DEM-CON MRF - Waste Recycling Equipment … · DEM-CON MRF 2015 Excellence Recycling Systems Award...

MATERIALS RECOVERY

DEM-CON MRF2015 Excellence Recycling Systems Award Entry

2015 EXCELLENCE AWARD ENTRY RECYCLING SYSTEMS EXCELLENCE

DEM-CON COMPANIES, LLC

BEN [email protected]

952-224-7111

DEM-CON MATERIALS RECOVERYSHAKOPEE, MN

POPULATION SERVED: 5.5MCOST PER HOUSEHOLD: N/A (PRIVATE VENTURE)

BUDGET: NOT DISCLOSED (PRIVATE VENTURE)

mailto:[email protected]

http://dcmrf.com/

EXECUTIVE SUMMARY

Executive Summary Page 1

MATERIALS RECOVERY


70,000 sq. ft. of state-of-the-art processing facility located conveniently off HWY 169 in Shakopee with quick truck access to tipping floor.

20 TONS per hour of source separated materials.

20 TONS per hour of commingled household and commercial recyclables.

Since 1965, privately owned Dem-Con Companies had been known by their local Twin Cities, MN, neighborhoods as the place to recycle construction and demolition debris. Late in 2013 that changed, as Dem-Con opened their new 20 TPH residential and commercial single stream recycling facility, a significant addition to their environmental campus.

The new Dem-Con MRF (DCMRF) is one of the largest of its kind in the state. The DCMRF was a perfect fit for the forward-thinking Dem-Con management team to complete their recycling portfolio. Dem-Con and strategic partner, Liberty Paper, who has end-market expertise, created a unique opportunity to provide recycling services to the Twin Cities and upper Midwest. The team identified growth in the Twin Cities population with increased recycling awareness, and responded to the need for additional capacity for single stream recycling. Aligned with Minnesota’s vision of increasing recycling rates, along with offering customers one campus to meet their needs, the DCMRF state-of-the-art vision became reality.

MATERIALS RECOVERY


1. DESIGN AND PLANNING OF RECYCLING SYSTEM

1. Design and Planning of Recycling System Page 2

July 11, 2013: Steel is erected on Dem-Con’s new MRF as the new MRF comes to life.

September 26, 2013: Dem-Con’s 70,000 square foot building is complete and ready for equipment.

February 1, 2014: Material begins to flow in shortly after Dem-Con’s MRF opening in Nov. 2013.

October 11, 2013: A fall morning sunrise as Dem-Con’s MRF nears completion.

Privately owned Dem-Con identified and responded to a local need for single stream recycling. The new Shakopee, MN, DCMRF was constructed in November 2013 in a brand new 70,000 sq. ft. building.

THE PLANNING PROCESS: In 2010, Dem-Con began planning a facility that would take consumer single stream materials to be separated and recycled. The planning process took approximately three years, and prior to the DCMRF ground breaking, the Dem-Con management spent years analyzing the market in the Twin Cities area to better understand the need for capacity in the market. As they learned about the market, they concurrently immersed themselves in the operation of a facility and the equipment needed to run the facility.

The Dem-Con team toured facilities throughout the U.S. to better understand what others were doing and what worked well. Once they determined the demand for further processing capacity in the Twin Cities marketplace, Dem-Con began to focus on the site design, building, and sourcing an equipment provider of the new MRF. In October 2012, Dem-Con purchased an adjacent 6 acre parcel to their existing environmental campus for the new MRF. The ideal location of being right on Hwy 169 with easy on and off access to the freeway was important. Additionally, many target customers were already customers at Dem-Con Landfill or Dem-Con Recovery & Recycling (Dem-Con’s C&D MRF). This aided in Dem-Con’s merchant model, focusing solely on processing and servicing their hauling customers. This allows Dem-Con to have a very broad customer base and geographic coverage, and their environmental campus would serve as a “one-stop shop” for customers.

After extensive research on equipment and MRF design, Dem-Con selected San Diego-based CP Group as the exclusive equipment provider for the DCMRF in May 2013. The partnership with CP aligned Dem-Con with a leading U.S.-based company that has decades of extensive success in the recycling industry; specifically engineering and manufacturing MRF’s. This project gained momentum quickly, and the first load was tipped at the DCMRF in November 2013.

MATERIALS RECOVERY

2015 Excellence Recycling Systems Award Entry

DEM-CON MRF

Page 31. Design and Planning of Recycling System


1. Tipping Floor2. In-Feed Hopper and Drum Feeder3. Pre-Sort Cabin4. OCCScreen5. Glass Breaker Screen6. OCC QC 7. ONP NEWScreen8. Mixed Paper CPScreen9. Fiber Cabin10. Fiber Bunkers11. Container Presort12. Drum Magnet

13. Aladdin Optical Sorter14. Container Cabin15. Eddy Current Separator16. Container Storage Silos17. Container Baler18. Fiber Baler19. Glass Cleanup System

Mixed single stream and commercial material arrive at the state-of-the-art 70,000 square foot Dem-Con Material Recovery Facility in Shakopee, MN. The commingled materials are then processed, separated, sorted and baled by advanced equipment. Below is a step by step look at the processing sequence.

STEP BY STEP LOOK AT THE DESIGN OF THE RECYCLING SYSTEM: The DCMRF design incorporates all of the advanced processing equipment needed to sort the targeted commodities with a 95% recovery rate: paper, plastic, ferrous, non-ferrous, and glass. Each component does its part it creating a marketable commodity.

Tipping Floor Conquest Baler Feed

MATERIALS RECOVERY


DEM-CON MRF

STEP BY STEP LOOK AT THE MATERIAL FLOW AND DESIGN OF THE RECYCLING SYSTEM



The In-Feed Hopper stores small amounts of recyclables and feeds them to the Drum Feeder which spins around and spreads the recycla-bles out evenly as they enter the system.

The tipping floor is used to store the incoming mixed recyclable materials prior to processing. The incoming trucks dump the recyclable materials onto the tipping floor after leaving the facility scale.

