The Changing Face of Plastics Recycling

The Big Story Headline Article in British Plastics & Rubber (Nov/Dec 18 Issue)

The BBC’s Blue Planet II appeared on our television screen in September 2017.  The amazing documentary series highlighted the challenges faced by marine life and generated a global anti-plastic tidal wave that shows no sign of diminishing.  However, has anything actually changed?

Since September 2017, there has been a swathe of political rhetoric culminating in the UK’s Autumn 2018 budget announcements.  Chancellor Philip Hammond outlined several new measures to tackle plastic waste.  This included introducing a new tax from 1 April 2022 on produced or imported plastic packaging that does not include at least a 30 per cent recycled content.

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Baled cleaned plastic waste

The European parliament is also taking action against plastic waste.  Under the parliament-backed directive, items such as plastic straws, cotton swabs, disposable plastic plates and cutlery would be banned by 2021.  Additionally, 90% of all plastic bottles would be recycled by 2025.

However, the fundamental difficulties in collecting, separating and re-using plastic remain.  In the UK, each council adopts their own recycling strategy.  Households in different regions are told to separate and collect different materials.  Swindon council has taken one step further and is considering burning plastic along with other rubbish rather than sending the material abroad for recycling.  Other councils, such as Basingstoke, has instructed residents to only recycle certain types of plastic.  Despite the Chancellor committing £20 million to tackle plastics and boost recycling, there is no unified country-wide strategy.

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Baled plastic waste

The successful recycling of any material requires good planning and execution.  Ironically, this must start at the end of the process.  Firstly waste plastic must be clearly categorised into material than is recyclable and unrecyclable, possibly using the global definition proposed by Plastics Recycling Europe and The Association of Plastic Recyclers.  This ensures that recovered plastic waste can be re-used.  Recovering, transporting and then discarding materials than are unrecyclable is costly in terms of effort, money and energy.

Ongoing research and changes in product design, will identify new techniques to broaden the scope of recyclable plastic waste.  The criteria for plastic waste collection will change accordingly.

Secondly. strategically located plastic waste recycling plants are needed to keep transportation to a minimum.  Each plant will receive the same mix of plastic waste, enabling continued development and improvement of the recycling process.  This stops each plant having to develop unique processes to suit the plastic waste collected in one region.

Hanbury Plastics Bunting Overband Magnet-2
Plastic Waste Recycling Plant

By having a clear country-wide recycling collection specification, contamination levels of the plastic waste will reduce.  Separation technology, such as magnetic separators and metal detectors, will still be required, but the purity levels of the end-product will increase.

Bunting Magnetics Drawer Magnets at Ecovyn
Metal contamination removed from granulated plastic waste

Politicians have only introduced these new policies due to the unprecedented reaction from the general public.  However, setting a target without any definitive plan of how to achieve that result may be considered foolish.  Equally, introducing new taxes, that may ultimately be paid by the consumer, is not addressing the key issues that prevent plastic waste from being recycled.  It is time for the politicians to sit down with the industry and agree a proper plan.

For further information about metal separation equipment designed for removing metal during the plastic or plastic product manufacturing process, please visit our website or contact us on:

Phone: +44 (0) 1442 875081
Email: press@buntingeurope.com
Via the website

Photographs taken by Paul Fears Photography

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3 Successful Plastics Recycling Projects for Recycle Week

Celebrating Recycling Success

The theme of the 2018 Recycle Week (24-30 September)  is ‘Recycling. We do. Because it matters.’  Recycle Week is a celebration of recycling, organised by WRAP under the ‘Recycle Now‘ brand.

Recycling has never been more prominent in the news, with managing plastic waste high on the agenda.  We work with many plastic recycling companies and have provided many magnetic separators and metal detectors to remove metal contamination.  To celebrate Recycle Week we wanted to talk about plastics recycling success and also highlight the changes faced by companies recycling plastic.

