Pelletising polypropylene: Applied Machinery

Daniel Fisher, Applied Machinery Project Manager, wants to revive domestic plastic recycling through sustainable Polystar pellets. 

The recycling conversation is becoming more layered and complex by the day, with notoriously problematic plastic often taking centre stage. While the problem of plastic waste is widely understood, manufacturing processes still heavily rely on the material.

Daniel Fisher, Applied Machinery Project Manager, says responsibly processing plastic while keeping up with demand requires straightforward remanufacturing options. He adds that one such option is recycled plastic pellet production.

Daniel says to implement a wider uptake of recycled pellets in the manufacturing industry, resource recovery operators need simple-to-use equipment.

“When dealing with a difficult waste stream such as plastic, it’s common for operators to think that a more complex system will perform better,” Daniel says.

“But as the exclusive Australian distributor of Polystar Machinery, Applied Machinery is committed to supplying customers with straight forward and cost-effective solutions.”

Applied Machinery has worked with the Taiwan-based recycling equipment manufacturer for four years.

Polystar manufactures a range of one-step machines designed to reprocess multiple waste streams, notably polyethylene and polypropylene flexible packaging material.

Polystar technology is designed to be simple to operate and easy to maintain.

“The recycled output result is high-quality plastic pellets that can be repurposed back into manufacturing straight away,” Daniel explains.

“The pellets save waste disposal costs by producing a saleable product, while also offering an alternative to raw material extraction.”

Applied Machinery can offer customers the full suite of Polystar products, including the Polystar HNT and the Polystar Repro-Flex.

“HNT machines are typically suited for flexible, post-industrial film and have the added benefit of being able to produce quality pellets from even the most heavily printed packaging material.”

Daniel says the Polystar Repro-Flex is suited to multiple recycling applications including plastic bags, film scraps, bubble wrap, shrink film and laminated film.

“Repro-Flex machines also work well for post-industrial film waste, as the system can process washed flakes, scraps and pre-crushed rigid plastic waste from injection and extrusion,” he adds.   

Both the HNT and Repro-Flex feature an integrated cutter compactor, which removes the need for pre-cutting.

“The cutter compactor, which generates frictional heat during the compacting process, also helps remove moisture from the material.”

According to Daniel, eliminating moisture is a particularly significant feature when generating recycled plastic pellets, as even minimal water can render a whole batch unusable.

Daniel says the integrated Polystar system also eliminates the need for separate crushers and the common problem of inconsistent feeding.

“The integration of the cutter compactor and extruder ensures extremely fast and stable feeding, as the tangentially connected extruder is continuously filled with pre-compacted material.”

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Ejecting for efficiency: Wastech Engineering

After Citywide developed an operational efficiency plan to boost productivity and payloads, It engaged Wastech Engineering for a new fleet fleet of Clearline Waste Transfer Trailers.

When the City of Melbourne announced it would fast-track the delivery of its Waste and Resource Recovery Strategy in early August, it illustrated a commitment to growing the state’s resource recovery capacity.

Similarly, the Victorian Government allocated $35 million to waste and resource recovery via the state budget in May. Both initiatives highlight a pledge to develop more efficient waste processing capabilities across the state.

Increasing productivity via efficient processes is a motivation shared by Melbourne City Council subsidiary Citywide, which recently revised its operational efficiency plan.   

Travis Martin, Citywide Commercial Waste Division Manager, says while investment in resource recovery facilities is critical, so too is streamlining operations at less glamorous but equally important waste transfer stations.

Being entrusted with the waste management of Victoria’s capital city, and the second largest in the country, highlights the scope and scale of Citywide’s operations. It similarly underscores the importance of finding the right equipment supplier.

Travis says to manage this scale, Citywide and Wastech Engineering developed a symbiotic relationship.

“Citywide and Wastech have worked together in many capacities over the years, with Wastech providing ongoing equipment maintenance and support at our transfer station and working with us in waste and recycling process innovation,” Travis says.

“In the most recent instance, we informed Wastech that we needed new waste transfer trailers to boost operations, and were directed to its Clearline range.”

Travis, who has worked in the waste industry for more than 30 years, says the Citywide Transfer Station and Resource Recovery Centre is the largest of its kind in Victoria, and one of the five largest in Australia.

“Located in West Melbourne, the centre provides waste management services to various local government and commercial clients, meaning effective transport arrangements are key,” Travis says.

“We process multiple waste streams at the facility, largely consisting of municipal waste, residential, commercial and industrial waste and multiple recycling streams such as paper, cardboard, steel and organics.”