Before the recyclable materials reach the pro-cessing equipment, sorters in the Presort Cabin remove trash and oversize recyclable items that do not process well in the system or that may damage or tangle in the recycling equipment.

The Old Corrugated Cardboard (OCC) Screen is an inclined series of rotating steel discs that separate 3D objects, such as containers, from large 2D objects, such as OCC, using specialized spacing between discs. 2D paper and other materials are removed by agitation, causing them to fall between the discs.

The Glass Breaker Screen is a series of rotating metal discs that break the glass and separate it from the three dimensional containers and the two dimensional fibers (office paper, junk mail, news, etc.). The broken glass is very abrasive and is removed early in the system to reduce wear and tear on the equipment. The material is then sent to the glass clean up system.

This station provides an opportunity for the sorter to remove any materials that are not OCC that may have made it through the OCC screens before the OCC drops onto the tipping floor to be baled and sent to the end markets.

The Old News Print Screen (ONP) is an inclined series of rotating rubber star discs that sepa-rates Old News Print from mixed paper andcontainers. Materials that are too small or rigid fall between discs or down the incline to be separated and the ONP continues up and over the screen into the Fiber Cabin.

The Mixed Paper Screen (CP NEWScreen) is a series rotating rubber discs with small screen openings that separate small fibers from containers—that is, 2D from 3D material. The mixed paper continues up and over the top of the screen and into the Fiber Cabin. Screens ensure that material is sized properly for the most efficient sorting possible.

The Fiber Cabin provides an opportunity for quality control and additional manual sorting of the ONP and Mixed Paper. Items removedfrom the belt in this area are typically containers, plastic film, small OCC, and trash. These mate-rials can be dropped into chutes that return theproducts back into the system for further pro-cessing or disposal.

The materials that pass through the Fiber Cabin drop into the Fiber Bunkers for storage prior to being pushed into the Fiber Baler.

The Container Presort provides an opportunity to remove any materials that are not containers such as paper, plastic film, and trash. Thesematerials are removed from the belt and dropped into chutes that return the products back into the system for further processing or disposal.

The Drum Magnet is a high-powered drum magnetic that attracts ferrous metals to the re-volving shell which rotates and moves past the magnetic field so the materials can be releasedonto a conveyor which transfers the materials into the ferrous metals silo.

MATERIALS RECOVERY

STEP BY STEP LOOK AT THE DESIGN OF THE RECYCLING SYSTEM


DEM-CON MRF



The MSS Aladdin automatically sorts selected materials through optical recognition. Using an infrared sorting system, it separates plastic bottles from any remaining materials on the container line. Within milliseconds, the Aladdin identifies plastic using an infrared camera, then instantly shoots a burst of air to blow the recyclables onto a conveyor which transfers the materials into the silo.

The Container Cabin is where cartons (milk, juice, broth, etc.) and other plastic containers, such as milk and juice jugs, yogurt containers, and detergent bottles are sorted from the line into their respective silos. After sorting and removing the plastic containers in this cabin the only items left on the belt are aluminum and trash.

The Eddy Current Separator uses the repulsive force of magnets to separate aluminum from the remaining materials on the belt. The alternatingmagnetic field repels the aluminum materials off of the belt and over a divider onto a conveyor which passes by a quality control station for final inspection before being blown into the aluminum silo.

The silos store all the sorted plastics and metals prior to delivery to the Container Baler. Once each silo is full, it is dumped onto the containerbaler conveyor which feeds the Container Baler.

The IPS 2 Ram Baler compresses the sorted plastic and metal materials into rectangular blocks called “bales”, which make them easier to store and transport to end markets. The bales, which are bound with steel wire, vary in size, but typically measure 3’x 3’x 4’and weigh up to 1,500 pounds each.

The IPS Conquest Baler compresses the fiber into rectangular “bales”, which make them eas-ier to stack and transport to the end markets. The bales, which are bound with steel wire, vary in size, but typically measure 3’ x 3’ x 4’ and weigh up to 2,500 pounds.

The Glass Cleanup System removes metals, shredded paper and other small fibers and plastics that pass through the Glass Breaker Screen from the broken glass by using a head-pulley magnet, vibrating high speed belt, suction hoods, and a cyclone. The clean glass is then conveyed outside the building to the Glass Storage Bunker.

A DCMRF Tour Viewing the Sorting Cabin

MATERIALS RECOVERY


DEM-CON MRF

Page 6

STATE-OF-THE-ART DESIGN: The DCMRF houses high-tech processing equipment with a system layout conducive to high efficiency. The MRF contains special automated and mechanical equipment for each targeted commodity. All equipment works together with synergy for a complete state-of-the-art system with maximum volume. The Dem-Con MRF is one of the newest and largest MRF’s in the Midwest with the most up to date technologies developed by a leader in MRF design and manufacturing, the CP Group.

• A state-of-the-art sorting machine, the MSS Aladdin™ Near-Infrared (NIR) optical sorter, is a focal point of technology as it is able to automatically sort plastic bottles at very high capacities. This was included in the design of the system to capture plastics in a highly automated fashion with 98% accuracy. Since plastic bottles as a commodity are increasing, it was important to be able to have the flexibility in the system design to capture more plastics as capacity increases over time. State-of-the-art electronics process the detected signals and activate air valves which eject the targeted bottles. The incoming material is distributed over the MSS Aladdin™ width and travels underneath the sensor array, which is mounted on top and at the end of a high/speed acceleration belt. Material is separated while it is “in flight” for increased efficiency and accuracy.

• The plant is equipped with two high-capacity IPS Balers, both with direct-bale ability. Including two balers was designed to give DCMRF more flexibility and capacity for high efficiency operations. The IPS patented Conquest Auto-Tie Hinge-Side™ baler provides the widest charge box opening available and has a very high production rate producing excellent bale density, allowing the DCMRF to bale large capacities of the residential or source separated OCC. Since the system receives 40% OCC, this was an important aspect to the design. The patented IPS 2-Ram Bale-Tie multi-material baler bales while it ties to increase through-put rates. This additional multi-material auto-tie baler was instrumental in design versatility and operational efficiency.

