recycling horticultural films: handling and marketing lois levitan recycling agricultural plastics...
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Recycling Horticultural Films:Handling and Marketing
Lois Levitan
Recycling Agricultural Plastics Program (RAPP) Dept Communication • Cornell University • Ithaca NY 14853
MID-ATLANTIC FRUIT & VEGETABLE CONVENTION, SMALL FRUITS – JANUARY 29, 2015
LEVITAN, CORNELL UNIVERSITY
My Objectives• Convey that recycling horticultural film won’t
all be smooth sailing, but is do-able
• By end of talk, have a roomful of well informed recycling enthusiasts
•
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Did you know?
Plastics embody as much
energy as gasoline
LEVITAN, CORNELL UNIVERSITY
Topics
• What is recycling?
• Challenges to recycling horticultural plastics.
• Overcoming the challenges.
• Products made with recycled horticultural plastics. By whom?
• What I hope to learn from growers.
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PLASTICS RECYCLING CONFERENCE 2014 – LEVITAN, CORNELL UNIVERSITY 5
Plastics-to-OilHEAT + PRESSSURE ( + catalyst) oil or wax + inorganic residue (e.g., carbon black)
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Waste-to-Energy ≠ RECYCLING
ENERGY RECOVERY BY INCINERATION
(COMBUSTION AT HIGH HEAT)
Graphic: SICK Sensor Intelligence. http://www.sick.com/group/EN/home/solutions/industries/waste/Pages/waste.aspx
≠
United States: 67 large Municipal Solid Waste incinerators + several hundred industrial, medical and hazardous waste incinerators of all sizes (Source: Waste Incineration. Unites States Response to UNEP Questionnaire for Paragraph 29 Study, Enclosure 4a, Rev. May 2010)
Organic waste inorganic ash, flue gas + heat
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Fuel PelletsPLASTIC PELLETS or 10% PLASTIC + BIOMASS
burns hotter, flows better
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PP bulk bags
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Horticultural Plastics Many different film and rigid products.
Many colors, multi-colored.Different resins, & mixes of resins, with additives.Mostly low density PE, but also HDPE, PP, PS.
PVC used historically; some still used, particularly in imported products.
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Greenhouse & tunnel covers
Mulch film
Plant pots, flats, trays: PE, PP, PS
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Horticultural PlasticsChallenges to recycling
• characteristics inherent to these plastic products
• characteristics of the products after use in fields & nurseries
• cost and logistics of collection and transport from fields (or nurseries) to recycling markets
3 categories:
Photo: Delta Planstics
Challenges to recycling:• characteristics inherent to complex, technical productsThin films with multiple extrusion layers, each with additives and colorants for specific agronomic or horticultural purposes:
Block UVRepel insectsAbsorb or reflect heatEVOH O2 barrierHold moistureReinforce structurePrevent backwashStretchabilityStickinessTensile strengthFlexibilityRigidityLongevityDegradability
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John DeereMax-Flat PEirrigation drip tape
Jphn Deere Pro-Flat
PVC drip tape
Plant pots, flats, seedling trays HDPE, PS, PP, blown, molded, thermo-formed
Photo: Lois Levitan, RAPP
LEVITAN, CORNELL UNIVERSITY
Maple syrup tubing Mostly LDPE tubing (some old PVC tubing) with fittings, connectors, and ball valves of nylon, polycarbonate,rubber
Photoa: Lois Levitan, RAPP
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Photo: Lois Levitan, RAPPUsed & stored outdoors, in mud, rain & snow
Often with residues of soil, plant debris, moisture, stones & grit Possible or perceived pesticide residues & soil pathogens
Bulky
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Photos: Lois Levitan, RAPP
Challenges to recycling:• characteristics of products after use (post-consumer)
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Photo: Delta Plastics
Delta Plastics (L)LDPE irrigation polytube,
Challenges to recycling:• characteristics of the products after use (post-consumer)
Photo: Lois Levitan, RAPP
Baled mulch filmMulch film: strips of LDPE, typically ≤ 1 mil thick ( high surface:volume ratio).Lays on soil, gets very dirty.
White, black, silver, occasionally clear or other colors. Sometimes 2+ color layers. Some with nylon or EVOH O2 barrier layer.
Photo: Sky Plastics
Pesticide containers, chemical drums. HDPE.
Example of Extended Producer Responsibility (EPR): Ag Container Recycling Council (ACRC) financed by pesticide manufacturers and distributors. ACRC protocols require triple rinsing, special handling & approved end-uses that minimize exposure. ACRC oversees a national network of collectors, processors, end-product manufacturers. 10 million lb collected 2014; 150 million lb since began in early 1990s.