According to Sustainability Victoria, over 12.8 million tonnes of waste was managed by the state’s waste and resource recovery system in 2017. In the same year, City of Melbourne residents generated 40,000 tonnes.

To keep up with accelerating service demands, Travis says Citywide recently developed and implemented an operational efficiency plan in order to lift productivity and payloads.

“With ever-increasing volumes of waste generated in and around Melbourne’s CBD – that needs to be processed through the Citywide transfer station – we needed to boost efficiency and invest in new operational and transport equipment,” Travis says.

“One facet of the plan was engaging Wastech for a new range of Clearline Waste Transfer Trailers, with an operational model of owner drivers and a drop and go system for productivity.”

Citywide already owned a number of Clearline trailers, but wanted to upgrade to the newer model. Travis says his previous experiences with Wastech made him confident the new trailer model would meet expectations and application requirements.

The Clearline Waste Transfer Trailer’s rolled wall body design provides durability and integral strength, which Travis says is critical to withstanding the high piercing forces present during compaction of industrial and commercial waste.

The trailer also incorporates the use of high-tensile steel plate in the body to reduce tare weight and increase payloads.

Citywide uses the Clearline trailers to transport waste from its central transfer station in West Melbourne to various landfill sites across the city.

“The Clearline’s smooth internal design, and hydraulic eject blade, safely and efficiently push the waste load out of the body at landfill,” Travis says.

“The full eject feature reduces each load by 20 minutes, equating to one extra load per shift.”

According to Travis, the Clearline trailers are fitted with Elphinstone weighing systems that provide 99 per cent weight accuracy. He adds that as the trailers are mass managed, the weighing systems can be used to full effect.

“The trailers have also reduced volumes at the transfer station, which makes the customer onsite experience quick and easy,” he says.

Wastech’s transfer trailers feature full cab controls to facilitate operator friendly conditions and heightened safety, as operators aren’t required to exit the vehicle when unloading.

“The previous Clearline Waste Transfer Trailer design was great, and worked well under harsh conditions, but the rear doors and hydraulic ejection of the new model really lifts ease of operations,” Travis says.

“As the last piece of Citywide’s operational efficiency plan, the delivery of Wastech’s trailers significantly increased our transfer station operations.”

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Handling gold: Kerfab

Ryan Hoban, Kerfab Marketing Manager, talks to Waste Management Review about the company’s new range of waste industry-specific-wheel loader attachments.

Green waste is regularly called black gold – black because it turns dark when fully decomposed, and gold because of its untapped reuse potential.

Green waste presents a number of handling challenges and as such, is often perceived as too difficult to work with, according Ryan Hoban, Kerfab Marketing Manager.

Ryan adds that green waste’s perceived unviability is one reason the material’s potential remains untapped.

“Green waste is biodegradable, and often comes in the form of garden or park waste like grass, tree cuttings, branches and hedge trimmings, as well as domestic and commercial timber waste,” Ryan says.

“It is wet and heavy, arrives as a mass of varied particle sizes and is ultimately very cumbersome to shift.”

According to Ryan, all waste streams present a unique set of challenges, which highlights the need for specialised equipment.

After years building custom bespoke attachments for the waste industry, materials handling equipment manufacturer Kerfab has noticed a gap in the market.

“We’ve conducted countless site visits across Australia and found most facilities were using ill-suited attachments originally designed for other industries,” Ryan says.

“Most industries aren’t as harsh as the waste sector, and therefore don’t require their attachments to work at the same capacity.”

To correctly handle waste, Ryan says operators require wheel loader attachments designed specifically for their material stream.    

“To tame glass waste for example, high dump buckets are useful as they streamline loading into high-sided trailers,” he says.

“But even then, when buckets are designed simply for general use applications, waste operators are likely to run into challenges.”

Ryan says that after extensive research, it became clear the waste industry needed its own range of prefabricated, purpose-built attachments.

“We developed the WastePro range in response to an evergrowing but demanding industry, where productivity is critical and downtime must be prevented at all costs,”  Ryan says.

“The WastePro range is the only set of attachments in Australia designed solely for the unique demands of waste management companies.”

Ryan says the WastePro range enables efficient procurement and removes the necessity of custom builds. He adds that in addition to green waste, the WastePro range features attachments suitable for all waste stream including glass, cardboard and construction and demolition.

“Kerfab is committed to customer service and working in collaboration with our clients. However, it is not uncommon for an operator to require quick and easy access to attachments,” he explains.

“We hope to facilitate this through our new WastePro range.”

Ryan says because general use attachments aren’t designed to handle waste conditions, they can decrease the effectiveness of wheel loaders and the lifecycle of buckets, which leads to premature wear and increased downtime.

