but when separated, they become more valuable.

We are now deploying a GREEN MACHINE® 20 TPH single-stream processing plant adjacent to our plastics recovery plant. We designed this plant to accept both single-stream and loose commingled containers. Our current GREEN MACHINE container processing system already handles our container stream so all we needed to add was the front end fiber GREEN SCREEN® Systems. Trigon Plastics will now be able to accept mixed bales of plastics, loose plastics and locally collected single-stream materials to separate, sort and produce a final recycled product all at one site. We believe that this full circle approach enhances our bottom line through the elimination of secondary brokers and costly trucking expenses.

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South Jersey’s Largest Commercial Recycling Plant

South Jersey’s Largest Commercial Recycling Plant Open for Business

Barrington, NJ – (RMR) Recycling Management Resources announces the commissioning of their GREEN MACHINE® commercial single stream recycling system. Owner, Reese Whitley, is ecstatic with the system’s tremendous throughput and clean sort. “We’re at full capacity right out of the gate processing our current tons and aggressively looking for more”

John Green, president of GREEN MACHINE®, says “This was a collaborative design effort which resulted in a system that efficiently processes multiple grades of commercial and industrial waste”.


GREEN MACHINE® is proud to offer only American made recycling products completely designed, manufactured, and installed in-house. Our 35 years of experience lend our customers affordable state-of-the-art technologies including our patented GREEN EYE®  hyperspectral optical sorters and recently released robotic sorters, which are only a couple of the many innovations we provide for less.


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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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In late 2018, New Jersey recyclers demanded that local governments remove mixed #3-#7 plastics from their curbside collection programs, which resulted in little change in those tonnages received. Tiffanie, of G&F Recycling located in Newark, NJ, understood that they couldn’t justify placing manual inspection sorters on the line to remove low value plastics, while avoiding added disposal costs. Tiffanie requested that Green Machine look into performing R&D on their existing GREEN EYE Hyperspectral Optical Sorter to improve their #3-#7 plastics sorting.

G&F had recently deployed a high capacity GREEN EYE to sort their high volumes of PET plastics, while their existing five-year-old GREEN EYE was placed after the new sorter to process all their HDPE plastics. In an effort to solve G&F’s problem, Green Machine set out to program G&F’s preexisting GREEN EYE to positively sort out all the #3-#7 plastics, while leaving the large HDPE plastics for hand sorting further down the line.

Green Machine’s optical engineer specialist, Neal Eason, led the field R&D endeavor. Neal says, “Green Machine’s patented GREEN EYE Hyperspectral Optical Sorter is essentially a high-speed spectrophotometer utilizing patented hyperspectral artificial intelligence. The machine can be trained to differentiate and separate a wide range of different plastic polymers, as well as other materials, individually or all at the same time. Giordano’s GREEN EYE is now programmed to sort #3-#7 plastics and a variety of other materials.”

Neal went on to explaining the results, “The enhancements made on their optical sorting system were so outstanding that Giordano’s GREEN EYE is currently able to produce highly marketable bales of #3-#7’s (see picture below). This reduced their labor and cut down their residue disposal costs. This feat is rarely accomplished in the recycling industry today. Now, Tiffanie and her father Pat need to decide whether to open the gates on #3-#7s”.

Green Machine’s patented GREEN EYE Hyperspectral Optical Sorters have now successfully added #3-#7s to the long list of materials they’re capable of identifying and separating including; SOP, OCC, newspapers, fibers, plastics, wood, textiles, aggregates, ASR, e-scrap, and more!

Plastic Recycling Inc, Plastics Recycling, Plastics Recycling Technology 2018, Plastics Recycling World

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Company leader discusses mixed-plastic sorting plans

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


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.


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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 Recycling Equipment Manufacturer