{"id":1476,"date":"2019-05-31T09:57:29","date_gmt":"2019-05-31T07:57:29","guid":{"rendered":"https:\/\/mthreeonsite.co.za\/?p=1476"},"modified":"2019-05-31T10:20:18","modified_gmt":"2019-05-31T08:20:18","slug":"new-carton-recycling-plant-enhances-recycling-of-liquid-packaging","status":"publish","type":"post","link":"https:\/\/mthreeonsite.co.za\/index.php\/2019\/05\/31\/new-carton-recycling-plant-enhances-recycling-of-liquid-packaging\/","title":{"rendered":"Recycling: New carton recycling plant enhances recycling of liquid packaging"},"content":{"rendered":"\n

An investment of R46-million in a first-of-its-kind recycling plant in South\u00a0Africa<\/a>\u00a0\u2013 commissioned in July after a six-month\u00a0construction<\/a>\u00a0period. At the Springs-based recycling facility of\u00a0paper<\/a>\u00a0and plastics\u00a0packaging<\/a> company Mpact is set to reduce the volume of liquid-\u00a0packaging<\/a>\u00a0cartons going to landfill sites, while enhancing the quality of virgin\u00a0paper<\/a>.<\/p>\n\n\n\n

\"MThree<\/a><\/figure>\n\n\n\n

Liquid\u00a0packaging<\/a>\u00a0primarily involves\u00a0paper<\/a>-based cartons that can hold various liquids. From milk and juice to wine and even on-the-go coffee in disposable cups.<\/p>\n\n\n\n

Food and beverage cartons are lined with an internal layer of polyethylene (PE) to prevent leaks, while a thinner layer of foil is embedded within this PE coating to block out light and outside air, thereby prolonging the shelf life of the product.<\/p>\n\n\n\n

Food processing and packaging<\/a> solutions<\/a> company Tetra Pak has partnered with Mpact to further the extent of the recycling of its growing line of carton-based food and beverage products<\/a> on sale in South Africa<\/a>.<\/p>\n\n\n\n

Carton packs produced by Tetra Pak contain six layers, primarily comprising paper<\/a> made from wood-fibre resources<\/a>.<\/p>\n\n\n\n

According to Tetra Pak, carton packaging<\/a> is environment<\/a>friendly, as it is made of renewable resources<\/a> and, therefore, has less impact than traditional plastic, which is usually made of fossil materials, which are derived from finite resources<\/a>. The square shape of the packaging<\/a> also allows for larger volumes to be transported, thus cutting<\/a> down on trips made and reducing carbon dioxide emissions.<\/p>\n\n\n\n

The Mpact liquid packaging<\/a> recycling plant can process all types of liquid packaging<\/a> products<\/a>, as well as wetproof packaging<\/a> \u2013 which is also paper<\/a>-based, but prevents the ingress of moisture to a lesser extent \u2013 using chemicals embedded within the paper<\/a>. Wetproof packaging<\/a> is typically used for moisture-sensitive products<\/a> such as cement<\/a> and flour.<\/p>\n\n\n\n

Mpact Springs pulp mill manager Godfrey Zwane<\/strong> notes that the liquid packaging<\/a> recycling plant can process a vast array of cartons and wetproof packaging<\/a>, which includes disposable paper<\/a>-based coffee cups. He says that prior to the liquid packaging<\/a> being fed into the plant, sorting into appropriate streams takes place to ensure the plant is set up accordingly to process the type of material being fed into it.<\/p>\n\n\n\n

Mpact Recycling MD John Hunt <\/strong>tells Engineering<\/a> News<\/em>that the need for such a plant arose out of the vast amount of liquid packaging<\/a> products<\/a> being sold in South Africa<\/a> without an effective and efficient method of recycling them. Although another plant in the vicinity of the Mpact plant can manage the recycling of liquid packaging<\/a>, it is much smaller and uses different technology<\/a>, he adds.<\/p>\n\n\n\n

The Mpact plant has, thus, created a new source of high-quality paper<\/a> fibre for the domestic market \u2013 pulp produced by the plant is directed into one of two of Mpact\u2019s large paper<\/a>manufacturing<\/a> plants (BM3 and BM6) located on the same premises, where it can be made into a range of paper<\/a>– or board-based products<\/a>.<\/p>\n\n\n\n