• The facility contains a permanent Drum Magnet for ferrous material recovery. The Drum Magnet has lower maintenance requirements, is more reliable and uses less power than a cross-belt electromagnet, which is what is typically used in single stream facilities.

• The facility is designed with very innovative screening technology. The CPScreen, the two NEWScreens, and the GlassBreaker Screen are equipped with CP’s SyncDrive™ technology. The CP SyncDrive™ is an advancement in disc screening which employs belt drives versus chains drives. These screens are the only ones in the industry with this patented feature, which decreases screen maintenance by eliminating the need for oilers, tensioners or adjustments. Belt-drives are also much quieter than chains. These are unique DCMRF operational benefits.

The Hinge-Side

1. Design and Planning of Recycling System


The high capacity balers: IPS Conquest Baler and the Two-Ram Bale-Tie Baler

“In-Flight” Optical Sorter Detection

CP SyncDrive™

MATERIALS RECOVERY


DEM-CON MRF

Page 7

ENVIRONMENTAL PROTECTION, IMPACTS ON HUMAN HEALTH, ENVIRONMENTAL QUALITY AND RESOURCE CONSERVATION: The addition of a materials recovery facility to Dem-Con’s environmental campus offers Dem Con’s customers and the surrounding communities one of the most integrated environmental campus’ in the Twin Cities and upper Midwest. Approximately 5,000 tons of materials per month are recycled at the DCMRF, avoiding landfills or incinerators. The facility offers material conservation of virgin materials otherwise needed to make new products derived from plastics, metals, glass, and fibers.

Dem-Con’s facility is strategically placed in the southwest corner of the Twin Cities metro to meet the needs of the surrounding communities. This offers a huge carbon footprint savings for the number of miles driven by residential trucks to previously unload materials. Given Dem-Con’s strategic location with easy access to many small communities, they are able to offer single stream to more rural counties and residences in greater Minnesota.

1. Design and Planning of Recycling System


Dem-Con companies has been committed to improving the environment of their surrounding Twin City neighborhoods for 3 decades, since 1965. Dem-Con is locally owned and family operated with the community and environment defining their industry leading business practices. Dem-Con’s environmental Campus (shown below) contains the Dem-Con MRF, Dem-Con’s Construction and Demolition facility, Dem-Con’s shingle processing facility, Dem-Con’s Landfill, the MSW transfer station, the scrap yard, and Dem-Con’s wood processing facility, which all work together towards an integrated waste management system.

OVERALL MERITS AND IMPACTS OF RECYCLING PROGRAM : Dem-Con’s facility offers the communities around the facility an opportunity to recycle more while minimizing their impact on the environment. With a facility strategically placed like DCMRF’s, many suburbs and surrounding small communities now have the ability to economically offer single stream recycling to their residents. A large facility with processing capacity allows many haulers in Dem-Con’s footprint to offer single stream recycling at a competitive rate. Dem-Con’s merchant model, focusing solely on processing and servicing their hauling customers, is a unique model and the only one in the local marketplace. This model allows Dem-Con to take a broad approach and look at different ways they can service their customers and have a positive impact in the communities they serve.

DCMRF is conveniently located in the far southwest corner of the metro, which allows them to source and accept materials not only in the Twin Cities, but from greater Minnesota as well. Hwy 169 is a major road that allows easy access to the facility from many areas. Rural counties and cities that once could not offer single stream now can.

Dem-Con C&D Recycling Wood

Processing Facility

Dem-Con Shingle

Recycling and Scrap

YardDem-Con

Offices

Landfill

Dem-ConMRF MSW

Transfer Station

MATERIALS RECOVERY


DEM-CON MRF

THE EQUIPMENT USED AT THE FACILITY : Dem Con Companies worked with San Diego-based CP Group to design, manufacture and install the new 20TPH processing system at their Shakopee MRF, with a focus on functionality, safety, innovation, education and the environment. The following describes the opera-tional and technological features of the equipment to manage the residential and commercial single-stream materials processed:

Page 82. Use of Equipment/Systems and Technologies

2. USE OF EQUIPMENT/SYSTEMS AND TECHNOLOGIES

The CP Drum Feeder cost-effectively layers light and heavy materials at theoutset prevents surges and provide a consistent material feed rate. It is configured with large unique bolt-on cast chromium alloy paddles, which helps break and fluff up the material without shredding or tearing and is very effective for commercial material, bagged material and broken bales. This horizontal drum feeder discharges onto a separate incline conveyor which feeds onto the pre-sort line.

Mechanical sorting plays an important role in the facility. The first screen is the CP OCC Disc Screen which removes cardboard from the rest of the stream. The OCC Screen uses large serrated offset steel discs that rotate and propel the cardboard forward. The elliptical disc pattern provides additional lateral agitation to liberate other material, leaving the OCC end-product well sorted and highly marketable. All other materials such as smaller fiber and containers fall through the openings and go on to the next screening step.

The second disc screening process removes all glass and small pieces of material, known as “fines”. The CP Glass Breaker Disc Screen uses durable cast chromium elliptical discs resistant to wear. These heavy duty spinning discs break all glass and separate it from fiber and containers at maximum efficiency, without losing aluminum or other valuable commodities.

After the fines and glass are removed from the main stream, the remaining material, mainly containers and fiber, travel to the next disc screening process in the system, the two CP NEWScreens. These screens are engineered to effectively separate larger fiber from mixed paper and containers. The patented finger-disc technology pulls the large fiber over the top and bounces containers and small fiber back off its bottom end.

OCC

UNDERS

GLASS & FINES

OVERS

NEWScreens OCCScreen Drum Feeder

CONTAINERS & 3D

NEWS & 2D

MATERIALS RECOVERY


DEM-CON MRF

Page 92. Use of Equipment/Systems and Technologies

2. USE OF EQUIPMENT/SYSTEMS AND TECHNOLOGIES

While the large fiber separated by the NEWScreens makes its way over to the inspection stations, the small fiber and containers continue along to the CPScreen™, where mixed paper is sorted from containers. The long-lasting rubber cam-style discs of the CPScreen™ feature small screen openings and are specially engineered to minimize loss of fiber to the containers, recovering even the smallest pieces of paper and ensuring that material is sized properly for the most efficient sort possible. The cam-discs are also highly resistant to wrapping and jamming.