“From green and general waste to plastic recyclables, Kerfab has designed multiple variants of our attachments to help maximise uptime and increase equipment life,” he says.

The new range consists of eight separate bucket and grapple attachments, with different models available depending on an operator’s specific material stream.   

“A bucket used to move large amounts of paper needs different functionality design to one working with abrasive material such as crushed glass, and Kerfab has designed the WastePro Range around that fact,”  Ryan says.

According to Ryan, Kerfab paid specific attention to durability during the WastePro design phase.

“More moving parts means there is a greater chance for breakdowns, which is why it’s so important for grapples and high dump buckets be built for purpose,” Ryan says.

“We have also developed heavier duty cylinders to cope with the immense pressure required to repeatedly operate a fully loaded high dump bucket.”

Unlike Kerfab’s standard line, the WastePro Range is manufactured using Hardox, a wear-and-abrasion resistant steel.

“These attachments are designed to increase efficiency, longevity and maximise return on investment,” Ryan says.

“We know how important it is for companies to have minimal downtime, so our attachments are designed to limit this, and subsequently drive productivity.”

Ryan says Kerfab’s after-sales service BackUp+ offers another line of defence for the range. He adds that Kerfab has a network of engineers and fabricators in every major city in Australia.

“They are in place and ready to assist in routine maintenance, such as replacing cutting edges and wear plates, complex fixes and warranty claims.

“This ensures that any attachment related issue will be dealt with quickly to minimise downtime. However, since Kerfab attachments have a less than one per cent failure rate, this scenario is unlikely,” Ryan says.

The WastePro range has recently undergone final testing, with buckets and grapples already in use at waste companies and councils across the country.

“Kerfab will officially launch the range at the Australasian Waste and Recycling Expo in October,” Ryan says.

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Tracing every last drop: Cookers Bulk Oil

Cookers Bulk Oil is helping the food services sector transition to a circular economy through a business model centred on managing the entire life of oil and traceability.

Traceability is a prominent concept across the waste and resource recovery sector as multiple players in the supply chain are tasked with looking after the movement of waste.

The same concept is just as important in Australia’s food sector with certifications that ensure products and services gain a tick of approval for best practice. Minimising environmental risks is central to providing customers with such a service.

With tens of thousands of eating establishments throughout Australia – all of which use cooking oil of one form or another – it is an issue that bulk oil specialist Cookers Bulk knows all too well.

When it comes to sustainability, traceability and how vegetable oil can affect its surrounds, the company has processes in place aimed at keeping the environment free from any negative outcomes caused by vegetable oils.

National quality and safety manager for the company Hari Srinivas says product traceability is a universally applicable concept.

He says this is why Cookers has rigid standards when it comes to sourcing its vegetable oil supplies.

“To deal with Cookers you need to be an approved supplier, which means we look and see what sort of practices and standards you are following,” Hari explains.

“Suppliers need to meet minimum standards and it means we don’t go to any supplier who hasn’t got a certification/traceability system in place that is not internationally recognised.”

He cites the Global Food Safety Initiative (GFSI) a private organisation established and managed by the Consumer Goods Forum in Belgium. It maintains a scheme to benchmark food safety standards for manufacturers.

Certification can be achieved through a successful third-party audit by schemes recognised by the GFSI including the British Retail Consortium (BRC) Global Standard for Food Safety Issue 8, IFS Food Version 6 and SQF Safe Quality Food Code 8th Edition, to name a few.

“Without those types of certification we don’t even entertain any supplier,” Hari says.

“We are stringent with our suppliers. If you look into the way the industry is going now, the majority of the supply chains are going through some sort of certification system, including HACCP. These sorts of certifications are one of the core fundamentals of traceability.”

Hari says he is proud that the company has yet to have any of its products recalled. He puts it down to not only the standards it sets, but also compliant suppliers, and their own end-users as well.

Every year, Cookers performs an exercise where they have a mock recall, which involves checking its suppliers’ traceability to make sure they have the correct systems in place and that they are working. This is because he knows that if there ever is a recall, they need to know where every drop of oil they have distributed has ended up.

The good news for end-users is that if that does happen, Cookers will be able to trace the batch number and know where the offending product
is very quickly through its centralised system.

Traceability is also key when it comes to dealing with customers in case things go wrong once the oil has been distributed. Cookers make sure its customers also comply with standards and regulations, too as it’s important the company ensures its customers are getting the product they paid for, according to specifications.

“We are audited every year, and our auditor reviews how long it takes to check something and what is the level of accuracy of our traceability,” Hari says.