EcoVyn Reduce Waste by 94% with Bunting Drawer Magnets

Bunting Magnetics Drawer Magnets at Ecovyn

EcoVyn Ltd is at the forefront of PVC compounding and brings pioneering new technology to the market place.  They offer one of the most advanced and innovative production processes in the UK producing reprocessed, blended and virgin compounds for a variety of applications.  By installing Drawer Magnet Filters, EcoVyn reduced their waste by 94%.

HFS Drawer Magnets Removes Metal from Recycled Plastics

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A French plastic recycling company installed the Drawer Magnets to remove fine iron contamination present in the recovered and granulated plastic.  If the metal is left in the reclaimed plastic, it causes serious defects in the new plastic product and can also damage processing equipment.

Metal Separation Module Cleans Recycled Plastics for Recapture Plastics

Bunting Metal Separation System Recapture Plastics LinkedIn

A new plastics recycling plant was built in Kent, UK.  The plant was designed to handle up to 25 tonnes per hour of reclaimed plastic.  Once shredded, the plastic is passed over a strong Drum Magnet (to remove small ferrous metals) followed by an Eddy Current Separator (to remove non-ferrous metals).  The end product is also passed through a Quicktron Metal Detector prior to the clean plastic being bagged ready for shipment.

Contamination Hinders Plastic Recycling

We work with many plastic recycling companies located across the world.  Every company is faced with the problem of contamination.  Contaminated plastic waste is worthless and processing is required to remove contaminants, such as metal and stone, to make this waste product reusable.

We are fortunate to be working with some amazing companies in the waste and recycling sector.  Their innovation and knowledge continually increases the amount of materials we can recycle and reuse.

For further information metal separation equipment designed for removing metal from plastic waste and in other recycling applications, please visit our website or contact us on:

Phone: +44 (0) 1442 875081
Email: press@buntingeurope.com
Via the website

Photographs taken by Paul Fears Photography

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A Rejuvenated RWM Exhibition

Busy Stand for Bunting Magnetics at RWM

At this year’s rejuvenated RWM Exhibition (NEC, Birmingham, 12th – 13th September), the Bunting Magnetics and Master Magnets stand proved to be a great success.  Being positioned in a prime stand in front of the entrance, and with working metal separators on the stand, visitors were drawn to see the latest developments in magnetic separation technology.

RWM 2018 Exhibition
Stainless Steel Magnetic Separator in action

In January 2018, Prysm Group announced that they had taken on the flagging RWM exhibition.  Attendance of the RWM exhibition in 2017 had been poor and many exhibitors had lost faith with the event.

At an event in the Google headquarters in London, RWM exhibition manager Nick Woore announced their intention to inject new life into the show.  The plans sounded positive, although there was still a great deal of doubt from many exhibitors.  In fact, in 2018 the number of exhibitors were lower than in 2017, but visitors numbers were higher.

“It was great to see people queuing outside the entrance on the first morning of the exhibition,” said Dave Hills, Bunting’s Head of Sales.  “As soon as the doors opened, our stand was full of visitors.”

Bunting had two operating production-sized metal separators on the stand:

Dave Hills also gave two presentations on ‘Stainless Steel Separation in Modern Day Recycling’.

RWM 2018 Exhibition

“Being able to show visitors the separation capabilities of the equipment was vitally important,” explained Hills.  “This made it easier to relate to their metal separation requirements.  Following the exhibition we will be conducting tests at our Master Magnets Redditch laboratory, where we can confirm the separation capabilities.  It is going to be a busy few months.”

Hills also explained the importance of a successful RWM.  “Recycling and good waste management is no longer an option but a necessity and it is essential that there is a UK based trade event.  We are looking forward to hearing how the organisers plan to further develop RWM for 2019.”

More photographs from the RWM exhibition can be seen on our Flickr photograph album.

