MSS FiberMax™ optical sorter cuts costs while handling challenging materials and optimizing output quality
(article published in Recycling Product News, April 2018)
MSS, Inc., part of the CP Group and based in Nashville, Tennessee, is in the process of supplying a total of 29 CIRRUS FiberMax optical sorter units for 13 customers across North America, and says more units are on order. According to Greg Thibado, MSS vice president, “Since it was unveiled a little over a year ago, the FiberMax optical sorter has been a very popular choice for MRF operators who want to optimize fiber quality and reduce manual sorter head count at the same time, providing the cleanest fiber at high volumes.”
Thibado says a single FiberMax unit can replace up to 25 manual sorters as it performs up to between 800 and 1,000 picks per minute, versus only about 40 picks per minute for a manual sorter. This is made possible by a high conveyor speed of 1,000 feet-perminute, which is twice the speed of conventional optical sorters. According to MSS, in one recent installation, FiberMax decreased the level of prohibitives in a residential mixed paper stream from over 10 percent to less than 3 percent, consistently. Additionally, it reduced the sorter head count by 12.
“We are very pleased with the success of the FiberMax and so are our customers,” says Thibado. “FiberMax’s ability to handle challenging materials like thin flexible plastics packaging and lightweight single-serve PET bottles ‘future-proofs’ MRFs and paper sorting facilities against foreseeable changes in the ever evolving material stream.”
Thibado adds that it is advanced scanning technology and software algorithms that truly give FiberMax the edge.
“With its ClearLight technology, FiberMax doesn’t use gratings or light beam splitters, so detectors receive the maximum amount of reflected light possible,” he says, adding that besides prohibitives, it is able to positively sort a variety of other materials such as ONP, mixed paper, OCC and SOP.
“FiberMax has changed the game,” adds Thibado. “And we look forward to many more customer success stories.”
CP Auger Screen™ sizes waste for many applications
SAN DIEGO, CA (April 11, 2018) – CP Group announces its newest screening technology, the CP Auger Screen™. This marks the industry’s first true anti-wrapping, non-blinding screen for material recovery facilities.
The CP Auger Screen™ sizes material by using a series of cantilevered augers that do not wrap or jam due to their corkscrewing motion, making it extremely low-maintenance. Any material that could wrap, such as hoses or plastic film, are released off the end of the auger.
Its low-wear augers are made from abrasion-resistant steel, making them durable while requiring little to no maintenance.
When placed in front of the presort, the CP Auger Screen™ dramatically decreases the volume on the presort. This decreases the amount of manual sorters needed and increases sorter safety by removing the small hazardous fraction. With decreased volume on the presort, manual sorters work more efficiently.
When used as a scalping machine, the CP Auger Screen™ fractionates the stream into an over 5” stream and an under 5” stream while keeping rigid materials together. Keeping the rigids together plays an important role in the recovery of OCC and chip. OCC has been increasing in volume due to the “Amazon effect.”
Terry Schneider, President and CEO of CP Group says, “This machine is unique compared to traditional disc screens. The cantilevered augers convey large flat materials over, while fines and flexible fiber go through to the unders, and the remainder goes to the side. What really sets it apart is that it does not wrap. The auger rotors act like a corkscrew, conveying any stringy materials over the side. There is a lot of interest in this machine for those reasons.”
CP has been developing the machine and running the prototype for over a year at their facility in San Diego, CA. The first three units are being installed in MSW facilities this summer, and several more are sold and in production.
The CP Auger Screen™ can be used in various applications including MSW, Single Stream, Construction & Demolition, and Commercial & Industrial. The largest model can handle 35 tons per hour of inbound single stream material, 60 tons per hour of commercial, and 80 tons per hour for construction and demolition.
The CP Auger Screen™ will be on display at Waste Expo in Las Vegas this April at CP Group’s booth 2336.
Fiberight to construct state-of-the-art MSW refinery
April 18, 2018, HAMPDEN, MAINE — CP Group, based in San Diego, CA, will install an advanced material recovery facility and front-end system for Fiberight’s state-of-the-art waste processing facility.
The Hampden, Maine facility is a fully functioning commercial application of Fiberight’s proprietary technology that upgrades MSW into refined energy and industrial products. A 144,000 square foot building is currently under construction and will begin receiving equipment this summer. The
material recovery facility will start up by fall 2018; upgrading processes will be commissioned shortly thereafter.
Fiberight has been working with the Municipal Review Committee (MRC) of Maine since 2013. In February 2015, the MRC approved a development agreement with Fiberight to process 180,000 tons per year of MSW from 83 municipalities and public entities pursuant to a 15-year contract. In January 2018, Fiberight announced the completion of $70 million in project financing for the plant.