At this point in the process, it is time to separate the steel from the rest of the containers. The steel comes into close contact with the Drum Magnet, a large rotating drum that magnetically attracts the steel to it, and pulls it over the top. The rest of the material falls onto a conveyor that takes the remaining material to the Aladdin and the Eddy Current Separator to separate the plastic and aluminum containers.

The next step in the sorting process is the most technologically advanced and automated. The MSS Aladdin Optical Sorter automatically sorts the plastic #1 bottles from the remaining material stream at 4-6 tons per hour with a 98% accuracy rate. The Aladdin identifies the plastics with near-infrared (NIR) and color sensing capabilities to sort by resin, color, and opacity.

As aluminum cans or other non-ferrous metals pass over the head pulley of the Eddy Current Separator, an alternating electro-magnetic field creates eddy currents that repel the aluminum cans away from the plastics, generating a clean aluminum fraction. At this point in the process, cardboard, mixed paper, glass, aluminum, steel, plastic, and small residue have been separated and are ready to be baled by one of the two high capacity balers in the system.

The facility houses bunkers for fiber and silos for containers. The sorted cardboard, newspaper mixed paper, aluminum, tin, and plastic commodities are stored in their respective silos and bunkers until they are ready to be baled and shipped . Once the silos and bunkers are full, the material is conveyed to either of the two balers: the fiber is baled by the IPS Conquest Baler and the containers and cans by the IPS Two-Ram Baler.

CONTAINERS & 3D

FIBER & 2D

PLASTIC EJECTED

Drum Magnet Eddy Current Separator Two Ram and Conquest Balers

MATERIALS RECOVERY


DEM-CON MRF

Page 103. Regulatory Compliance

3. REGULATORY COMPLIANCE

• Minnesota Pollution Control Agency (MPCA) PRB #001011 • Industrial storm-water permit #MNR053453• Scott County solid waste facility license• Conditional use permit #1358-C-7 with Scott County Minnesota

Additionally, Dem-Con’s environmental campus also consists of a fully permitted industrial waste landfill, construction and demolition materials recovery facility, wood recycling facility, MSW transfer station, shingle recycling facility, and metal recycling yard. All of these facilities are in compliance with local and state rules and regulations.

COMPLIANCE- ENVIRONMENTAL LAWS & REGULATIONS: DCMRF permits:

REGULATORY CITATIONS: The Dem-Con MRF has no regulatory citations to date.

Minnesota Pollution Control Agency DCMRF Solid Waste Recycling Facility Permit By Rule Acknowledgment

Criteria Met for Plat Approval and Compliance:1. Adequate Drainage 2. Adequate Potable Water Supply3. Adequate Roads or Highways to Serve the Subdivision 4. Adequate Waste Disposal Systems5. Consistency with the Comprehensive Plan6. Public Service Capacity7. Consistency with the Minnesota Environmental Quality Board's Policies8. Consistency with Capital Improvement Plans9. Landscaping10. Building Code and Design

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MATERIALS RECOVERY


EMPLOYEE TRAINING AND FREQUENCY AND TOPICS: New hires are on-boarded with immediate readings and discussions on safety policies at the MRF. This is a 2 page document that highlights basic safety, protocols, and procedures for safe operation at the facility. Permanent Dem-Con employees attend periodical online webinars that highlight critical tasks such as lock out tag out, ladder safety, safe lifting procedures, and forklift safety. Employees participate in sorting training, which focuses on teaching sorters how to identify hazards and unacceptable material. DCMRF employees also complete an online safety training module and must answer questions accurately to earn certificates. These certificates are printed with employees’ names with dates completed. DCMRF operators attend a MRF operators class that is offered through the MPCA. Safety classes are conducted quarterly with MRF employees that are focused meetings with near-miss occurrences talked about and highlighted as well as other specific safety tasks. Random safety checks are performed and enforced by supervisors.

Page 114. Worker Health and Safety

4. WORKER HEALTH AND SAFETY

SAFETY PROCEDURES, ENFORCEMENT AND INJURY RATES: DCMRF takes employee safety very seriously as their number one priority and enforce with zero tolerance. Safety highlights:• Monthly safety audits are done by the plant manager to ensure overall site safety.• Some violations are zero tolerance policies that result in termination such as lock-out tag out• Other violations are on a yearly warning system. 1st violation is verbal, 2nd is written warning, 3rd is day off

with no pay, 4th is termination. The situation dictates which degree of enforcement is taken.• Dem-Con has had 1 lost time injury since inception in Nov. 2013, shortly after startup.

• An employee using a ladder over a pit area without using the proper ladder techniques outlined in the employee safety manual. This individual fell from the ladder and was injured from the fall which resulted in a lost time incident. The direct supervisor and management had an incident review meeting with the employee within 48 hours to review what happened and talk about how to prevent it from happening again. An additional ladder use and safety training program was implemented and required that all employees who touch a ladder have been certified through the training program. The safety manual was reviewed and additional language added to include the formal ladder safety class requirement. An articulating man lift with a bucket was purchased to avoid ladder use for most applications. There have been no incidents since.

• Dem-Con has had 5 minor injuries with no-lost time with employees on the sorting line• The minor injuries reported were all hand pricks from various sharp objects on the line.

The safety team has worked hard to find the right gloves that work well for employees given the drastic change in seasons, which range from 100 degrees in the summer to below zero in the winter. The appropriate gloves have been identified to wear during the seasons to protect workers.

When Dem-Con was considering MRF equipment vendors, equipment safety was one of the factors considered in determining the right supplier. CP Group’s approach to engineering safe equipment stood out. Numerous design elements were included for operational safety, including: • All disc drives on screens have brake motors with locking hand release levers. Brakes activate

when power goes off, locking rotors, which can’t turn when personnel is walking on them.• Lanyard anchorage connectors, which wrap around l-beams and other structures support

workers during maintenance mode. Crossbars above the rotors provide valid anchor points.• Trapped key interlocks (lock-out tag-out) are used to ensure safe access to potentially live

equipment. A safe sequence of operations is enabled through transfer of keys that are either trapped or released in a predetermined order. With the double key system, the machine cannot be started while the doors are unlocked.