“If we have an issue, we can compare it with the same batch delivered nationally to different customers. We can get a sample and test it with the same batches from other customers.”

Cookers’ circular economy solution ensures that the customers who procure its fresh oil are also its used oil collection customers.

Within this setup, Cookers also run a fleet of vehicles, including stainless steel trucks delivering fresh cooking oil and blue vehicles picking up the used product.

Not only do they pick it up, but the company provides storage equipment used on-site by the customer and facilitates the management of the entire life of the oil.   

“Once they use the oil, we provide the equipment to transfer the used oil product into our blue tankers, which collect it at regular intervals,” Hari says.

“We get the oil back and we have got mechanisms to handle the oil in such a way it can go into biodiesel production.

“It means that with every drop of oil we sell, we make sure not a single drop goes into the drain.”

Taking this a step further, Cookers can measure the amount of oil collected and ensure it is the same as that delivered.

“We do all the calculations, so if there are any big variations we will go and speak to the customer to see if there is anything wrong and find out whether we can help with oil management.”

He says another reason to use a company like Cookers Bulk Oil is that due to its tanker delivery method, no empty oil tins head to local landfill. If a customer needed 100 litres of oil per week, that would usually consist of five 20-litre drums which may end up in landfill. With Cookers’ tankers, the drums are redundant.

Importantly, Hari says most of the oil is Australian sourced and more than 90 per cent refined locally.

“For example, the canola oil we sell is 100 per cent Australian.

“Other oils, depending on the cropping situation, are imported in crude form from reputable suppliers who have proper certifications in place – usually from Argentina and European countries.”

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Landfill loading: Caterpillar

Caterpillar Asia Pacific explains how differential locks and Cat Connect technology can increase landfill operation efficiency.

Not all landfill sites are the same, with many posing unique and harsh environmental challenges for operators. Land is often unlevel, with small space for movement and barriers to reach cells.

In these environments, managing multiple seemingly competing requirements such as maximising operational efficiency, economic viability and worker safety, can be a challenge.

Ayden Piri, Caterpillar (Cat) Asia Pacific Industry Specialist Account Manager, says landfill operators require reliable and efficient machinery to facilitate safe site management and consistent operations.

He says Cat is uniquely positioned to understand machinery requirements relevant to the waste industry, with over 40 years experience providing for the sector in multiple application modes.

According to Ayden, Cat M Series waste handling wheel loaders are popular with landfill operators due to their heavy-duty handling capacity.

“Cat’s waste handling wheel loaders deliver sustainable productivity, fuel efficiency, ease of serviceability, ergonomics and operator comfort,” Ayden says.

“These environmentally-friendly front end loader machines apply proven technology systematically and strategically, to meet our customer’s high expectations.”

With a global network of 172 dealers, factories in 30 countries and more than 10,000 Cat and dealer employees in Australia and New Zealand, the extensive reach ensures CAT is able to draw on a network of experts to solve its customers’ challenges.

Ayden says M series 950- and 972-metre models have a standard front axle differential lock, which is manually activated by a switch on the cab floor.

The fully automatic front and rear axle differential locks work by measuring differences in axle speeds and require no operator intervention to activate.

“These disc-type differential locks will reduce tyre scuffing compared to other traction aids, further reducing operating costs for customers,” Ayden says.

“The proven Z-bar linkage combines efficiency with great visibility to the tool, resulting in excellent penetration into the pile, high breakout forces and superior production capabilities.”

M Series’ next generation ride control works as a shock absorber, which Ayden says improves ride quality and smoothness over the rough surfaces often found in transfer stations.

“When paired with the Fusion coupler, from a loaded high-dump bucket to a fork to move material, the ride control system provides reduced cycle times, better productivity and a smoother, more comfortable ride for the operator,” he adds.

M Series wheel loaders are equipped with Cat Connect technology, which allows operators to monitor, manage and enhance job site operations.

“Cat Connect facilitates easier service access, with the legacy one-piece hood, centralised service centre’s, windshield cleaning platform and harness tie-off,” Ayden explains.

“Optional purpose-built guarding is also available to help protect your machine from the harsh environments common in waste applications.”

The wheel loader’s machine guarding protects the unit’s major components and systems, facilitating reliable durability.

“Wear in waste handling applications is severe and can drastically cut down a machine’s life,” Ayden says.

“All Cat waste handling machines are protected in key impact areas, including undercarriages, radiators, axles and cabs.”

According to Ayden, the M Series medium wheel loader is 10 per cent more fuel efficient than the industry-leading K Series, and up to 25 per cent more fuel efficient than the H Series.