Hunt points out that the fibre used to make cartons needs to be highly rigid to prevent collapsing and to maintain its form from factory to shelf, as well as to withstand bursting resulting from accidental drops and knocks. The recycled form of cartons can, thus, be used to make corrugated boxes, which are currently in short supply in South Africa<\/a>.<\/p>\n\n\n\n

The recycling of liquid packaging<\/a>, and especially that of cartons, is relatively low worldwide, notes Hunt, adding that this is catalysing a massive campaign to try to increase the recovery rates of such packaging<\/a> to promote a sustainable<\/a>and clean future. In South Africa<\/a>, he says, fewer than 20% of cartons are recycled. \u201cWe hope that this plant will enable us to increase that recovery rate to between 30% and 40%.\u201d<\/p>\n\n\n\n

One of the difficulties encountered with recycling liquid packaging<\/a> is that it is a composite<\/a> material of paper<\/a> and polyethylene.<\/p>\n\n\n\n

\u201cThe beauty of our plant is that it separates the paper<\/a> cleanly from the plastic,\u201d he enthuses, pointing out that other technologies available to recycle liquid packaging<\/a> tend to macerate everything, causing some plastic to go through into the paper<\/a> pulping and manufacturing<\/a> process. Consequently, when drying the paper<\/a> using high temperatures, the plastic melts and sticks onto the paper<\/a> rolls, causing paper<\/a> breaks and paper<\/a> contamination.<\/p>\n\n\n\n

\u201cOur technology<\/a> results in a very high efficiency<\/a> of separation . . . It is custom-built technology<\/a> specifically for liquid packaging<\/a>,\u201d notes Hunt.<\/p>\n\n\n\n

HOW IT WORKS<\/strong><\/h2>\n\n\n\n


Liquid\u00a0packaging<\/a>\u00a0is sorted and separated by, for example, manual sorting at\u00a0waste<\/a>\u00a0collection sites, after which it is compacted into square bales and tied. It is then transported to the Mpact facility, where it is sorted into different streams for materials of different types of\u00a0paper<\/a>, before being untied and loaded onto a conveyor-belt\u00a0system<\/a>.<\/p>\n\n\n\n

The material then reaches an elevated hopper, which houses an industrial<\/a> agitator \u2013 the hopper and agitator are the basis of the technology<\/a> of a machine called the hydropulper. Once loaded into the hopper, a small volume of water<\/a> is added according to the volume of material.<\/p>\n\n\n\n

Hunt points out that the volume of water<\/a> is a critical aspect in ensuring that the plant operates efficiently to cleanly separate the plastic and paper<\/a> fibre. The plant is then operated at high consistency using a relatively small volume of water<\/a>, unlike the liquid packaging<\/a> plant, which uses larger water<\/a> volumes. This produces a thick mixture, like a porridge, which is agitated for a predetermined time, depending on the type of carton or wetproof packaging<\/a> being recycled, he explains.<\/p>\n\n\n\n

The agitator, combined with the high consistency of the pulp, results in the rubbing of the paper<\/a> and plastic constituting each carton, thereby separating the two materials. The plastic simply sheers off the paper<\/a> and is relatively intact after processing. \u201cYou can blow up the plastic sleeve afterwards and it will resemble the carton it was once attached to,\u201d quips Hunt.<\/p>\n\n\n\n

\u201cIt is essentially a very simple concept of separation. All paper<\/a>is hydrophilic \u2013 it will attract water<\/a> and lead to fibres separating themselves,\u201d he says.<\/p>\n\n\n\n

The method used for recycling wetproof packaging<\/a> differs slightly, with caustic soda used to extrude the chemicals from the paper<\/a>.<\/p>\n\n\n\n

USES FOR MATERIAL<\/strong><\/h2>\n\n\n\n


All the\u00a0paper<\/a>\u00a0fibre produced by the liquid\u00a0packaging<\/a>\u00a0recycling plant is currently redirected into one of two\u00a0paper<\/a>\u00a0machines at the Mpact plant, says Zwane.<\/p>\n\n\n\n