• The CPScreen and NEWScreen contain a fold-down service platform to access rotors. The floor is moved by hydraulic cylinders, and can only be unfolded when the screen is in its lowest position, or maintenance mode. This system eliminates the risk of falling during maintenance.

Lock-Out Tag-Out

ScreenFolding Floor

Safe Screen Access Door

MATERIALS RECOVERY


DEM-CON MRF

Page 12

5. PERFORMANCE, ECONOMICS & COST-EFFECTIVENESS

THE FACILITY’S WASTE SCREENING PROCEDURE: DCMRF accepts recyclable materials generated from commercial and residential sources. Before the material enters the MRF, Dem-Con goes to great lengths to ensure proper material is being put in the proper bin. DCMRF educates residents and partners alike to maintain a high quality material stream. The brochure to the right is an example of an educational piece produced and released by DCMRF.

The screening starts at the scale by scale operator asking the haulers what material they have and what their origin is. Material is then screened on the tip floor by the loader operator, line supervisor, and presort cabin personnel. Any unacceptable material is sent back with the hauler immediately. If material is found in presort cabin, it is pulled off the line and disposed of properly on site.

5. Performance, Economics & Cost-Effectiveness

The Dem-Con MRF has proven capable of operating at its anticipated production rate of 20 tons per hour for commingled materials and 20 tons per hour of source separated materials. The plant was designed to recover 95% of the targeted recyclable materials, and it is achieving that goal.

EFFICIENCY AND EFFECTIVENESS OF THE EQUIPMENT: Dem-Con selected CP Group as the DCMRF equipment provider after months of research, site tours, and discussions. The equipment has allowed Dem-Con to be successful as a facility right from the beginning, since the key turned and the system started up. This allowed Dem-Con to focus on different areas such as customer service and community education. The system as a whole operates very smoothly with each of CP’s components working together synergistically to produce the highest quality product possible. Dem-Con relies on the quality of products that are sent to end markets to develop strong relationships based on trust built through Dem-Con’s ability to send high quality products to market. The highly efficient equipment makes this possible. DCMRF is achieving a 95% recovery rate of the targeted materials.

HOW FACILITY SUCCESS IS MEASURED: The DCMRF has created value numerous ways in their community and within their organization. This is how they measure success of the DCMRF:• Number of jobs created and sustained for the community. When this facility opened, close to 50 new jobs were

created opening up many opportunities for individuals in the local community.• Financial performance. Maintaining and operating a facility that has positive, healthy margins month in and

month out that allow Dem-Con to optimally run the facility and service customers.• Recycling rate. Being able to positively impact the Twin Cities and greater Minnesota offering single stream

recycling to their hauler customers while increasing recycling participation.• Employee engagement. Offering a safe, secure work environment where Dem-Con employees can grow in their

careers and have a positive impact on the company.

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FIBERS PLASTICSMETALS & GLASS UNACCEPTED

Beer & soda cases

Brown grocery bags

Broth boxes

Cake & snake boxes

Cardboard (non-waxed)

Catalogs

Cereal boxes

Drink boxes

Juice cartons

Junk mail

Magazines

Milk cartons

Newspaper & Inserts

Office / school paper (all colors)

Pizza delivery boxes

Telephone books & other soft cover books

Aluminum cans

Cooking pots & pans

Empty aerosol cans (non-toxic & no caps)

Steel food cans

Tin & other household metals

All colored glass (brown, green and clear)

Beer bottles

Glass containers that contained a food or beverage product

Berry containers

Butter tubs

Juice containers

Milk jugs

Narrow neck and screw top plastic containers with symbol #3-#7

Plastic containers with symbol #1 & #2

Plastic toys

Plastic totes & bins

Sqeezable bottles with symbol #4

Water bottles

Yogurt tubs

Auto glassCeramicsChristmas lightsClothesCoat hangersCompostable plastics (#7 PLA)DiapersDishwareDrinking glassesElectronic waste (batteries, phones, etc.)Extensions cordsFood waste / organic materialGarden hosesGlass bakeware/cookware (Pyrek)Hazardous chemical containersLight bulbsMedical wasteMicrowave traysMirror glassMotor oilNeedlesPacking peanutsPaper products with food residuePlastic bags and filmPlastic tarpsPlastic food wrapsPorcelainStyrofoamSyringesWaxed cardboard and paperWindow glassEDUCATE. INNOVATE. RECYCLE.

Beer & soda casesBrown grocery bagsBroth boxesCake & snake boxesCardboard (non-waxed)CatalogsCereal boxesDrink boxesJuice cartonsJunk mailMagazinesMilk cartonsNewspaper/ InsertsOffice / school paperPizza delivery boxesTelephone books /soft cover books

Aluminum cansCooking pots & pansEmpty aerosol cans(non-toxic & no caps)Steel food cansTin & other householdmetalsAll colored glass (brown,green and clear)Beer bottlesGlass containers thatcontained a food orbeverage product

Berry containersButter tubsJuice containersMilk jugsNarrow neck and screw- top plastic containers withsymbol #3-#7Plastic containers withsymbol #1 & #2Plastic toysPlastic totes & binsSqeezable bottles withsymbol #4Water bottlesYogurt tubs

Auto/mirror glassCeramicsChristmas lightsClothesCoat hangersCompostable plas-tics (#7 PLA)DiapersDishwareDrinking glassesElectronic wasteExtensions cordsFood waste Garden hosesCookwareHazardous chem.Light bulbsMedical wasteMicrowave traysMotor oilNeedles/syringesPacking peanutsPlastic bags / filmPorcelainStyrofoam

MATERIALS RECOVERY


DEM-CON MRF

Page 13

5. PERFORMANCE, ECONOMICS & COST-EFFECTIVENESS

OPERATIONAL PERFORMANCE EXCEEDS GOALS AND EXPECTATIONS: DCMRF opened in November of 2013. Little did they know, that winter was going to be one of the harshest winters they’ve had in many years in the Twin Cities. Extremely cold weather proved to be very challenging operationally as Dem-Con opened their new facility. This challenge proved to help understand the system better and what it takes to successfully run the MRF. The DCMRF team pulled together and successfully navigated the start-up, holidays, and winter, and hit their stride when the spring temperatures came. As a new single stream MRF operator, Dem-Con learned how to consistently get better at managing the facility. They strove to produce a better, more efficient way to recycle that creates a better quality product in the end. Today, the Dem-Con MRF processes about 250 tons per day, or 5,000 tons of material per month, and is producing a very high quality product. They’ve met processing goals and aim to continue adding volume to reach their ultimate shift capacity.