The Fiberight facility will feature the latest generation of machinery and technology from the CP Group to recover recyclable commodities and prepare residual waste for further processing on-site. Fiberight anticipates landfill diversion of up to 80%, including recovery of metal, plastic, OCC and other commodities for beneficial re-use or recycling. Other commodities to be recovered include contaminated cellulose, food waste and other organic materials that may be converted into biomass, sugars, market pulp, and biogas.
Terry Schneider, CEO and President of CP Group, says, “We are very honored to be a part of this groundbreaking technological advancement with the Fiberight team. Their forward-thinking approach could change the way the industry processes waste, particularly fiber. We look forward to beginning installation and getting this facility into operation.”
The Hampden facility features a CP Trommel Screen with bag-opening knives, a steel-disc CP OCCScreen™, an anti-wrapping CP Auger Screen used to size material, two reduced-wrapping CPScreens™ for 2D/3D separation, the abrasion-resistant CP Glass Breaker to remove glass and fines, and 4 MSS CIRRUS® optical sorters. Two MSS CIRRUS® PlasticMax™ optical sorters will recover PET and HDPE, one MSS CIRRUS® FiberMax™ optical sorter will sort and clean fiber, and one MSS CIRRUS® will be used as a scavenger optical sorter to recover any remaining commodities.
Craig Stuart Paul, CEO of Fiberight stated, “We are delighted to have teamed with the CP group to create a new paradigm for waste disposal. Our end-to-end solution was made possible by CP’s thoughtful design process and application of the latest generation in front-end waste processing, geared specifically to our needs for downstream material upgrading.”
Fiberight’s technology is the first commercial process to convert organic wastes to biofuel and refined bioproducts. Its technology platform has been demonstrated since 2010 at its Virginia prototype production plant, using MSW feedstock. In addition to the Hampden project, Fiberight is currently involved in the development of similar projects in New England.
Craig Stuart Paul will be speaking about Fiberight’s conversion technology at Waste Expo on Wednesday, April 25, from 1:45-3:00pm in the session A Case Study for Waste Conversion in room N102-N103.
Fiberight is a privately held company founded in 2007 with current operations in Maine, Virginia, Maryland and the United Kingdom. Fiberight’s proven, proprietary waste processing technology converts Municipal Solid Waste into high-value commodities to enable next generation recycling and maximum resource recovery from municipal waste.
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.
From the article “Depending on the Variables,” published in Recycling Today, July 3, 2017
While optical sorters commonly are used to sort paper in material recovery facilities (MRFs) that handle single-stream commercial material, their use on residential fiber sort lines is increasing for a variety of reasons, according to industry source.
For MSS Inc. in Nashville, Tennessee, contamination is one of the greatest factors to consider when adding optics on the fiber lines of residential MRFs. This is because, Sales Director Felix Hottenstein says, “on the residential side, we’re using it to clean up news or mixed paper, not to sort higher grades.”
Residential MRFs that use MSS optical sorters have two things in common: high volumes and high contamination levels. However, he adds, “You need to have the right volume and material coming in that’s not too contaminated, or else you won’t get a higher grade.”
Optical sorters typically are installed in residential MRFs when they operate at 25 tons to 30 tons per hour with an average material stream composition. If the tonnage is lower, installing an optical sorter isn’t justifiable unless the material is extremely contaminated.
Hottenstein says MSS customers using optical sorters on their residential fiber lines offer three reasons for doing so: improved technology, reduction of manual labor and improved material quality.
Hottenstein says eight hand sorters on a line can make about 400 picks per hour, but optical sorters can make about 2,000 picks in that same time
“The savings on the manual labor is the last reason,” he says of MRF operators objectives when adding optical sorting on their residential fiber lines.
While optical sorters normally are used to sort plastic bottles, MSS can replace the sensor head and reroute the conveyor to sort fiber.
Hawn suggests moving from the VIS-NIR (visible near-infrared) spectroscopy typically found in MRFs to either a SWIR (short-wave infrared) or IR (infrared) spectroscopy to segregate fiber, but he says some suppliers are using IR thermography to sort by grammage (thickness).
“For that technique to work, you need to have control on your infeed material’s temperature and humidity,” he says.
While making the plunge to install an optical sorter on a residential MRF’s fiber line can be intimidating, Hottenstein says the advancing technology makes the justification undeniable.
“I think we made quite a big step in the last two years, especially in the last two to three months,” he says. “It’s a matter of whether you save enough labor to justify it. New specifications and the need for cleaner paper from the China situation may cause more need for optical sorters, especially on the residential side. Bigger machines are more expensive, but you have to do what you have to do. You either have to save money or make money.”