For further information metal separation equipment designed for removing metal from plastic waste and in other recycling applications, please visit our website or contact us on:

Phone: +44 (0) 1442 875081
Email: press@buntingeurope.com
Via the website

Photographs taken by Paul Fears Photography

Other Plastic Waste & Recycling Articles

RWM 2018 Exhibition

 

3 Facts About Plastic Packaging Waste

Latest 2016 Waste Recycling DEFRA Data

The UK’s largest recycling exhibition, RWM, takes place on the 12th and 13th September 2018 (NEC, Birmingham, UK).  Leading up to the show, we wanted to review three key facts relating to the latest DEFRA data (from 2016) on plastic packaging waste (published in February 2018).

Waste Drinks Containers-9048

The Amount of Plastic Packaging Waste

UK households generated 1,015,000 tonnes of plastic packaging waste in 2016.  This is actually 12% lower than in 2012, although the amount has been relatively stagnant since 2103.  In 2016, 20% of all packaging waste was plastic (by weight), although this percentage would be far higher if measured by volume due to the low bulk density of the material.

A Rising Recycling Rate

45% of plastic packaging was recycled or recovered in 2016 compared with 25% in 2012.  The 2016 figure is higher than the EU target of 22.5%.  Since the beginning of 2018, the UK Government has set a new recycling and recoverable target of 57% by 2020.  This means that new strategies are needed to raise the rate by 12% in just four years.

Plastic Packaging Recycling Rates

However, there remains a question about what to do with the plastic once it has been recovered.  The UK still exports a large proportion of its waste, but this is still classed as being ‘recovered’ and is included in the 45%.  Since China closed their doors to waste, plastic waste has being shipped to countries around the world, including Malaysia, Thailand and Vietnam.  This is not a sustainable solution, but it not reported in the statistics.  An increasing amount of plastic waste is expected to remain in the UK and it is unclear how it will be managed.

Plastics Recycling Plants

It is widely accepted that there are not enough plastic recycling plants in the UK.  In the past, it has been difficult to economically operate a plant with high costs associated with equipment investment and site difficulties due to the flammable nature of plastic waste.

Bunting Magnetics Drawer Magnets at Ecovyn
FF Drawer Filter Magnets (supplied by Bunting Magnetics Europe Ltd) removing metal from plastic waste to enable recycling

One successful plant is located near Wrexham in North Wales where EcoVyn process 1,000 tonnes per month of good quality plastic waste.  EcoVyn installed several Drawer Filter Magnets to remove ferrous metal contamination from the granulated plastic.

The Future

There has been a huge change in the public perception of plastic waste since the showing of the BBC series Blue Planet II in 2017.  This has forced politicians to start taking action and it will be interesting to see the level of political and governmental engagement at the RWM exhibition.

For further information on metal separation equipment designed for removing metal from plastic waste and in other recycling applications, please visit our website or contact us on:

Phone: +44 (0) 1442 875081
Email: press@buntingeurope.com
Via the website

Other Plastic Waste & Recycling Articles

Metal Detectors Detecting More Than Treasure

Technology Keeping Waste Metal-Free

The BBC television series Detectorists has significantly increased the public’s awareness of metal detectors, but many people remain unaware of their importance in the recycling of waste materials.

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Although the size and design of metal detector used in the recycling industry may be different to those used by the enthusiasts on the television show, the basic concept is the same.  When an electric current is passed through the coil of a metal detector, it creates a magnetic field.  If a piece of electrically conductive metal is close to the coil, eddy currents will be induced in the metal, and this produces a magnetic field of its own.  A separate control recognises that the new magnetic field has changed the metal detector’s magnetic field and identifies that there is metal present.

Metal Detectors are becoming increasingly important in the recycling industry.  Magnetic Separators and Eddy Current Separators are widely used to remove liberated ferrous, non-ferrous and even some stainless-steel metals, but are unable to separate metals that are imbedded in material or are unresponsive to these types of metal separators.

This is particularly important in recycling operations where the waste material is large in size and needs to be shredded or granulated.  A common location for the Metal Detector is on the conveyor prior to size reduction, where it identifies the presence of any metal that may damage the shredder or granulator.  The effect of metal damage can be costly in terms of repair and also downtime.  Typical waste materials include plastic, wood, and demolition waste.

