Recycling Horticultural Films: Handling and Marketing Lois Levitan Recycling Agricultural Plastics...

Recycling Horticultural Films:Handling and Marketing

Lois Levitan

Recycling Agricultural Plastics Program (RAPP) Dept Communication • Cornell University • Ithaca NY 14853

MID-ATLANTIC FRUIT & VEGETABLE CONVENTION, SMALL FRUITS – JANUARY 29, 2015

LEVITAN, CORNELL UNIVERSITY

My Objectives• Convey that recycling horticultural film won’t

all be smooth sailing, but is do-able

• By end of talk, have a roomful of well informed recycling enthusiasts

•

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Did you know?

Plastics embody as much

energy as gasoline


Topics

• What is recycling?

• Challenges to recycling horticultural plastics.

• Overcoming the challenges.

• Products made with recycled horticultural plastics. By whom?

• What I hope to learn from growers.

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PLASTICS RECYCLING CONFERENCE 2014 – LEVITAN, CORNELL UNIVERSITY 5

Plastics-to-OilHEAT + PRESSSURE ( + catalyst) oil or wax + inorganic residue (e.g., carbon black)

LEVITAN, CORNELL UNIVERSITY 6

Waste-to-Energy ≠ RECYCLING

ENERGY RECOVERY BY INCINERATION

(COMBUSTION AT HIGH HEAT)

Graphic: SICK Sensor Intelligence. http://www.sick.com/group/EN/home/solutions/industries/waste/Pages/waste.aspx

≠

United States: 67 large Municipal Solid Waste incinerators + several hundred industrial, medical and hazardous waste incinerators of all sizes (Source: Waste Incineration. Unites States Response to UNEP Questionnaire for Paragraph 29 Study, Enclosure 4a, Rev. May 2010)

Organic waste inorganic ash, flue gas + heat


Fuel PelletsPLASTIC PELLETS or 10% PLASTIC + BIOMASS

burns hotter, flows better

PP bulk bags


Horticultural Plastics Many different film and rigid products.

Many colors, multi-colored.Different resins, & mixes of resins, with additives.Mostly low density PE, but also HDPE, PP, PS.

PVC used historically; some still used, particularly in imported products.

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Greenhouse & tunnel covers

Mulch film

Plant pots, flats, trays: PE, PP, PS


Horticultural PlasticsChallenges to recycling

• characteristics inherent to these plastic products

• characteristics of the products after use in fields & nurseries

• cost and logistics of collection and transport from fields (or nurseries) to recycling markets

3 categories:

Photo: Delta Planstics

Challenges to recycling:• characteristics inherent to complex, technical productsThin films with multiple extrusion layers, each with additives and colorants for specific agronomic or horticultural purposes:

Block UVRepel insectsAbsorb or reflect heatEVOH O2 barrierHold moistureReinforce structurePrevent backwashStretchabilityStickinessTensile strengthFlexibilityRigidityLongevityDegradability


John DeereMax-Flat PEirrigation drip tape

Jphn Deere Pro-Flat

PVC drip tape

Plant pots, flats, seedling trays HDPE, PS, PP, blown, molded, thermo-formed

Photo: Lois Levitan, RAPP


Maple syrup tubing Mostly LDPE tubing (some old PVC tubing) with fittings, connectors, and ball valves of nylon, polycarbonate,rubber

Photoa: Lois Levitan, RAPP


Photo: Lois Levitan, RAPPUsed & stored outdoors, in mud, rain & snow

Often with residues of soil, plant debris, moisture, stones & grit Possible or perceived pesticide residues & soil pathogens

Bulky


Photos: Lois Levitan, RAPP

Challenges to recycling:• characteristics of products after use (post-consumer)


Photo: Delta Plastics

Delta Plastics (L)LDPE irrigation polytube,

Challenges to recycling:• characteristics of the products after use (post-consumer)


Baled mulch filmMulch film: strips of LDPE, typically ≤ 1 mil thick ( high surface:volume ratio).Lays on soil, gets very dirty.

White, black, silver, occasionally clear or other colors. Sometimes 2+ color layers. Some with nylon or EVOH O2 barrier layer.

Photo: Sky Plastics

Pesticide containers, chemical drums. HDPE.

Example of Extended Producer Responsibility (EPR): Ag Container Recycling Council (ACRC) financed by pesticide manufacturers and distributors. ACRC protocols require triple rinsing, special handling & approved end-uses that minimize exposure. ACRC oversees a national network of collectors, processors, end-product manufacturers. 10 million lb collected 2014; 150 million lb since began in early 1990s.