The updated Caterpillar powershift transmission, with a lock-up clutch torque converter, is standard on all M Series wheel loaders.

“The new torque converters have been matched with engine power and hydraulics to improve performance and fuel efficiency, while also managing the pile or loading trucks,” he says.

“The rugged transmission also has a new split-flow oil system, which uses multi-viscosity oil to reduce parasitics and improve fuel economy.”

Ayden says the M Series hydraulic system has recently undergone significant design changes.

“The main hydraulic valve is now a mono-block with an integrated ride control section,” Ayden says.

“The mono-block design also reduces weight, has forty per cent fewer leak points and is common across all M Series models.”

On 950- and 972-metre models, auxiliary hydraulic functions can be added at the factory or in the field, with the addition of a second remote valve.

“A new thermal bypass valve has also been added to improve hydraulic system warm-up,” Ayden says.

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Paddles and packaging: Wastech Engineering

Wastech Engineering’s Jeff Goodwin explains how the ATRITOR Turbo Separator can help businesses achieve a food waste recovery rate of 99 per cent.

Growing populations and an associated increase in food consumption is accelerating the organic waste problem in Australia and around the world.

As reported by Waste Management Review in June, many Australian businesses are hesitant to engage in the source separation of food waste.

This is due to a limited number of recycling facilities able to process the recovered organics, together with concerns around the ability to recycle packaging.

With the National Packaging Targets are squarely on the waste industry’s agenda, the ability to effectively separate recyclable packaging from its contents is therefore equally important.

Jeff Goodwin, Wastech Engineering’s National Product Manager Projects, says growing issues around food waste generation, paired with rising landfill restrictions and capacity levels, was the driving factor behind a recent addition to Wastech’s product portfolio.

“Working with UK manufacturer ATRITOR, Wastech has added a range of turbo separators for food de-packaging to our product roster,” Jeff says.

“As the exclusive Australian representative for ATRITOR, Wastech can provide customers with a solution offering a typical food waste recovery rate of 99 per cent for both dry and liquid products.”

Jeff says the high recovery rate makes the Turbo Separator ideally suited for use in product destruction units.

The Turbo Separator range comprises four models designed and engineered to efficiently remove a wide range of products from their packaging.

“Wastech’s distribution range includes the TS1260, TS2096, TS3096 and TS42120 models, with a material dependant separation rate ranging from 600 kilograms an hour to 20,000 kilograms an hour,” Jeff says.

According to Jeff, the equipment ideal for separating out-of-date, out-of-specification or mislabelled products.

“Historically, expired and mislabelled food products were consigned to landfill due to the difficulty of extracting organics from packaging,” Jeff says.

“With the ATRITOR Turbo Separator we can begin shifting that practice.”

Jeff says the Turbo Separator is sufficiently flexible and can de-package a range of products and packaging materials including supermarket waste, tin cans, polymer bottles and soft packaging.

“Additionally, the Turbo Separator is equally at home separating gypsum from the backing paper in plasterboard,” Jeff says.

“The recovered gypsum can be used in agriculture or re-used in plasterboard manufacturing, while the recovered paper can be further recycled.”

Jeff says the Turbo Separator also works for blister packs, sachets, pouches, paper bags, aluminium cans, plastic bottles, plastic drums and TetraPak.

“The only unsuitable application is glass containers or bottles, as the glass shatters and the shards will contaminate the organics,” he explains.

The Turbo Separator combines centrifugal forces, self-generated airflow and mechanical processes to remove organic material from packaging.

Jeff says this allows the recovered materials to be recycled or disposed of correctly.

Packaged materials are fed by an infeed conveyor into the separation chamber, where a number of rotating paddles open up the packaging.

The force of the paddles then creates a squeezing effect, which separates packaging from its contents without destroying the packaging.

Depending on the material, the recovered organics can then be used for animal feed, nutrient-rich compost or anaerobic digestion.

Wastech can supply the Turbo Separator as a complete package, with an infeed hopper and conveyor, separation chamber and outfeed conveyors.

The separator is also delivered with a maintenance access platform and control cabinet.

“The Turbo Separator’s rugged and durable construction, coupled with high product separation rates and economy of operation, is an ideal proposition for all de-packaging applications.”

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Ecocycle: battery revamp

Daryl Moyle, Ecocycle Business Development Manager, speaks with Waste Management Review about the company’s battery recycling capabilities and recent rebrand.    

Less than three per cent of all batteries purchased in Australia are recycled, with the rest ending up in landfill. According to Sustainability Victoria, this means over 14,000 tonnes of batteries are destined for landfill each year.