There are primarily two different types of Metal Detector suitable for detecting metal in such conveyed material.  The Underbelt Conveyor Metal Detector is ideal when handling larger materials of variable shapes and sizes and the aim is to detect larger metal.  Two different coil designs mean that the Metal Detector is suitable for belt widths from 100mm to 1200mm.  This design of Metal Detector identifies and then stops the conveyor belt.  Operators then locate and manually remove the metal contamination.

The second type of Metal Detector surrounds the conveyor belt.  This increases the detection sensitivity and is also needed when there is a deeper burden depth on the conveyor.  There are various coil configurations, such as the QDC, QTA, and TN77, and the selection is based upon each application.

Once the waste has passed through the process of size reduction and separation, Metal Detectors are commonly used to check that metal is not present in the final product.  In some applications, the material will still be conveyed and so previously mentioned designs are used.  However, in applications where the particles are now significantly smaller different designs of Metal Detector are required.

Bunting Metal Separation System Recapture Plastics-0424In plastic recycling plants, Free Fall Metal Detectors such as the quickTRON 03R not only detect but also reject metal contamination.   Gravity free-fall style metal separators are specifically designed to isolate and separate any contaminated material moving in the product flow.  They automatically detect, pick up and reject both ferrous and non-ferrous from the product flow without any interruption to the line process.

As each application can be unique, selecting the optimum Metal Detector for an application is best achieved by conducting a site visit to understand the process and the objective.

Bunting Magnetics is one of the world’s leading suppliers of Magnetic Separators and Metal Detectors which includes the Master Magnets and Metal Detection branded range of equipment.

For further information on metal separation equipment designed for detecting and removing metal from plastic waste and in other recycling applications, please visit our website or contact us on:

Phone: +44 (0) 1442 875081
Email: press@buntingeurope.com
Via the website

Other Plastic Waste & Recycling Articles

RWM Becomes Metal Separation Test Centre

Interactive Stand 5Q11 at RWM

Visitor interaction is the theme of the Bunting stand at this year’s RWM (12-13 September, 2018, NEC, Birmingham, UK).  With their stand (5Q11) in prime-position opposite the entrance to the show, Bunting will invite visitors to take a lump of non-ferrous metal or stainless steel, place it on the belt of the metal separator, and witness separation.

Bunting Magnetics Europe at RWM16
The separation of stainless steel on a magnetic separator

“We wanted to do something different this year,” explained Dave Hills, Bunting’s Head of Sales.  “Visitor interaction is so important and we want people to handle the metal and then see what happens when they place it on the belt of the metal separation system.”

Operating on the stand at RWM will be a production-sized Eddy Current Separator and Stainless Steel Magnetic Separator, and demonstration-sized model of the popular Permanent Overband Magnet.

On the Stainless Steel Magnetic Separator, visitors will be able to separate several different materials.  These include large lumps of fragmented stainless steel, from secondary metal recycling plants, and printed circuit boards (PCBs) from electronic recycling operations.

The Stainless Steel Magnetic Separator uses a patented high strength magnetic roll that generates enough attractive power to separate even the weakest magnetic materials.  When passing through a shredder, the edges of stainless steel become weakly magnetic and this enables the effective separation.  Also, PCBs have small components that are weakly magnetic and these are attracted by the strong magnetic field and separated from non-magnetic materials.

Dave Hills will be speaking about the Stainless Steel Magnetic Separator in the Alternative Fuels Theatre on Wednesday 12th (12:30-13:00) and Thursday 13th (11:45-12:15).

Eddy Current Separators are a common feature at the RWM exhibition.  The Master Magnets design focuses on maximising non-ferrous metal separation whilst maintaining product purity levels.  The ability to produce the optimum separation of non-ferrous metals is dictated by the design of the high speed rotating magnetic rotor and visitors will be able to place non-ferrous metals on the separator and witness the dramatic and violent separation.

Bunting Master Magnets at RWM17
Non ferrous metals being separated on the Eddy Current Separator

As the Permanent Overband Magnet is one of the most commonly used magnetic separators in the recycling and waste industry, it was important to have a model on show.  Hundreds of Permanent Overband Magnets are built at the Redditch manufacturing facility each year and they can be seen on many pre-sorted refuse operations recovering steel cans and mobile plant such as crushers and screens.

