CP Providing Front-End Solution to State-of-the-art MSW Refinery
Earlier this summer, CP Group broke ground on the installation of the advanced material recovery facility that will be the front-end system for Fiberight’s waste processing and refining facility. This site will feature Fiberight’s first full-scale operation of its biofuels and biogas processing systems.
Serving 115 municipalities, the 144,000-square-foot Hampden, Maine facility will feature the latest technologies from CP Group to recover recyclable commodities and prepare residual waste for further processing on-site.
“I have known and have worked with CP since the 1990’s on various jobs. CP is an engineering-focused company, which brought great value and utility when working with Fiberight to create a flexible design that is optimized for our unique processing needs,” said Craig Stuart-Paul, Fiberight CEO.
The recovery system features a CP Trommel Screen with bag-opening knives, a steel-disc CP OCCScreen™, the new non-wrapping CP Auger Screen™ used to size material in place of a traditional scalping screen, two CPScreens™ for 2D/3D separation, the abrasion-resistant CP Glass Breaker to remove glass and fines, and 4 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.
“The system is a blend of traditional and new equipment to provide Fiberight with flexibility for changing markets with extremely low-maintenance and durable machines,” stated Terry Schneider, President and CEO of CP Group.
Fiberight’s proprietary anaerobic digestion and biogas technology is the first commercial process to convert organic wastes to biofuel and refined bioproducts. Residual waste at the facility will be processed by Fiberight’s technology, upgrading the MSW residue into industrial bio-energy products.
Fiberight anticipates landfill diversion of up to 80%. By designing the plant to be adaptable based on future market trends, this state-of-the-art facility will be well suited to handle changing market conditions, particularly because it is capable of upgrading mixed paper to pulp-based products.
“We are very honored to be a part of this groundbreaking technological advancement with the Fiberight team,” says Schneider. “Their forward-thinking approach could change the way the industry processes waste, particularly fiber.”
CP’s installation of the material recovery facility will take just over 3 months, with a forecasted system startup date in Q4 2018.
Article published in Waste Dive, June 25, 2018
After years of debate, fundraising, competition and a winter construction delay, a unique new project is quickly taking shape in northern Maine that its creators say may be coming at just the right time.
In the years since Fiberight began pitching its $70 million concept, local disposal prices have gone up, China has roiled commodity markets, and New England’s main glass buyer closed its doors. While Fiberight’s mechanical biological process was already promised to reach recovery rates of 80%, the concept’s adaptability has allowed it to keep making changes along the way as each of these factors arise.
“Essentially, we got all our players on the field long before this happened,” CEO Craig Stuart-Paul told Waste Dive. “I’m delighted.”
With work on the 144,000-square-foot facility now well underway, Stuart-Paul is planning a September opening for the facility’s recycling operation. The facility’s anaerobic digestion and biofuels component is projected to be up and running by the end of this year.
The fact that this was all supposed to be happening earlier has added a wrinkle to contract timing for many of the 115 municipalities that ended a disposal contract with the Penobscot Energy Recovery Center WTE facility in March. A small handful have even gotten permission to keep sending their waste there in the meantime, though the majority are now utilizing either the Crossroads Landfill operated by Waste Management or the Juniper Ridge Landfill operated by Casella Waste Systems. Recyclables are going to a separate Casella-owned MRF.
Stuart-Paul maintains his company’s approach will be worth the wait, because it provides a more affordable and sustainable alternative for municipalities throughout Maine’s more rural mid-coast and northern areas. It will also require a slight leap of faith for residents into a less common mixed waste approach. While Fiberight has a prototype in Virginia, this will be its first full-scale operation.
“People have been reluctant to go one bin because they’re unsure that the resulting commodities removed could find a home. So we need to prove that,” said Stuart-Paul. “I think we do open up an entirely new marketplace and new opportunities for recycling.”
Because proving the concept will rely in large part on the material it produces, Stuart-Paul chose to team up with a company he’d been working with since the ’90s: CP Group. Stuart-Paul was drawn to the company’s engineering capabilities after utilizing its technology at his former company Fairfax Recycling in Virginia.
CP’s contributions to the front-end of Fiberight’s plant include a combination of existing technology utilized at other facilities as well as specially designed pieces. Highlights include a trommel screen with bag-opening knives, an anti-wrapping CP auger screen that is said to eliminate just about any tangler it encounters, an abrasion-resistant glass breaker, and multiple types of screens and optical sorters.
CP CEO Terry Schneider said that Fiberight’s unique approach already made it an appealing project, and the potential has only increased since China’s import restrictions came out last year.
“This become an even better project to be a part of,” he said.
In light of China’s market effects, Schneider said he is particularly interested in exploring new markets and demonstrating the value of additional sorting technology to enable that. Like Stuart-Paul, he also recognizes the chance to showcase a concept that elicits skepticism from many in the industry.
According to Stuart-Paul, the fact that Fiberight’s tip fees are expected to be $55 less than the closest single-stream MRF will go a long way toward doing that. Though the real key will be showing that its end products have value.
“We have to prove that this can work and that we can make a marketable material out of something that’s coming out of one bin,” said Schneider, adding that this has been harder to prove in the U.S. marketplace.
By designing the plant to be adaptable based on future market trends, Fiberight has said it is better suited to keep up with market conditions than the average MRF. For example, the company’s ability to create marketable pulp from mixed paper will be especially key at a time when the material is seen as nearly worthless in the Northeast.
“Our entire ethos was that we had to assume that we needed to perfectly integrate all of our products to an end market,” said Stuart-Paul.
With that approach in mind, Fiberight has been emphasizing its role in filling market gaps recently for paper and other materials.
Earlier this month, the company also announced a new partnership with New Hampshire-based Impact Apparel to set up a system of textile collection boxes throughout the region and previewed plans to help with local glass issues. The recent closure of a Massachusetts bottling plant has severely disrupted New England’s glass market, with effects as far north as Maine. So Fiberight now plans to establish a glass processing component within its own yard to create construction aggregate from material that is otherwise likely being disposed.
In addition to designing the Hampden plant to be adaptable to robotics or other upcoming market-driven technology changes, Fiberight and CP are also looking to partner on more facilities. While Stuart-Paul is keeping information close to the vest, he told Waste Dive more news can be expected in the not-so-distant future about other sites in New England.
“We have significant interest and we are actively engaged with several counterparts for larger plants that we’re building in Maine,” he said.
CP Group is expected to be a partner on whatever comes next, so the company is optimistic its work at the Hampden facility can be a showcase for more to follow.
“This is a unique project and I think there’s a lot of opportunities for both of our companies to prove that this technology can work,” said Schneider. “So we’re all excited about it.”
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.
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.