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.”
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.
Allows users to walk through full recycling systems using virtual reality
SAN DIEGO, CA (May 9, 2017) – CP Group, recycling solutions provider and equipment manufacturer based in San Diego, CA, unveil the Virtual MRF today at Waste Expo in New Orleans, LA.
The Virtual MRF is a virtual reality simulation that uses two hand held controls and a virtual reality headset. The simulation allows users to explore every inch of a life-size computer-generated model of a material recovery facility (MRF) in real time.
“This unlike anything that has been done before in our industry,” says Ashley Davis, Director of Sales and Marketing for CP Group. “Our Virtual MRF uses the most cutting-edge tech to provide our customers with a very concrete sense of what their facility will be like before anything is actually built. This technology has a lot of potential, not only for our sales force, but for our engineers, and we’re proud to be the first to bring it into the recycling equipment manufacturing industry.”
CP Group will be running Virtual MRF demonstrations at their booth #3647 throughout Waste Expo, May 9-11.