5. Performance, Economics & Cost-Effectiveness

THE SYSTEM’S EXPERIENCE WITH DOWNTIME: The Dem-Con MRF has encountered little downtime. When down time has occurred, CP Group’s Electrical Control division Advanced MRF, has been able to correct by dialing in remotely. The remote control and electrical access CP has to the system, even though they are 2,000 miles away, has been extremely helpful in reducing downtime and fixing any technical issues quickly. Other downtime has been due to unacceptable material making it through the line and jamming equipment. DCMRF is prudent with education on acceptable material, but occasionally unacceptable materials makes their way through.

HOW THE ORGANIZATION FOSTERS CUSTOMER SERVICE: Dem-Con is a 3rd generation family owned company that takes pride in their operations and relationships. DCMRF has a hands on approach with each of their customers demonstrated by transparency and communication in regards to recycling rebates. The customer has a waste sort performed on their loads periodically to determine the matrix of commodities they bring to the DCMRF which is used to determine how the revenue sharing will be allocated each month. This approach enables customer to have individual rebates based on the quality of the materials they bring to the MRF. Each customer is then called individually by DCMRF’s business unit manager to discuss current markets and the rebates they will receiving. DCMRF believes in working with customers to educate the public to better understand what goes in the bin and what does not through educational flyers and the DCMRF website (www.dcmrf.com). Customers receive tours of the facility as a part of the account on-boarding process, they also meet the team and see the facility that will be processing their recyclables.

OPERATING WITHIN BUDGET: Dem-Con has been able to successfully operate within their budget during the first 15 months of operation. Many factors are important to facilitate operational success: • Operating the facility with minimal downtime.• Managing shifts appropriately as volumes fluctuate throughout the seasonalities of the business.• Procuring volume in geographies with customers and maintaining high customer satisfaction.• Ensuring sales to the best end markets. Many Dem-Con employees travel to tradeshows throughout the country

to network and learn what markets are available for their products.

ROI APPLIED TO THE COMMUNITY: A focus of Dem-Con from the start of the DCMRF has been education and outreach to the community and service area. The DCMRF has a state-of the art educational experience, including a “Green Grades” educational program targeted at 4th-6th graders. With over 700 visitors in year 1, the DCMRF is already on pace to nearly triple the visitor rate in year 2. The Dem-Con team is excited to grow their outreach programs and continue to help the community recycle more and recycle right.

RECOUPING COSTS: Dem-Con, a private company, maintains high industry standards when analyzing the DCMRF, and looks forward to a positive return on their investment. DCMRF takes pride in focusing on customers, offering good programs, and ensuring services match customer needs while Dem-Con maintains a healthy business.

DCMRF & the Community

MATERIALS RECOVERY


DEM-CON MRF

PUBLIC RELATIONS, PUBLIC EDUCATION, AND WHY DCMRF IS A GOOD NEIGHBOR: Dem-Con understands the importance of education and has invested in programs teaching how the facility works, what materials residents can and cannot recycle, and what residents can do to increase the amount they recycle. This is done through active social media outreach as well as on-site tours. The DCMRF educational room contains a blown-up 16’X5’ 3D rendering of the system where the Dem-Con team can “walk” people through the system using augmented reality, headphones and tablets, before they head onto the site floor. The facility houses an end-market room allowing individuals to get hands-on educational experience while learning what materials can and cannot be recycled. DCMRF’s comprehensive “Green Grades” educational program is geared towards 4th-6th graders to tour the facilities and learn about recycling and how they can be and environmental steward. Numerous custodial groups from schools tour the MRF to understand how it works and what should and should not be in the single stream bin. In the first year of operation, over 700 individuals toured the DCMRF and education center. Busing is covered by Dem-Con for the tours. Public tours of the DCMRF are offered the 3rd Wednesday of each month. DCMRF also hosts local Earth Day and Earth Week tours. DCMRF sponsors the local kids baseball teams to stay active in and supportive of the communities. DCMRF stays active in the local townships by working closely with township by participating in area clean-ups and partnering for recycling and disposal options for Township.

Page 146. Public Acceptance, Appearance and Aesthetics

6. PUBLIC ACCEPTANCE, APPEARANCE AND AESTHETICS

Explore the MRFLearn more about the MRF’s specific

capabilities and processes by:

Following the images and descriptions.

Grabing a tablet, opening AURASMA app and experiencing an interactive tour.

- Open the Aurasma Application- On the map to the right, focus on

the numbered orange shape

Following the material through the sorters, screens, conveyors and serperators. Grab your hard hat,

head phone tour and a Dem-Con tour guide and head to the tipping floor.

MAINTENANCE PROGRAMS TO KEEP FACILITY CLEAN AND AESTHETIC: Facility maintenance and cleanliness is valued and honored by all DCMRF employees and is led by the plant and assistant plant managers. Equipment is maintained by a strict daily-check schedule. Any problems are noted and fixed as immediately as possible. DCMRF also has a cleaning schedule for the interior and exterior property and equipment, some of the equipment is cleaned hourly, and more thorough cleaning is done weekly, and noted in the housekeeping log. Weekly trash pick-ups are done by employees in and around the DCMRF property. Fencing with screens installed on around building catch any debris and make the site more pleasing to eye. Netting installed on southwest corner of building where glass is discharged to keeps any debris from blowing away. Decorative paneling and landscape was completed on the east side of the building that faces the major highway and makes the building, facility, and landscape more aesthetically appealing.

