Plexus Recycling Technologies commissioned to install system for C&D sorting
ZenRobotics sorting system layout
San Jose-based Zanker Recycling, a national leader in construction and demolition (C&D) materials processing systems and recycling, has announced that its awarding a contract to Plexus Recycling Technologies, the North American distributor of ZenRobotics the world’s leading, and most experienced AI robotics team for sorting waste materials. The ZenRobotics ZRR2 AI Robot will be the second to operate in the U.S. and operational by fall 2018.
Zanker Recycling currently handles 2,600 tons of C&D material daily processed through three recycling systems. This high volume taxes the limits of these systems resulting in excessive overtime. By providing a fourth processing line featuring the ZenRobotics system, Zanker Recycling will dramatically increase diversion from landfills and decrease
in overtime and operating costs.
“The advantage of deploying AI robotics to recycling differentiates Zanker from our competitors,” said Michael Gross, Director of Sustainability for Zanker Recycling. “In this case it means identifying the sweet spot where a hybrid mix of our employees and robot delivers the biggest payback, both to the bottom line and also to our employees while
increasing the diversion of recyclables.”
The ZenRobotics ZRR2 AI will operate 20 hours per day with total system production at 150,000 tons per year increasing diversion of recyclables by 20%. The operation will only allow a very small amount of human interaction to the sorting process, possibly as quality control, thanks to the two ZenRobotic Recyclers installed on the 3D material
sort line handling the majority of difficult to handle materials.
In a new twist for recycling systems, material feeding will be highly automated from the beginning of the process. The front end will only have to operate 50% of the time to process the inbound material. In the middle of the system are two large dosing bunkers that can store up to 100 tons of material. The ZenRobotics Brain will control these along with all equipment downstream to allow a very smooth-running operation focused on recovery and efficiency.
“This will be the most advanced waste material processing facility in the world,” said Dane Campbell, the project’s System Engineer from T3CHCOMP. “We have combined the very best equipment available, into one fantastic recycling system for Zanker.” Plexus Recycling Technologies will provide key European systems such as the ZenRobotic Recyclers, Komptech Terminator, Komptech Ballistor and Komptech Fines Drumscreen. To bring all of these systems together, along with key equipment from Action Equipment Company, Steinert and Keith Manufacturing, Plexus selected long time C&D system leader, Krause Manufacturing of the CP Group.
“This will be a substantial milestone for all of us,” said Ashely Davis director of Sales and Marketing for CP group. “Bringing the Krause name back to lead the C&D material processing industry again, with such a great team to support Zanker’s automated system will be amazing. We are able to showcase the new Air Drum Separators and superior Glass Breaker fines screen next to technology partner Plexus’s equipment offering.”
The entire system’s PLC Electrical Control will be provided by Hertlein Industries, one the most experienced and knowledgeable teams ever used for controlling and integrating waste material processing systems.
“Zanker’s investment into the newest and best technology available is a testament to the ownership and management of Zanker,” Marcel Vallen, CEO of Plexus and Komptech Americas says. “We could not have partnered with a better organization than Zanker to unveil the power of ZenRobotics ZRR2 AI Robot in California. I am very excited.”
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Denver-based Plexus Recycling Technologies is changing the face of the environmental solutions industry by combining years of experience with premier technologies that solve entrenched problems. It’s not enough to just be the best solution today, at Plexus Recycling Technologies, we look towards the future. As a full line recycling solutions provider, we scour the globe for high end, highly efficient comprehensive solutions so our customers don’t have to.
San Jose-based Zanker Recycling, owned by Zanker Road Resource Management Ltd., is a privately-owned solid waste and recycling company that began operations in 1985 by developing a landfill into a full-service resource management and composting/recycling facility. In 1998, Zanker expanded operations by permitting an adjacent landfill site as a construction and demolition debris processing facility. These two facilities process more than 2,600 tons of mixed debris per day. Currently, Zanker operates four nationally-recognized recycling facilities: The Zanker facilities are national leaders in construction of demolition debris diversion and composting. Through its aggressive and innovative recycling efforts, Zanker diverts more than 80 percent of waste they receive from landfilling.
New MapLine™ Algorithm Improves Material Targeting
Nashville, TN (September 5, 2017) – MSS, Inc., the optical sorter division of CP Group, introduces MetalMiner™, the next generation of induction-based true all-metal detectors. MSS has designed and built induction metal sorters for over 40 years, and this latest iteration was designed specifically to handle auto shredder residue (ASR), electronic scrap, plastic flake and glass cullet applications. One of the most relevant new technical features of the MetalMiner™ is the patent pending MapLine™ algorithm.
