Among a ambit of accost and polymer processing systems in abode at the Vernon bulb are three Welex area curve supplied by Graham Engineering Corp. and able with EDI extrusion dies and BKG cook commitment apparatus from Nordson Corp.
rPlanet Earth Co-CEOs Joseph Ross (left) and Robert Daviduk (right) in the new bulb at Vernon, Calif.
rPlanet Earth, a new aggregation committed to closed-loop recycling of post-consumer plastics, has started up a ample grassroots ability that the aggregation calls the “world’s first” absolutely angular chip bulb for converting PET packaging decay into accomplished rPET articles with backdrop reportedly commensurable to those fabricated from abstinent PET.
The 302,000 sq.ft ability in Vernon, Calif., takes in bottles, clamshell containers, and added packaging decay from curbside collection; puts it through an all-encompassing alternation of allocation and charwoman procedures; grinds it into cell and accommodation it to accurate ablution and decontamination; raises the built-in bendability (IV) of the actual in accordance with end-use requirements; and processes it into food-grade sheet, thermoformed containers, and bang molded preforms for bottles. The new rPlanet Earth bulb has an anniversary accommodation of 80 actor lb.
The absolute advance at Vernon appropriately far is over $100 million. According to rPlanet Earth co-CEO Robert Daviduk, affairs are in the works to add a additional bales-to-end-product assembly band in the ability aural the aing two years. “The utilities and added basement are already in abode to abutment a new band that can accept a accommodation 50% beyond than that of our absolute line,” says Daviduk. “Our aggregation has affairs to body three or added new plants at sites abroad in the U.S. and possibly in added countries.”
Beyond recycling PET, rPlanet Earth meets added sustainability goals, acclaimed co-CEO Joseph Ross. “While our rPET packaging provides appearance, abstention and concrete backdrop commensurable to those of abstinent PET, our carbon brand is 60% beneath than that of packaging fabricated from abstinent adhesive and in actuality is 20% beneath than that for rPET articles from added companies,” says Ross. He added that the abstracts booty into annual curbside collection, baling, and busline as able-bodied as the operation in the Vernon plant. “In addition, our recycling operation uses 90% beneath water, per abundance of output, than a PET adhesive plant.”
Among a ambit of accost and polymer processing systems in abode at the Vernon bulb are three Welex area curve supplied by Graham Engineering Corp., York, Pa., and able with EDI extrusion dies and BKG cook commitment apparatus from Nordson Corp., Westlake, Ohio.
After bales entering the rPlanet Earth ability accept been burst into a distinct beck of bottles and thermoforms, the actual is subjected to assorted allocation procedures. Magnetized sorters aish adopted bulk such as wire; near-infrared scanners analyze PET and abstracted it from added polymers; and accession allocation footfall separates PET abstracts by color. Aing comes a dry arrangement for cutting the actual into flake; baptize is abhorred because it is a carrier for inks and adhesives that can abnormally affect the affection of the accomplished rPET. The aboriginal appointment with baptize is in the ablution line, area the actual is bankrupt afore it moves to a catchbasin area PET, which is added than water, sinks, while labels, adhesives, and added bulk are skimmed off. Subsequently the cell enters a Krones (U.S. appointment in Franklin, Wis.)MetaPure reactor area ~200 °C calefaction and exhaustion are acclimated in a final decontamination process; solid accompaniment polymerization (SSP) raises the IV of the rPET to assorted levels, depending on the ambition application.
rPlanet Earth bypasses the pelletizing footfall in favor of abacus bulk to cell by application it in its own centralized plastics processing lines. “By absence the pelletizing of rPET we potentially abstain aspersing our products’ appearance, back a melting footfall that can abnormally affect blush is absolutely eliminated,” Daviduk says. “Our barter are adorable for articles that appear from a absolutely closed-loop recycling system.” He acclaimed that rPlanet Earth can accumulation sheet, thermoformed packaging, or preforms whose rPET agreeable can ambit up to 100%, depending on whether or not a chump requires some allotment of abstinent PET.
The aggregation currently operates seven plastics processing lines: Two Husky, Bolton, Ontario, Canada, injection abstraction systems are for assembly of preforms; and three Welex, York, Pa., extrusion curve aftermath area for auction as rollstock to the merchant bazaar or for use centralized on two ample Lyle thermoforming machines. The thermoformed articles bogus by rPlanet Earth may accommodate bubbler cups, aftermath packaging, clamshell containers, and around any added food-grade thermoformed packaging currently fabricated from PET.
The three Welex area curve supplied by Graham engineering accommodate extruders that crop widths up to 75 in. and can be configured for coextrusion; XSL Navigator controls able of amalgam with plant-wide automation systems; Nordson’s BKG HiCon awning changers, BlueFlow accessory pumps, and changeless mixers; and Nordson’s EDI Ultraflex area dies. Graham Engineering additionally supplied array scanners, bend trim systems, winders, and added equipment.
“We spent an astronomic bulk of time researching plastics processing accessories suppliers and chose Graham Engineering because of their abstruse capabilities, their engineering and architecture support, and their Converge CTS [Conical Twin Screw] technology, which is added bunched and automated in allegory with conventional twin-screw systems,” Ross says. “It was a collective accommodation amid us and Graham Engineering to accommodate Nordson components. The in-line backflush adequacy of the BKG awning changers was decidedly adorable because this self-cleaning affection enables us to abstain shutdowns due to awning buildup. In addition, Nordson backed their EDI die with all-encompassing acquaintance in PET area processing, beyond that of added die suppliers.”
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