“Participating in a demonstration is different to simply watching,” explained Hills.  “Visitors to the stand can choose the item they want to separate and then see what happens on the metal separator.”

For further information metal separation equipment designed for removing metal from plastic waste and in other recycling applications, please visit our website or contact us on:

Phone: +44 (0) 1442 875081
Email: press@buntingeurope.com
Via the website

Photographs taken by Paul Fears Photography

Other Plastic Waste & Recycling Articles

Defining Plastics Recyclability

Global Definition of Recyclable Plastic Packaging and Products Released

The global outcry of hostility against plastic products has been gathering momentum since the end of 2017 and, subsequently, politicians and governments have pledged to introduce measures to reduce plastic waste.   However, many of these new policies have been deemed to be popularist and lacking in substance.

plastic-bottles

Many governments, including the European Union, have set recycling targets that have been questioned by the recycling and plastics industries.  The EU has made a pledge to have all plastic packaging recyclable or reusable by 2030, a far more aggressive strategy that the UK Government’s plan for plastic waste reduction.

However, until recently, there has not been a definition to govern the use of the term “recyclable” and so how could any of those targets be quantified?  Due to the public outrage about how plastic waste is damaging our planet, politicians have wanted to be seen to take urgent action, but maybe a more considered approach is needed.  Should the first step be to engage with:

  • Plastic product designers and producers;
  • Companies who will ultimately recycle the products;
  • Businesses that will use the recycled plastic products in the manufacture of new products.

One issue that has often plagued the waste sector is the defining the terminology.  Even the classification of “Waste” differs from country to country.

However, two leading global international plastics recycling organisations have worked together to define the term “recyclable” in terms of plastic products and packaging.  In July 2018, Brussels-based Plastic Recyclers Europe (PRE) and the Association of Plastic Recyclers in Washington, USA have concluded that there are four conditions that define a plastic product as being “recyclable”.  These are:

  1. The product must be made with a plastic that is collected for recycling, has market value and/or is supported by a legislatively mandated program;
  2. The product must be sorted and aggregated into defined streams for recycling processes;
  3. The product can be processed and reclaimed/recycled with commercial recycling processes;
  4. The recycled plastic becomes a raw material that is used in the production of new products;

Technology already exists to help with the sorting of plastic waste into defined streams.  Additionally, there is processing equipment available to remove contamination such as metal (Magnetic Separators, Eddy Current Separators, Metal Detectors) and other contaminants (Optical, X-Ray, Infra-Red).

A recent case history report highlighted how EcoVyn, a PVC compounder in the UK, already processes 1000 tonnes of plastic waste each month of which 80% is post-consumer.

Bunting Magnetics Drawer Magnets at Ecovyn

Such clarity of the definition of whether a plastic product is really “recyclable” can only be beneficial, assisting product designers, users and recyclers.  However, it remains unclear whether the EU, UK and other governments will use this new definition when setting their recycling and plastic waste targets.

For further information on metal separation equipment designed for removing metal from plastic waste and in other recycling applications, please visit our website or contact us on:

Phone: +44 (0) 1442 875081
Email: press@buntingeurope.com
Via the website

Other Plastic Waste & Recycling Articles

Metal Recovery Focus at CARS 18

Metal Recovery Equipment on Show at CARS Exhibition

At the CARS 2018 exhibition (11-12 July 2018, NAEC, Stoneleigh, UK), the focus on stand M6 will be on maximising the recovery of metal whilst also maintaining purity levels.

The Complete Auto Recycling Show (CARS) is Europe’s premier event for auto recyclers and material processors. It is the only event of its kind, drawing over 1,200 attendees from across the globe in 2016.

Unlike traditional trade shows, visitors get the chance to experience not only the indoor exhibitions, but to see working line demonstrations, participate in offsite tours, visit the Skills Lab and access the Conference Theatre – all included within the free ticket.