“MapLine™ allows users to target specific metal types or objects by amplifying the sensitivity for non-ferrous metals, especially wire, while simultaneously reducing it for ferrous dust,” says Felix Hottenstein, MSS Sales Director. “MetalMiner™ is exceeding our customers’ expectations. We’ve found up to 15% higher recovery rates for Zurik when directly compared to other vendors.
Hottenstein continues, “Additionally, MetalMiner™ reduces cross contamination with ferrous-dust-covered wood, plastics, and foam. This creates a noticeably cleaner product.”
Greg Thibado, MSS Vice President, says, “In addition to the technological advances, we’ve implemented new manufacturing techniques that allow for MetalMiner™ to become even more competitive, especially for the wider units.”
The MetalMiner™ is manufactured up 112″/2800mm wide as either a stand-alone model in a conveyor configuration or it can be integrated as an upgrade to the MSS CIRRUS NIR and L-VIS Color optical sorters. Depending on the application, different induction coil configurations and spacings are available.
For certain small particle applications such as plastic flake or glass cullet, MSS also offers the MetalMiner™ in a slide configuration which provides an even higher sensitivity and sorts ferrous, non-ferrous, and stainless steel down to 1mm in size.
Technologically Advanced Single Stream and Commercial Recycling System
FRESNO, CA (May 31, 2016) – Mid Valley Disposal, a family owned recycling and hauling company, announces the grand re-opening of its Mid Valley Disposal Elm MRF in Fresno, California. Designed and manufactured by San Diego, California-based CP Group, the recycling system processes 35 tons an hour of residential and commercial material. The system start-up was April 26, 2017.
“We are pleased to have partnered with CP Group and reinvested in the San Joaquin Valley,” says Jonathan Kalpakoff, VP of Mid Valley Disposal. “Increased processing capacity and the recovery of more recyclables will help with our commitment to increase diversion for the communities we serve. We selected CP Group because of their commitment to quality and being a California family business like us.”
The original system was installed in 2001 and processed 20 tons an hour. Due to needs for increased capacity and better recovery, Mid Valley turned to CP Group, who supplied all the new processing equipment. The bunkers, silos, baling system and tip floor pit from the original system were reused in the existing building.
“This system includes some of our latest recovery technologies, including glass processing and optical sorting technology,” says Ashley Davis, Director of Sales and Marketing at CP Group. “We are honored to work with Mid Valley on this project and bring this modern facility to Fresno. It is an integral part of the recycling capabilities offered to the county.”
The advanced material recovery facility features three MSS optical sorters. The CIRRUS® FiberMax™ is used to remove film and other contaminants out of the fiber stream, while the two CIRRUS® PlasticMax™ units separate HDPE, PET, and Mixed Plastics. The system also features proprietary CP disc screening technology, including CP’s steel-disc OCCScreen™, Scalping Screens, and Glass Breaker Screens, along with 1 NewScreen™ and 2 CPScreens™. An air drum style glass cleaner is used to remove the lights from the glass. The system recovers cardboard, mixed paper, glass, PET, and both color and natural HDPE.
“Like myself, the Kalpakoff brothers are third generation in the waste industry. It is rewarding to work with another family-owned company and see recycling progress through the generations,” says Davis.
With its fleet of 165 trucks, Mid Valley serves 89,000 households in Fresno and the surrounding counties. The MRF processes recyclables for half of the City of Fresno, and also for 75,000 households from 3rd party haulers in the counties of Madera, Tulare, King, and San Luis Obisbo.
System is Most Modern Recycling Facility in the Country of Argentina
The City of Buenos Aires, in partnership with San Diego-based CP Group, opened the most advanced recycling system in the country of Argentina. The new 10 TPH residential single stream recycling system began running last October in Villa Soldati, a neighborhood of Buenos Aires. Since then it has helped the city achieve its sustainability goals.
“It’s the most modern recycling center in Argentina,” announced the Head of Government of Buenos Aires, Horacio Rodríguez Larreta, at the inauguration of the plant in October 2016. “The city has improved a lot in the separation and treatment of recyclable waste,” he continued. “4 or 5 years ago nothing was separated. Today, this system is recovering 400 tons of dry materials per week, and that amount is expected to double to 800 tons per week in 2019.”
The system features CP separation equipment, including the CPScreen™ for 2D/3D separation, MSS Aladdin™ optical sorter, CP Metering Drum, CP OCCScreen™, and CP Glass Breaker Screen with patented Cam-Discs™.