The DCMRF Team is very active with local community and schools to help them better understand recycling and how they can recycle more and more efficiently. The DCMRF has proved to be a great neighbor.

DCMRF: Clean & Aesthetic

The DCMRF Green Grades Program and Community Educational Tours

https://www.youtube.com/watch?v=YxDSEUcKpjI


DEM-CON MRF

MATERIALS RECOVERYPage 15Supplemental Materials

SUPPLEMENTAL MATERIALS

80 Recycling Today August 2014 RecyclingToday.com

MRF SERIES

The forward-thinking approach of Dem-Con Cos.’ management has allowed it to incorporate single-

stream recycling into an already extensive integrated waste management campus in Minnesota.

B Y K R I S T I N S M I T H

Operating a construction & demolition (C&D) recycling facility, a shingle processing yard, a wood processing facil-

ity and a landfill on one campus sounds like a pretty full portfolio of waste and re-cycling services for one company to han-dle. But for Shakopee, Minnesota-based Dem-Con Cos., providing customers with an environmental campus to meet all of

FORWARDMoving

COMMITTED to

COMMITTED to your success.

It runs in our family of companies.

The leader in advanced sort systems

INNOVATION DURABILITY RELIABILITY

CALL 888.837.5065

OR VISIT www.cpgrp.com

INTELLIGENCE

August 2014 Recycling Today 81RecyclingToday.com

MRF SERIES

their recovery and disposal needs meant adding a single-stream material recovery facility (MRF) to its robust offerings.

As Dem-Con CEO and co-owner Jason Haus explains, “The more integrated we can be from top to bottom, the better we can service the needs of our customers.”

Dem-Con has served the Minneapolis/St. Paul and greater Minnesota area since 1965. The company operates four busi-ness units: Dem-Con Recovery & Recy-cling (DCRR); Dem-Con Shingle Process-ing (DCSP); Dem-Con Landfill (DCL); and its newest addition, Dem-Con Mate-rials Recovery (DCMRF).

“The completion of the single-stream MRF in November 2013 was a significant addition to the Dem-Con Cos. portfolio, which resulted from several years of mar-ket research and business plan develop-ment,” says Haus.

It was through research and develop-ment that Dem-Con recognized the need for additional single-stream recycling ca-pacity for the Twin Cities region and the state of Minnesota.

“With growth in the Twin Cities pop-ulation and as recycling participation increases, we saw a need for additional capacity for single-stream facilities in the state,” says Dem-Con Vice President Bill Keegan. “Additionally, Minnesota has a vision of raising recycling rates, and with more cities going to single stream, the market needed additional processing ca-pacity,” he continues.

A NATURAL FITDem-Con seemed ideally suited to handle the projected volume growth. “Having the single-stream co-located with the C&D MRF as well as a landfill creates some syn-ergies that we can capitalize on that help us better serve our customers,” Keegan says. “It was a natural fit with Dem-Con’s history of processing materials.”

Dem-Con says it was excited to part-ner with Liberty Paper Inc. (LPI) of Becker, Minnesota, on the venture. LPI recycles old corrugated containers (OCC)

into new packaging grades. It consumes 200,000 tons of OCC each year.

“Liberty Paper has a great reputation in the marketplace and has many years of experience marketing materials,” Keegan says. “Leveraging this expertise on the end markets as well as Dem-Con’s experience in facility operations, it was a natural fit to partner together.”

Permitting for the new 60,000-square-foot single-stream facility went smoothly, according to Keegan, taking only nine months for state and local approvals. Dem-Con broke ground in May 2013, and the plant was running by November 2013.

CP Group of San Diego designed, sup-plied and installed the equipment, which includes an OCC screen, glass-breaker screens and two additional screens for old newspapers (ONP) and mixed paper. A MSS Aladdin optical sorter separates vari-ous types of plastics. The single-stream processing equipment also includes an eddy-current separator, a glass cleanup

system and two IPS balers: a two-ram baler for containers and specialized ma-terials and a Conquest for fiber baling.

Keegan says Dem-Con selected the CP Group because the U.S.-based company rated highly in terms of customer service, attention to details and value.

As for the installation process, he says, “Overall the process went smoothly and we were able to meet our deadlines before cutting the ribbon in November.”

CHILLY CHALLENGESThe MRF opened just in time to face one of the coldest, snowiest winters in recent history. Minnesotans are used to bad win-ters, but the winter of 2013-14 was partic-ularly severe, according to Keegan.

“The winter was brutal,” he remarks. “Having 53 days of below-zero tempera-tures presented a lot of equipment chal-lenges. Getting all the belts and conveyors to run each morning after being idle in sub-zero temperatures was a work of art.”

Keegan says, despite the weather, the MRF continued to run without major hic-cups or halts in service during the winter.

The MRF accepts all fibers, plastics No. 1-7, glass and metals.

Dem-Con operates a merchant model, meaning third-party haulers collect mate-

rial and haul it to the facility for process-ing. The materials come from the Twin Cities, greater Minnesota and surround-ing states. About 80 percent of the ma-terial is from residential recycling, while 20 percent is from commercial recycling programs. The facility is currently operat-

Dem Con’s new single-stream MRF includes screens, an optical sorter, an eddy-current separator and balers.

COMMITTED to

COMMITTED to your success.

It runs in our family of companies.

The leader in advanced sort systems

INNOVATION DURABILITY RELIABILITY

CALL 888.837.5065

OR VISIT www.cpgrp.com

INTELLIGENCE


COMMUNITY INVOLVEMENTDem-Con Cos., Shakopee, Minnesota, is interested in more than processing single-stream recyclables at its new material recovery facility (MRF), which opened in November 2013. Within the 60,000-square-foot building is an educational room where members of the community can view the recycling process in action.

The company invests in programs to educate the public on how the facility works, what materials are accepted in the recycling program and ways to increase recycling. A 3-D rendering of the single-stream system with aug-mented reality technology is housed in the educational room to help the public gain an understanding of how the equipment works prior to touring the facility. In addition, an end-market room shows firsthand the materials that can and cannot be recycled.