Master Magnets, the recycling focused division of Bunting Magnetics Europe Ltd, will be demonstrating the separation and recovery of non-ferrous metals and stainless steel on stand M6.

“Our focus is on recovering as much metal as possible in a high value grade,” explained Dave Hills, Bunting and Master Magnets Head of Sales.  “There is always a balance between recovery and purity and the best results often come from several stages of separation.”

Master Magnets has a complete range of metal separation equipment for every stage of metal recovery.

Ferrous Metal Separation

drum_magnet_installation

The primary metal separation stage in any recycling plant focused on ferrous metals.  Large Drum Magnets, specifically designed for the arduous environment, are commonly used along with smaller Drum Magnets and Pulley Magnets.

Non Ferrous Metal Recovery

Eddy Current

Eddy Current Separator designs have been perfected to enable the recovery of even the smallest non-ferrous metals.  Two rotor configurations (ie concentric or eccentric) are available to suit the specific application.  Recent developments include a precise splitter positioning system to maximise recovery and purity.

Stainless Steel Separation

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Stainless Steel Magnetic Separators are a relatively new addition to the metal separation range of equipment that has been extremely popular in USA secondary metal processing plants.  There are two variations available:

HISC (High Intensity Separation Conveyor) – This enables the magnetic separation of small and mid-sized stainless steel – 10mm to 40mm (½” to 1½”) – and for wire-cleaning applications.

SSSC (Stainless Steel Separation Conveyor) – With a patent magnetic circuit design of high-intensity neodymium magnets, the SSSC can remove up to 94% of irregular shaped stainless steel – up to 125mm (5”) in size – from auto shredding or wire chopping stream.

On stand M6 at the CARS exhibition there will be demonstrations of both non-ferrous metal recovery on an Eddy Current Separator and Stainless Steel separation.

For further information on Bunting Magnetics and Master Magnets and our range of metal separation equipment designed for the metal recycling, please visit our websites or contact us on:

Phone: +44 (0) 1442 875081
Email: press@buntingeurope.com
Via the website

Metal Separation MOT at WASTE 18

A Free Review of Magnetic Separators and Eddy Current Separators

At this week’s WASTE’18 Expo (Thursday, 5th July 2018, Warwickshire Event Centre, Leamington Spa, UK), on stand A Bunting Magnetics and Master Magnets are offering a free Metal Separation MOT.

The Metal Separation MOT involves a site visit to review the positioning, set-up, strength, and separation performance of Magnetic Separators and Eddy Current Separators.

Over time, it is not unusual to find that the positioning and set-up of metal separation equipment has been changed.  This may have occurred during a maintenance period or during a break down, or there could have been a change in the plant layout.  Assessing the installation as an external auditor enables a review with a fresh pair of eyes.  At the end of the MOT, a report is prepared and submitted and this can form part of a company’s quality management.

For further information, please see us on stand A at the WASTE’18 expo.

At the show, Bunting and Master Magnets will be exhibiting and demonstrating the Stainless Steel Magnetic Separator and the Mastermag Eddy Current Separator.

Separating Stainless Steel

Bunting Master Magnets at RWM17

The successful recovery or extraction of stainless steel from mixed non-ferrous metals (eg WEEE) or non-metallic materials (eg plastic waste) has been an issue for many recycling companies.  The Stainless Steel Magnetic Separator has been designed with an ultra strong magnetic circuit to attract and deflect the weakly magnetic metal.  Stainless Steel becomes weakly magnetic, usually on the edges, when passing through a shredder or granulator.  Demonstrations on stand A at WASTE’18 will show stainless steel being separated.

Separating Non Ferrous Metals

MasterMagnets_ECS-0634

Maximising the recovery of non-ferrous metals, such as aluminium and copper, increases financial return whilst also reduces the amount of material passing to landfill.  On the stand, there will be demonstrations to show how effective the Mastermag Eddy Current Separator is in the high yield and high purity separation of small and large non-ferrous metals.