The recycling system is part of the city’s Green Center, a program involved with recovering recyclable materials and providing education about waste treatment processes and its importance in Buenos Aires.
“Throughout the entire process, the City of Buenos Aires has demonstrated environmental leadership as well as a long term commitment to developing a sustainable solution for capturing the valuable recyclables and diverting them from the landfill,” says Dirk Kantak, International Sales Director for CP Group.“Between the City of Buenos Aires, and our local Distributor (Coinsa Construcciones), we could not have asked for two better partners on this successful project.”
The materials recovery facility (MRF) began running October 2016. During the training and commissioning period, CP Group worked closely with the Spanish-speaking local staff to operate and maintain the MRF.
New Advanced Sorting System Brings Increased Recycling Capability to Region
SONOMA COUNTY, Calif. (April 19, 2017) – Republic Services celebrated its enhanced recycling facility today that will enable Sonoma County to achieve their sustainability goals for years to come. The Sonoma County Recycling Center is capable of processing more than 200 tons of recyclable material per day, and is expected to increase the recycling capacity in the region.
“The new enhanced Recycling Center offers significant environmental benefits to the community and the customers we are fortunate to serve,” said Mike Caprio, area president of Republic Services. “We now have the ability to increase recycling efforts, while diverting valuable materials from the landfill. The facility has the potential to significantly reduce greenhouse gas emissions, which offers a substantial contribution to the community’s climate protection goals.”
The existing 32,000-square foot Recycling Center was expanded with an additional 6,000-square feet constructed by ET Environmental, bringing the new combined square footage to 38,000. The processing system was designed and installed by the CP Group.
The facility offers a variety of features to provide flexible processing capabilities. The equipment includes two material processing options. The first is an in-feed conveyor for collected commercial materials such as cardboard, mixed paper, containers, film and plastics.
The second is a hopper-fed construction and demolition (also known as C&D) conveyance system with multiple sorting stations. The system includes a baler for packaging recyclable materials such as cardboard, mixed paper and other materials. The facility also has a separate bale storage building to protect the finished products from rain prior to shipment to market.
The enhanced Recycling Center was part of a three-year Solid Waste Advisory Group (SWAG) collaborative process between multiple municipalities, the County and a diverse group of public stakeholders. They identified three underserved waste streams; self-haul, commercial dry waste, and C&D waste materials that could be addressed with a robust recycling center and program.
Republic Services of Sonoma County employs 26 employees. They proudly serve over 265 commercial customers as well as thousands of residents throughout the year. Republic also operates the Central Landfill and five transfer stations in the County of Sonoma.
Known as the Blue PlanetTM sustainability initiative, Republic is defining its approach to corporate social responsibility through reduced emissions from operations, materials management, safety, community engagement, and employee growth opportunities. Republic collects and processes approximately five million tons of recyclables per year at 64 recycling centers nationwide.
To view Republic’s Sustainability Report, go to https://www.republicservices.com/sustainability.
About Republic Services
Republic Services, Inc. is an industry leader in U.S. recycling and non-hazardous solid waste. Through its subsidiaries, Republic’s collection companies, recycling centers, transfer stations and landfills focus on providing effective solutions to make proper waste disposal effortless for its 14 million customers. We’ll handle it from here.TM, the brand’s promise, lets customers know they can count on Republic to provide a superior experience while fostering a sustainable Blue PlanetTM for future generations to enjoy a cleaner, safer and healthier world.
The facility originally opened in 2008 after a major renovation.
Waste Pro opened a new 14,000-sq.-ft. material recovery facility at its regional operations center in Sarasota, Fla.
“Waste Pro’s expansion is a wonderful addition to the southern end of Manatee County,” Manatee County Commissioner Robin DiSabatino said in a statement.
The facility originally opened in 2008 after a major renovation.
“We are proud to have partnered with Manatee County on this recycling initiative,” Waste Pro Division Manager Sean Jennings said in a statement. “We are committed to the community and are excited about the long term effects this will have on improving the quality of life for the residents in Manatee County.”
The project is a direct result of the need to process the large volume of recycled materials collected curbside by Waste Pro’s vehicles. “The convenience and larger capacity of the new recycling carts has increased the overall amount of recyclables,” Waste
The SRQ Material Recovery Facility was designed by Tom Walter of the Walter Group of Sarasota and constructed by Metropole Construction of Fort Myers. The MRF is equipped to deal with Manatee County’s conversion to single-stream recycling, which went into effect last October. The facility will be processing up to 2,000 tons of mixed glass, metals, plastics, paper and cardboard, per month, from residential and commercial sources throughout unincorporated Manatee County.