“We are excited to provide these services to the Twin Cities and greater Min-nesota and [to] be an active part of increasing recycling rates and diverting more materials from landfills,” Bill Keegan, vice president of Dem-Con, says.

MRF SERIES

ing two shifts per day and has the ability to process in excess of 110,000 tons per year at full capacity. It is currently processing 275 tons per day.

Haus says, “To be continually success-ful, we believe that if we are not moving forward, we are losing ground. We spend a lot of time as a company looking at what is left over after our current pro-cesses and find new options to deal with those materials, with the landfill being the last option.”

While Keegan says Dem-Con wishes to further process material and to look for opportunities to expand, he also rec-ognizes the customers’ role in its innova-tion. “We are fortunate to have customers who are forward thinking as well and look for ways to better service the communi-ties around us together,” Keegan says.

The author is a managing editor for the Recycling Today Media Group and can be reached at [email protected].

We help recycling plants and MRFs reach their full potential.• Plant operations and maintenance consulting• Equipment installation and moves• Plantretro-fits

We do not sell recycling machinery.We help make recycling machinery work for you!

MRSS, Inc. 855 ׀ Rowland Springs Rd., Cartersville, GA 30121 ׀ 770.382.1720 ׀ MRSSinc.com

Optimize Operations.Optimize Profitability.

OperatingCoast-to-

Coast

H E L P I N G Y O U M A X I M I Z E Y O U R M A C H I N E R Y I N V E S T M E N T .


COMMUNITY INVOLVEMENTDem-Con Cos., Shakopee, Minnesota, is interested in more than processing single-stream recyclables at its new material recovery facility (MRF), which opened in November 2013. Within the 60,000-square-foot building is an educational room where members of the community can view the recycling process in action.

The company invests in programs to educate the public on how the facility works, what materials are accepted in the recycling program and ways to increase recycling. A 3-D rendering of the single-stream system with aug-mented reality technology is housed in the educational room to help the public gain an understanding of how the equipment works prior to touring the facility. In addition, an end-market room shows firsthand the materials that can and cannot be recycled.

“We are excited to provide these services to the Twin Cities and greater Min-nesota and [to] be an active part of increasing recycling rates and diverting more materials from landfills,” Bill Keegan, vice president of Dem-Con, says.

MRF SERIES

ing two shifts per day and has the ability to process in excess of 110,000 tons per year at full capacity. It is currently processing 275 tons per day.

Haus says, “To be continually success-ful, we believe that if we are not moving forward, we are losing ground. We spend a lot of time as a company looking at what is left over after our current pro-cesses and find new options to deal with those materials, with the landfill being the last option.”

While Keegan says Dem-Con wishes to further process material and to look for opportunities to expand, he also rec-ognizes the customers’ role in its innova-tion. “We are fortunate to have customers who are forward thinking as well and look for ways to better service the communi-ties around us together,” Keegan says.

The author is a managing editor for the Recycling Today Media Group and can be reached at [email protected].

We help recycling plants and MRFs reach their full potential.• Plant operations and maintenance consulting• Equipment installation and moves• Plantretro-fits

We do not sell recycling machinery.We help make recycling machinery work for you!

MRSS, Inc. 855 ׀ Rowland Springs Rd., Cartersville, GA 30121 ׀ 770.382.1720 ׀ MRSSinc.com

Optimize Operations.Optimize Profitability.

OperatingCoast-to-

Coast

H E L P I N G Y O U M A X I M I Z E Y O U R M A C H I N E R Y I N V E S T M E N T .

12 RR | May 2014

One of the primary attractions of Shakopee, Minnesota is “The Landing,” an

almost 100-acre historic village that offers a working representation of life in the

Land of 10,000 Lakes from the mid-19th Century. While residents of the suburb

of the Twin Cities didn’t have curbside recycling pick-up in 1860, much of greater Minnesota

does in 2014, and the brand-new Dem-Con Materials Recovery Facility in Shakopee can

process recyclables from any and all of the haulers in the region.

The 60,000-square-foot MRF is fed through mostly single-stream recycling collection

programs from the greater Minneapolis and St. Paul area and is expected to take in 60,000

tons of commingled curbside materials in 2014 along with 25,000 tons of source-separat-

ed material.

The mix of that material is approx-

imately 55 percent fiber and 35 percent

containers.The equipment for the state-of-the-

art facility is entirely provided by the

CP Group and incudes a drum feeder,

various proprietary screens – including

the company’s OCCScreen, glass breaker,

NEWScreen and CPScreen. The facility

also contains an eddy current separator, a

drum magnet, a glass clean-up system, an

MSS optical sorter – a near-infrared sorter

for plastics – and two IPS balers.

The facility is a merchant MRF

catering to all of the haulers serving the

Twin Cities and accepts materials from

commercial entities, handling single-,

dual- or multi-stream loads.

The daily throughput of the MRF is

around 280 tons for both commingled

recyclable materials and for fiber, all

processed on the facility’s one processing

line. The residue rate for the MRF is

less than 10 percent and the issues facing it will sound familiar to all MRF owners and operators,

MRF of the Month

Dem-Con Materials Recovery Facility

echnical

Specifications

Dem-Con Materials

Recovery Facility

Location:

Shakopee, Minnesota

Start-up date:

November 2013

Number of processing lines:

One

Throughput:

20 tons per hour for both fiber

or commingled materials

Tons of material expected to

be processed in 2014:

Over 85,000 tons

Residue rate:

Less than10 percent

www.resource-recycling.com

July 2014

Cleaning Up Dirty MRFsTracking Industry Nonprofits

DCMRF has been featured in many industry publications: Resource Recycling, including a cover shot and MRF of the Month, Recycling Market’s feature story, Recycling Today’s MRF Series and numerous other articles within the trade publications such as Waste360 and Recycling Product News. They have also been featured in the local StarTribune, Belle Plaine Herald, and Shakopee Valley News.

DEM-CON MRF - Waste Recycling Equipment … · DEM-CON MRF 2015 Excellence Recycling Systems Award...

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