With the global focus on waste management and recycling, especially with regards to plastic waste, this year’s WASTE’18 is expected to be busier than ever.

To register for WASTE’18 go to Free Visitor Registration.

For further information on Bunting Magnetics and Master Magnets and our range of metal separation equipment designed for the waste and recycling sector, please visit our websites or contact us on:

Phone: +44 (0) 1442 875081
Email: press@buntingeurope.com
Via the website

EcoVyn Reduce Waste by 94% with Bunting Drawer Magnets

Magnetic Separators Remove Contamination from Plastic Waste

EcoVyn Ltd has installed two Bunting Drawer Filter Magnets to remove ferrous metal contamination from plastic waste.  Since the installation of the magnetic separators, EcoVyn has reduced their waste by 94%.

Bunting Magnetics Drawer Magnets at Ecovyn
Bunting Drawer Filter in situ at EcoVyn

EcoVyn Ltd is at the forefront of PVC compounding and brings pioneering new technology to the market place.  They offer one of the most advanced and innovative production processes in the UK producing reprocessed, blended and virgin compounds for a variety of applications.

EcoVyn first met Bunting at the Interplas international plastics exhibition in September 2017.  The company use a high proportion of plastic waste, of which 80% is post-consumer.  Presently, EcoVyn processes 1000 tonnes per month of good quality reclaimed plastic waste, which they plan to increase to 16,000 tonnes per annum.  The cleansed plastic waste is blended into virgin material, resulting in a 90% output of grade A product.  Waste generated during the manufacturing process is also recycled leaving less than 1% being discarded.

Bunting Magnetics Drawer Magnets at Ecovyn
Granulated plastic waste

However, plastic waste is often highly contaminated with metal.  Metal Detectors were already installed to remove the metal contamination, but the reject rate was very high with over 60 tonnes of waste being generated, of which a high proportion was good quality plastic.

At Interplas, EcoVyn explained the problem to the Bunting team who agreed to conduct a site review.  During the review it was concluded that easily removable magnetically-susceptible metal could be removed, leaving the metal detectors to detect and separate non-ferrous metals.  This would then significantly reduce the number of metal detector rejections and, therefore, the amount of waste generated.

After a review of the process, Drawer Filter Magnets were recommended to be installed between the screw conveyor transporting the 8-10mm sized infeed material and the metal detector.  The metal-cleansed material would then pass onto a pulveriser before continuing through the process.

The Bunting Drawer Filter Magnet is used widely in the plastics industry and enables the simple and effective removal of ferrous metal from free-flowing materials.  The Drawer Filters installed at EcoVyn have two rows of high strength Rare Earth Neodymium Magnets.  The top row has two Tube Magnets with three in the second row aligned to sit below the gap in the top row.  This ensures that all the product strikes at least one of the Tube Magnets, where ferrous metal is attracted by the strong magnetic field and captured.

Bunting Magnetics Drawer Magnets at Ecovyn
Ferrous metal captured on the surface of the Tube Magnets

After the installation of Drawer Filter Magnets, the amount of waste was reduced from 60 tonnes to 4 tonnes.

Since installing the Drawer Filter Magnets, EcoVyn has established that a 20 minutes cleaning frequency is required, highlighting the high level of metal contamination commonly found in plastic waste.  The ferrous metal found captured on the Tube Magnets ranges from small fine ferrous dust to nails, washers, steel sheet shards and electrical capacitors.

Bunting Magnetics Drawer Magnets at Ecovyn
Ferrous metals captured by the Bunting Drawer Grate Magnet including nails, a capacitor, washer, wire and steel sheet shard

Following the installation of the Bunting Drawer Filter Magnets, controlled laboratory tests have been conducted at Bunting’s Master Magnets facility in Birmingham which indicated that 99.9% of all ferrous metals had been removed.

The final plastic product produced by EcoVyn is then used to manufacture products such as pipe, internal windows, beading, picture frames, and shoe soles.

For further information on separating metal from plastics during the production of the virgin product or during the recycling process, please contact the Bunting team on: