Transiting from carbon sequestration to eco-friendly plastic segregation technologies
Plastic Dreams: Beckum's Transformation from Industrial Waste Dump to Eco-Maverick
Nearly a decade ago, Umweltdienste Kedenburg breathed new life into Beckum's once-blighted industrial zone, transforming it into a hub for sustainable recycling. A epicenter of cement production in the past, and a warehouse for coal afterwards, Beckum's industrial legacy has been supplanted by a cutting-edge recycling operation: a shining example of circular economy reimagining.
Klaus Kuhlenbeck, the technical director of the plant, refers to the project as a strategic investment in the circular economy: "Our primary objective here is to extract valuable plastic films and convert them into desirable, eco-friendly products."
From Trash to Treasure
In partnership with Otto Graf GmbH, Umweltdienste Kedenburg has constructed a state-of-the-art separation plant, capable of processing a myriad of lightweight packaging films. Approximately two-thirds of the raw material utilized is polypropylene (PP) film, with the remainder primarily consisting of polyethylene (PE) or a mix of polyolefins (PO), normally sourced from packaging sorting facilities across Europe, ranging from Austria to Norway.
Technological Adroitness as the Crux
At the core of this innovative plant are two STEINERT UniSort Film EVO 5.0 machines. These state-of-the-art machines harness a specialized airflow system that harmonizes perfectly with the conveyor speed. "What truly impressed us is the targeted and stabilized airflow," explains Kuhlenbeck. "Thanks to this, even the lightest and most fragile films remain stable on the conveyor belt. Furthermore, the airflow extends to the exhaust hood, preventing the material from shifting substantially post-expulsion."
This sophisticated material management allows for a blazing conveyor speed of 4.5 m/s, a necessity for achieving optimal throughput and profitable separation, particularly when dealing with bulky 2D materials. This ensures the plastic films don't overlap or tangle, thereby permitting the pairing of near-infrared (NIR) sensors and color cameras to fully realize their potential. This accurate data collection is crucial for fulfilling the 98% purity objective for PP film mercilessly.
Remodeled Plastic Films into Secondary Raw Material
Following the separation stage, the films undergo a process of agglomeration—compaction by way of heat and friction to produce manageable granules. These intermediate products are then entrusted to GRAF, which utilizes them to craft durable items, like rainwater tanks. Thus, consumers receive products that are not only environmentally conscious but also stamina-matched to their new counterparts, and never compromising on reliability.
Agility for Future Obstacles
Klaus Kuhlenbeck emphasizes the significance of preparing for the future: "Our setup is adaptable to changes in demand. We're well-aware that packaging materials are constantly evolving. With the combination of NIR and color sensors, we're geared up for future advancements."
For Kuhlenbeck, one truth remains indisputable: "A system is never truly complete. New challenges continue emerging, such as composite materials, which remain challenging to separate, or aluminum vaporized films, which, if unnoticed, can impact the final product." Consequently, he places an emphasis on communication across the supply chain: "Collaboration has always been paramount. Now, more than ever, we're talking. As a unified force, we work towards heightened recycling, superior packaging, and the advancement of circular economy."
Assurance Through Testing: Sustainability as the Cornerstone
The collaboration between STEINERT and Umweltdienste Kedenburg began at the company's Test Center in Cologne, where the blueprint for success in 2023 was laid. "STEINERT's machines have done exactly what they promised from the beginning," recaps Kuhlenbeck. "I've never seen anything quite like it. This reliability is precisely what we need to translate our vision of sustainable plastic recycling into reality." With the new plant in Beckum, an erstwhile source of carbon emissions stands reincarnated as a sentinel of sustainability. With each kilogram of plastic reintegrated into the loop, Umweltdienste Kedenburg propels itself forward in the fight against climate change, conserving CO2, and preserving finite resources.
- The innovative recycling operation in Beckum, a hub for sustainable recycling, is a shining example of environmental science and the circular economy, converting plastic films into desirable, eco-friendly products.
- Klaus Kuhlenbeck, the technical director, highlights that the primary objective at the plant is to extract valuable plastic films and contribute to sustainable living and lifestyle, both at home and in the garden.
- To achieve this, they have constructed a state-of-the-art separation plant capable of processing a myriad of lightweight packaging films, with data and cloud computing playing a crucial role in accurate data collection to ensure 98% purity.
- The plant's long-term adaptability is critical, as it is prepared to cater to future advancements in packaging materials, embracing composite materials and other challenges in the circular economy, ensuring their continued fight against climate change and the preservation of finite resources.