Australia’s performance in this space is poor, with the UK recovering just under 30 per cent and Switzerland recovering 72 per cent. Things are potentially looking up however, with a recent meeting of environment ministers endorsing the work of the Battery Stewardship Council to design a product stewardship scheme.

Battery recycling has many benefits, ranging from keeping harmful materials out of the environment, recovering non-renewable resources and ensuring used batteries don’t start fires.

Australasian mercury recovery and recycling company Ecocycle, formerly CMA Ecocycle, have recently updated their branding to highlight different business divisions, such as Ecobatt.

Daryl Moyle, Ecocycle Business Development Manager, says the revamp comes at a time when the company is continuing to invest in modern equipment and technology, specifically in the sphere of batteries.

“There are so many different products that can be recycled in the sector today, however we focus on specific products and niche markets rather than being a general waste company,” Daryl says.

“The idea is to help customers distinguish our different services, so having a specific brand like Ecobatt will help customers identify us as a battery recycler.”

According to Daryl, the Ecobatt unit is already bringing specific battery safety products to market to minimise environmental risk, including electric vehicle recovery containers to address potential battery fires.

Daryl says batteries are made up of metals, chemicals and other materials that may not seem reusable, however most elements found in batteries can, in fact, be recycled.

Ecocycle recycles all type of batteries to recover metals like lead, cadmium, nickel, steel, zinc, mercury, cobalt, lithium, silver and manganese.

“The more complex the battery chemistry gets, the more difficult it is to extract materials and the more technical the process has to be,” Daryl says.

“We’ve taken a well-researched, systematic approach to the problem, and partnered with world-leading companies to roll out proven technology to manage each step of the battery recycling process – collection, sorting and processing.”

The majority of batteries on the Australian market are alkaline batteries, such as non-rechargeable AA and AAA batteries, and therefore make up the majority of the recyclable battery waste stream. But forecasts reveal that lithium-ion batteries will make up a huge volume in years to come.

“Alkaline batteries, including paper, steel, zinc and manganese, can be easily recycled because the battery chemistry is simple to work with, however lithium ion presents a far more complex recycling problem,” Daryl says.

“Lead-acid batteries, commonly used as car batteries, also have high recycling rates of around 95 per cent. Lead acid batteries are a success story in the recycling world.”

“Ecocycle is constructing a new high-tech battery sorting plant and this will be the first of its kind in Australia and operational before the end of the year.”

The sorting plant will have the capacity to process more than 5000 tonnes of batteries each year, with the ability to identify more than 3000 battery types by chemistry, brand, size and shape.

Daryl says the facility will combine pre-sorting, automated and manual sorting and separate all types of batteries into their respective streams, whether it be alkaline and zinc, which make up the greatest proportion of battery waste, or lead acid, nickel cadmium, nickel metal hydride, lithium and button cell batteries.

Despite recent actions, Daryl says a lot of work still needs to be done to develop new technology to make the battery recycling process successful.

“In a world that’s increasingly reliant on batteries, recycling will become an ever-increasing source of raw materials for new batteries production,” Daryl says.

“As a specialist battery recycler, the team at Ecocycle will continue to track new developments in this space.”

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Palfinger: hooked on expansion

Kelly’s Waste Management has invested in a new Palfinger hookloader to maximise payloads and support expected growth in Tasmania’s resource recovery sector.

Tasmania’s resource recovery sector is expected to grow once the state’s new Waste Action Plan is implemented.

The plan sets a transition framework for the state’s waste sector through a series of ambitious resource recovery targets. Targets include achieving an 80 per cent average recovery rate from all waste streams by 2030.

To capitalise on anticipated economic growth and grow their collection fleet, Kelly’s Waste Management has invested in a new Palfinger Hookloader to maximise payloads.

Kelly’s operates out of Romaine in north-west Tasmania, an area with substantial parklands and a growing population. Key industries include heavy manufacturing, forestry and farming and, as a result, the region produces a sizeable amount of waste.

John Kelly, Kelly’s Waste Management Director, says the family-owned and operated business has been providing environmental solutions to Tasmania for over 50 years.

John explains that after purchasing a Volvo truck with a mounted Palfinger unit, he was impressed with how well it performed.

He adds that noticing how the unit supported consistent operations and driver performance inspired him to contact Stuart Cameron, Palfinger’s Key Account Manger.

After explaining Kelly’s application requirements, John says Stuart suggested a telescopic T22A hookloader.

“We required a unit that could carry our large waste transfer bins, as well as our general hooklift and vacuum hooklift tankers,” John says.

