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In all of the processes used to convert plastic raw materials into end products there is an inevitable arising of some scrap material. This results from the start-up and shutdown periods of the processing machinery, from out of speci cation products, and from quality-control samples. Material of this type is termed industrial scrap. Almost all molding companies recycle their own plastics waste, or scrap, in house. The specialist plastics recycling industry also recycles material of this type, mostly skeletal waste from thermoforming and off-speci cation moldings. Mechanical recycling is where the plastics, which soften on heating, are, reformed into molding granules to make new products. The process involves collection, sorting, baling then size reduction into ake ( lm and sheet) or granules, which may then need washing and drying. This is then recompounded with additives and/or more virgin raw material, extruded and chopped into pellets ready for reuse. Feedstock or chemical recycling is where the plastics are broken down into their chemical constituents usually by heat and pressure. Good design for recycling should:
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Allow for easy disassembly of a product into its component parts Avoid the use of too many different types of plastic
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Markets for some recycled plastic resins, such as PET and HDPE, are stable in most geographical areas in the United States and are expanding in many others. Currently, both the capacity to process postconsumer plastics and the market demand for recovered plastic resin exceed the amount of postconsumer plastics recovered from the waste stream. The primary market for recycled PET bottles continues to be ber for carpet and textiles, while the primary market for recycled HDPE is bottles, according to APC. In the future, new end uses for recycled PET bottles might include coating for corrugated paper and other natural bers to make waterproof products like shipping containers. PET can even be recycled into clothing, such as eece jackets. Recovered HDPE can be manufactured into recycled-content landscape and garden products, such as lawn chairs and garden edging. The plastic lumber industry also is beginning to expand. New American Society for Testing and Materials (ASTM) standards and test methods are paving the way for use of these materials in decks, marinas, and other structural applications for both residential and commercial properties. Source reduction is the process of reducing the amount of waste that is generated. The plastics industry has successfully been able to reduce the amount of material needed to make packaging for consumer products. Plastic milk jugs weigh 30 percent less than they did 20 years ago. Plastic packaging is generally more lightweight than its alternatives, such as glass, paper, or metal.
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STARTEX produced multilayered plastic lm sheeting and used a blow- lm extrusion process to make plastic packaging for commercial, medical, food, construction, and agricultural products. It manufactured about 60 million pounds of packaging materials annually. STARTEX was disposing of approximately 16 to 20 tons (two or more 40-yd dumpsters) of solid waste weekly. This waste consisted of polyethylene lm scrap (extruded plastic waste), resin pellets, and cardboard (from Gaylord boxes and paper cores). As production increased, the waste volume increased to three 40-yd dumpsters weekly, or approximately 1150 tons annually. In addition, disposal costs were increasing by approximately $3 per ton annually. STARTEX addressed its growing waste problem by establishing a waste reduction team. The team consisted of ve to eight employees who worked to identify the types, amounts, and sources of solid waste generated, and to nd ways to reduce this waste. To start the waste reduction process, the waste reduction team held early morning dumpster dives, during which team members would sort and document the types and volumes of solid wastes being disposed of in dumpsters at STARTEX. After collecting this initial data, the team developed a strategy for reducing solid wastes, which included
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