Photo: Nate Leonard, RAPP

Horticultural Mulch Film: Before & After Washing

BEFORE WASHING 1 MINUTE LATER


Paul Vanderpool: “Recyclers have learned how to recycle better”


New technologies & advances in processing equipment creating new recycling options

F. Paul VanderpoolAmerican Cierra Corporation491 Grant Ave. Auburn, NY 13021office 315-252-6630. m 315-730-6156email: [email protected]

“Recyclers have learned how to recycle better”

www.americancierraequipment.com19Photo: Lois Levitan, RAPP

• Mobile film reclamation system

• Cleans film ON-SITE, allowing flexibility in scheduling

• Bales film for shipment ON-SITE

• Self-contained, small footprint

• Meets all California power plant restrictions

• Cleans film with proprietary non–water processes

• High volume capacityContact:

Lloyd Gleaves, CEO209 495-1282, <[email protected]>

Mobile cleaning, baling, grinding equipment


Photo: Romall Ind

mailto:[email protected]

Best Management Practices (BMPs)

What not to do!

• Keep plastic clean and dry as possible

• Shake out pebbles & clumps of soil

• Roll or fold into pillow-sized bundles

• Store off ground, out of mud, grit, gravel

• Separate plastic by color and type

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Photo: Jim Zecca. Madison Co

Greenhouse, hoophouse, high tunnel coversClear or white sheets of (L)LDPE. Excellent quality for recycling.Challenge: Keep clean & remove efficiently, meeting needs of growers & recyclers



Without prep for baling:

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Photo: Jim Zecca. Madison Co

4 hrs to finish bale, vs. ½ hr with plastic prepped in stacked

bundles

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2.

3.

4.


Efficient compaction:

Challenges to recycling:• Cost & logistics of collection and transport from fields or

nurseries, etc. to recycling markets• In most of the U.S., agricultural plastics are dispersed

acrosss the rural landscape high costs of collection


Difficult to amass full 40,000 lb truckloads


Why should society & recyclers care about this particular set of plastics?

• Less than 2% of plastic discarded in US, but possibly 10% of film*

• Very visible 2-10%

• When left in the fields catches in bushes, ditches, ravines

• Alternatives to recycling not pretty: burning, burying in fields bad for air & water quality

• Landfilling costly to society

• Societal value of recycling >> economic value: All society benefits from conservation of resources & energy.

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Plastic discarded in US

Agr film

*based on VT data calculated by Annie

Macmillan, VT Agency of Agriculture.


Agricultural Plastic Recycling Markets: Processors (Reclaimers) &

Manufacturers

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• Domestic markets can & do process used horticultural plastic.• Location. Location. Location. More options, less costly to

recycle where farms (& plastic use) are concentrated: FL, CA.• Smaller, regional recycling markets important for co-mingled

supply from less concentrated areas.• Some recycling markets vertically integrate to guarantee

supply & increase efficiency. • Some pick up & some require drop-off.• Only a few pay for material.• Some take-back products after use & give credit on purchases.

Recycling markets typically put < value on difficult-to-recycle plastic than it costs to collect & transport.

BUT


http://www.deltaplastics.com/


[email protected]

Capacity to recycle 200 million lb/yr, with potential to double. Only (L)LDPE


http://encore-recycling.com/• Recycling arm of

Command Packaging.

• Opened late 2013

• 100 million lb/yr capacity (CA uses 150 mm lb/),

• Convert mulch film to 125x reusable smarterbags™ .

• $3 million CA grant Nov’14.


http://www.flagplastics.com/

Opened 2014. Collect mulch film & drip tape from large Florida farms. Shred, clean, dry film. Sell to pelletizers worldwide. 40 million lb/yr at current site.


http://www.netafimrecycling.com/

California collection area only. Pay based on dry weight polyethylene tubing, 8¢/lb towards new orders, 4¢/lb cash.


http://www.bridoncordage.com/forage/revolver.html

bridon cordage


The Blackmore Company http://www.blackmoreco.com/Call (800) 874-8660 about recycling polystyrene trays.


http://www.eastjordanplastics.com/recycling-program

Manufacture & recycle plant

containers: HDPE, PP, PS.

10 million lb/yr recycling capacity

NBF Plastics: plywood substitute, PIMS technology, anticipate 1-2 million lbs/yr

TERREWALKS® sidewalk pavers from

agricultural bale wrap, thermokinetic

processing

[email protected]

Top skin: blue boat wrap

Top skin: black & white silage bag film

Top skin: maple tubing

& fittings

Core: Irrigation drip tape

LEVITAN, CORNELL UNIVERSITY36

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TERRECON

Dishashish Plastic Manufacturers LLC: garbage bags, ~ 20% recycled b/w silage bags (1 million lb/yr). [email protected]

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Lois Levitan, PhDRecycling Agricultural Plastics ProgramDept Communication, Cornell University

Ithaca NY [email protected] 607-592-0356

QUESTIONS from YOUR EXPERIENCE:• Efficient methods/equipment that minimize dirt/debris in removing cover plastic & mulch?

• Rollers, balers or other equipment that compact plastics tightly for transport?

Please

contact

me!

mailto:[email protected]

Recycling Horticultural Films: Handling and Marketing Lois Levitan Recycling Agricultural Plastics...

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