In addition to carrying large waste transfer bins, Kelly’s required a unit to accommodate a dismount vacuum container.

“Kelly’s had worked with Palfinger in the past and I knew they could supply a unit to facilitate all of this in the one truck,” John says.

“We initially hired Palfinger to fit the unit but ended up needing a lot more, including a vac system hydraulics installation, which they accommodated.”

John says the unit’s high-tensile steel reduces hookloader weight, allowing the company to significantly increase payloads.

“Optimised weight also increases longevity and reduces fuel cost, which is a plus given our large area of operations,” he says.

The T22A hookloader is a bi-point unit, meaning horizontal forces are reduced and tipping capacity is increased.

Additionally, the unit comes with an automatic mechanical safety latch that secures containers from falling during loading and unloading. John says drivers can open the latch on demand.

“Our drivers love the easy operation and control they have over the unit,” he says.

“It assists smooth operation, safety and reliability, which drivers say helps them run efficient and predictable routes.”

The T22A allows for the use of multi-length containers and features integrated in-cab controls, that position the articulated arm during low loading situations and allows a maximum tipping angle of 48 degrees.

Before assembling, the unit’s main components are sandblasted, degreased, primer painted, and electro-statically coated according to customer specifications. All additional parts are treated for anti-corrosion, maximising the life of the unit and providing a greater re-sale value.

According to John, the Palfinger T22A Hookloader has run smoothly since joining the Kelly’s fleet.

“The unit is really helping us keep up with demand, while also guaranteeing a quality of service to councils, industry and the wider public,” John explains.

“With this hooklift, Kelly’s can continue to grow and expand our range of waste services.”

John says Stuart and the wider Palfinger sales team were in regular contact throughout the unit build.

He adds that spare parts are only a phone call away, with Stuart travelling down from Victoria to oversee the handover, training and first few days of operation in the field went smoothly.

“I’ve worked with Palfinger in the past, and while the superior quality of their units is unquestionable, it’s their commitment to service and ensuring the unit matches our requirements that keeps me coming back,” John says.

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Finlay: woodchips to energy

Veolia’s recent moves in the waste-to-energy market has seen them team up with specialist equipment supplier Finlay.

Populations are growing and, as a result, so too is waste generation. Conversely, landfill capacity is declining as urban areas become increasingly dense.

While the waste hierarchy privileges avoidance, reuse and recycling, interest in waste-to-energy as a solution for material that falls through the cracks is growing. Capturing this potential was the driving force behind Veolia’s decision to open a new facility in Horsley Park, New South Wales.

According to site manager Stephen Bernhart, the new resource recovery facility handles wood waste material, which it then processes into a wood chip product.

“After running multiple equipment trials in 2018, we have recently kicked into operation,” Stephen says.

He adds that the wood chip product will be provided to a customer where it will be used as a substitute for coal within a cement kiln.

Veolia’s facility processes a significant amount of wood waste, such as pallets, offcuts and plywood which need to be shredded, and has the capacity to receive 430,000 tonnes of general solid non-putrescible waste per year.

“We have detailed specifications we need to meet to supply our waste-to-energy customer, and a big part of that is ensuring we achieved a material size sub 50 millimetres,” he says.

“It’s quite a challenging task because it’s such a small grade, so we decided to invite multiple suppliers out to the site to run tests and demonstrate their equipment.”

Stephen says Finlay Screening, Crushing and Recycling Systems, a supplier of screening and processing equipment for the waste and recycling industry, stood out during the trials.

“Finlay were heads and shoulders above the rest in demonstrating not just what their equipment could achieve, but how it could achieve it consistently,” he explains.   

Finlay initially trialed a medium speed shredder, however, the resulting material didn’t quite meet specifications. Three weeks later they were back, with a Terex Finlay 693+ Super Track Screening Plant that, according to Stephen, worked extremely well.

“During the second trial there was a large lump of steel which had passed through the primary shredder into the secondary shredder,” Stephen says.

“The TDSV20 shredder shut down as intended, and Finlay representatives opened it up to remove the steel. The machine was back up and running in approximately three minutes – I was very impressed with how the equipment handled it.”

According to Stephen, Finlay also demonstrated how the shredding equipment could maintain the required tonnage throughput in spite of the small material specifications.

In addition to the screening plant, Stephen purchased a Terex Finlay TDS 820 Slow Speed Shredder and a Terex Finlay TDS V20 Mid Speed Shredder and Finlay 5032HD wheeled conveyor.

Built to process bulky, solid waste, the TDS 820 has a two-metre shaft manufactured with a fully welded tooth configuration. Stephen explains that the length allows for significant throughput and size reduction of material.