\u201cPulp from the liquid packaging<\/a> recycling plant can go into the mix of papers produced by Mpact,\u201d says Hunt, noting that such fibre is used primarily for the manufacture of rigid carton board, owing to its strength properties.<\/p>\n\n\n\n

\u201cOur machines are unique . . . as they can transform any type of recyclable paper<\/a> into a multilayered product, with up to seven layers of different grades of paper<\/a>,\u201d he notes, adding that Mpact\u2019s mills can also make core paper<\/a> and various other grades of industrial<\/a> papers.<\/p>\n\n\n\n

In terms of available avenues to process or use the plastic produced by the recycling plant, Hunt notes that the company currently does not process plastic, with the plastic sleeves being sold to another company that can process them.<\/p>\n\n\n\n

However, Hunt highlights that, through Mpact\u2019s interaction with Tetra Pak, the company is aiming to actively pursue some \u201cinteresting applications\u201d it has seen internationally. \u201cThis is an interesting part of the recycling development chain . . . sometimes, with a new plant, you come across a new material that you need to find a home for . . . Ultimately, this enables you to create new solutions<\/a> . . . there is some interesting market potential for plastic.\u201d<\/p>\n\n\n\n

MATERIAL COLLECTION<\/strong><\/h2>\n\n\n\n


Mpact has been running its pavement\u00a0paper<\/a>\u00a0collection campaigns for several years, with its \u2018Ronnie\u2019 bags distributed to various suburbs of Johannesburg. These bags are freely available to anyone willing to fill them with used\u00a0paper<\/a>\u00a0and are collected on a regular basis.<\/p>\n\n\n\n

The company also has a similar collection project<\/a> in Durban, and another project<\/a> through which material is bought from collectors in Cape Town.<\/p>\n\n\n\n

Prior to the commissioning of the liquid packaging<\/a> recycling plant, Mpact advised people using Ronnie bags to exclude any liquid packaging<\/a> products<\/a>, as such items could not be processed, and to include only paper<\/a>.<\/p>\n\n\n\n

However, the liquid packaging<\/a> recycling plant has enabled Mpact to embark on a multilateral campaign to reverse its previous request to exclude liquid packaging<\/a> and cartons from Ronnie bags, Hunt says. \u201cIt is an interesting process \u2013 we spent many years telling people not to supply us with liquid packaging<\/a> material because we were unable to recycle it, and now we are changing the message,\u201d he states, adding that a lot of effort is being made to get the new message across.<\/p>\n\n\n\n

In terms of other avenues to collect suitable material for the plant, Hunt says the company has approached many packaging<\/a> manufacturers as its first port<\/a> of call and through which it has set up procedures to collect material.<\/p>\n\n\n\n

Further, Mpact is working with a number of schools through which it is implementing recycling awareness and collection campaigns, with the company having placed about 2 000 green bins at schools and community centres in Johannesburg, Durban and Cape Town.<\/p>\n\n\n\n

It also conducts the collection of suitable material from landfill sites through on-site reclaimers.<\/p>\n\n\n\n

The major challenge in getting increased volumes of suitable material to recycle is to get more people involved in household recycling, where they separate the material before it is binned. \u201cThe more we can encourage people to do that, the better,\u201d Hunt concludes.<\/p>\n","protected":false},"excerpt":{"rendered":"

An investment of R46-million in a first-of-its-kind recycling plant in South\u00a0Africa\u00a0\u2013 commissioned in July after a six-month\u00a0construction\u00a0period. At the Springs-based recycling facility of\u00a0paper\u00a0and plastics\u00a0packaging company Mpact is set to reduce …<\/p>\n","protected":false},"author":1,"featured_media":1479,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"footnotes":""},"categories":[22,21],"tags":[],"class_list":["post-1476","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-cardboard-and-paper","category-recycling"],"yoast_head":"\nRecycling - MThree On Site - Recycling - New carton recycling plant<\/title>\n<meta name=\"description\" content=\"An investment of R46-million in a first-of-its-kind recycling plant in South Africa \u2013 commissioned in July after a six-month construction period\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/mthreeonsite.co.za\/index.php\/2019\/05\/31\/new-carton-recycling-plant-enhances-recycling-of-liquid-packaging\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Recycling - 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