Photo: Lois Levitan, RAPP
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Photo: Nate Leonard, RAPP
Horticultural Mulch Film: Before & After Washing
BEFORE WASHING 1 MINUTE LATER
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Paul Vanderpool: “Recyclers have learned how to recycle better”
Photo: Lois Levitan, RAPP
New technologies & advances in processing equipment creating new recycling options
F. Paul VanderpoolAmerican Cierra Corporation491 Grant Ave. Auburn, NY 13021office 315-252-6630. m 315-730-6156email: paul@cierrainc.net
“Recyclers have learned how to recycle better”
www.americancierraequipment.com19Photo: Lois Levitan, RAPP
• Mobile film reclamation system
• Cleans film ON-SITE, allowing flexibility in scheduling
• Bales film for shipment ON-SITE
• Self-contained, small footprint
• Meets all California power plant restrictions
• Cleans film with proprietary non–water processes
• High volume capacityContact:
Lloyd Gleaves, CEO209 495-1282, <lloyd@romallindustries.com>
Mobile cleaning, baling, grinding equipment
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Photo: Romall Ind
Best Management Practices (BMPs)
What not to do!
• Keep plastic clean and dry as possible
• Shake out pebbles & clumps of soil
• Roll or fold into pillow-sized bundles
• Store off ground, out of mud, grit, gravel
• Separate plastic by color and type
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Photo: Jim Zecca. Madison Co
Greenhouse, hoophouse, high tunnel coversClear or white sheets of (L)LDPE. Excellent quality for recycling.Challenge: Keep clean & remove efficiently, meeting needs of growers & recyclers
Photo: Lois Levitan, RAPP
LEVITAN, CORNELL UNIVERSITY
Without prep for baling:
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Photo: Jim Zecca. Madison Co
4 hrs to finish bale, vs. ½ hr with plastic prepped in stacked
bundles
1.
2.
3.
4.
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Efficient compaction:
Challenges to recycling:• Cost & logistics of collection and transport from fields or
nurseries, etc. to recycling markets• In most of the U.S., agricultural plastics are dispersed
acrosss the rural landscape high costs of collection
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Difficult to amass full 40,000 lb truckloads
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Why should society & recyclers care about this particular set of plastics?
• Less than 2% of plastic discarded in US, but possibly 10% of film*
• Very visible 2-10%
• When left in the fields catches in bushes, ditches, ravines
• Alternatives to recycling not pretty: burning, burying in fields bad for air & water quality
• Landfilling costly to society
• Societal value of recycling >> economic value: All society benefits from conservation of resources & energy.
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Plastic discarded in US
Agr film
*based on VT data calculated by Annie
Macmillan, VT Agency of Agriculture.
LEVITAN, CORNELL UNIVERSITY
Agricultural Plastic Recycling Markets: Processors (Reclaimers) &
Manufacturers
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• Domestic markets can & do process used horticultural plastic.• Location. Location. Location. More options, less costly to
recycle where farms (& plastic use) are concentrated: FL, CA.• Smaller, regional recycling markets important for co-mingled
supply from less concentrated areas.• Some recycling markets vertically integrate to guarantee
supply & increase efficiency. • Some pick up & some require drop-off.• Only a few pay for material.• Some take-back products after use & give credit on purchases.
Recycling markets typically put < value on difficult-to-recycle plastic than it costs to collect & transport.
BUT
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http://www.deltaplastics.com/
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recycling@deltaplastics.com800.277.9172
Capacity to recycle 200 million lb/yr, with potential to double. Only (L)LDPE
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http://encore-recycling.com/• Recycling arm of
Command Packaging.
• Opened late 2013
• 100 million lb/yr capacity (CA uses 150 mm lb/),
• Convert mulch film to 125x reusable smarterbags™ .
• $3 million CA grant Nov’14.
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http://www.flagplastics.com/
Opened 2014. Collect mulch film & drip tape from large Florida farms. Shred, clean, dry film. Sell to pelletizers worldwide. 40 million lb/yr at current site.
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http://www.netafimrecycling.com/
California collection area only. Pay based on dry weight polyethylene tubing, 8¢/lb towards new orders, 4¢/lb cash.
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http://www.bridoncordage.com/forage/revolver.html
bridon cordage
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The Blackmore Company http://www.blackmoreco.com/Call (800) 874-8660 about recycling polystyrene trays.
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http://www.eastjordanplastics.com/recycling-program
Manufacture & recycle plant
containers: HDPE, PP, PS.
10 million lb/yr recycling capacity
NBF Plastics: plywood substitute, PIMS technology, anticipate 1-2 million lbs/yr
TERREWALKS® sidewalk pavers from
agricultural bale wrap, thermokinetic
processing
info@terrecon.com
Top skin: blue boat wrap
Top skin: black & white silage bag film
Top skin: maple tubing
& fittings
Core: Irrigation drip tape
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TERRECON
Dishashish Plastic Manufacturers LLC: garbage bags, ~ 20% recycled b/w silage bags (1 million lb/yr). ashish@dishallc.us
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Photo: Lois Levitan, RAPP
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Lois Levitan, PhDRecycling Agricultural Plastics ProgramDept Communication, Cornell University
Ithaca NY 14853lcl3@cornell.edu 607-592-0356
QUESTIONS from YOUR EXPERIENCE:• Efficient methods/equipment that minimize dirt/debris in removing cover plastic & mulch?
• Rollers, balers or other equipment that compact plastics tightly for transport?
Please
contact
me!
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