“The machine’s independent gearboxes enable each shaft to be run separately, which reduces material wrappage and facilitates viable shredding,” he adds.

The Terex Mid Speed Shredder has a twin-shaft, allowing it to perform both primary and secondary shredding. The TDS V20 also has the ability to self-protect against uncrushable material like steel, making it well suited to shredding waste wood materials.

“We have had no trouble meeting specifications after procuring the equipment, all three machines have been running very well.”

According to Stephen, there has been very little down time at the Horsley Park facility.

“There were one or two minor teething issues initially, but Finlay were able to handle them quickly and without fuss,” he says.

Finlay representatives also assisted on-site equipment training when the facility was commissioned.

“They are very forthcoming with their information and we were able to get local contractors trained up on how to run and maintain the shredders and screening plant as well,” he says.

“We are at a really exciting stage in our capability with an eye for expansion, so it’s crucial to have equipment that’s both reliable and efficient.”

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The behaviour changing bins

A well-designed bin could change the way individuals interact with waste and recycling in the workplace, writes Dan Crawford, Method Australia Business Development Manager.

Why do aesthetics matter when it comes to a bin?

A seemingly unimportant factor of a formerly ‘basic’ office fixture became the foundation of the award-winning bins from Method Recycling.

The beautiful bins have helped leading organisations around the world to recycle more and waste less.

Method has quickly emerged as the preferred waste and recycling solution for modern offices, workspaces, venues and facilities around the world.

The bins have a proven record of diverting waste from landfill and are featured in leading spaces including Foster + Partners, the Sydney Cricket Ground, Canva, Atlassian, Qantas and many more.

Method began when co-founders Steven and India Korner continuously saw organisations that wanted to recycle, without the tools to be successful.

Bins and recycling systems had often been an afterthought – with ugly bins hidden in cupboards and kitchens, or desk bins – both of which don’t encourage or facilitate recycling.

The Korners believed that a well-designed bin could change the way individuals interact with waste and recycling in the workplace, and it has.

With the desire to make a visible difference, they set off on a three-year journey of research and development to understand the needs of all those involved in a buildings waste and recycling process.

They held focus groups, developed prototypes, and even helped cleaners on the night shift to gain a truly holistic view and ensure that the bins worked for everyone.

More than just a bin, the Korners created a system that is considered, well designed and purposeful.

Recycling is no longer an afterthought, but instead a featured part of workspace design.

Open Plan Recycling

Through the design process, Method pioneered Open Plan Recycling – a new philosophy of workspace recycling and waste.

Method’s bins are designed to be placed together to form flexible recycling stations, that are then located consistently throughout an open-plan space. These flexible stations mean that organisations can easily adapt the Method system to their needs; adding or moving waste streams as their needs change, or based on feedback from users.

Single bins or smaller stations can also be placed where recyclables are produced to maximise results; such as a paper bin next to the printer or an organics bin in the kitchen.

In its most simple form, this changes the way that individuals interact with waste and recycling in the workplace. By removing desk bins users are unable to simply throw their waste away without a thought. Instead, recycling bins are available alongside all general waste bins.

Further, having consistent recycling stations throughout a building standardises recycling. Consistency in location, streams and colour-coding means that through regular interaction recycling becomes an unconscious behaviour.

One of the fundamental principles that makes Method’s philosophy successful is visibility – so the appearance of the bins is crucial.

Method’s bins are designed to be out in the open as a visible statement of an organisations commitment to recycling and sustainability.

Further, the visibility also increases awareness and accountability, while instilling a collective culture of responsibility into an organisation – changing recycling behaviours at work and subsequently at home.

The New Method in Practice

Having worked with an array of organisations around the world, Method has continued to find that the bins can have a significant impact.

The durable bins are made from 50 per cent recycled materials and are fully recyclable at the end of their life, so you can feel confident you are making a sustainable choice.

Design giant Canva introduced Method bins as they were working towards some lofty sustainability goals.

They continued to grow rapidly with new offices around the world so needed a recycling system that was simple to implement and maintain, while complementing their beautifully designed offices.

Canva’s Global Office Architect Shamal Singh says Method’s bins allow the sometimes daunting task of having four waste and recycling options to be manageable and scalable across our ever-expanding offices.

The results of Methods bins speak for themselves. Westpac Bank in New Zealand reduced waste to landfill from 70 per cent to 40 per cent. Meanwhile, Palmerston North City Council reduced waste to landfill by 62 per cent in three months.

Can Method help you achieve your recycling and sustainability goals? Click here.

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