Campus Highlight - Recycling

J.P. Mascaro & Sons TotalRecycle Case Study

During a single-stream recycling process, all of the recycled items go into one large container without sorting. The large container is then transported to the local recycling centers to be sorted out using Material Recovery Facilities (MRF). This recycling system, with the help of MRFs, makes recycling easier for individuals, and increases the amount of recyclable materials being diverted from landfills, reducing the amount of waste going to disposal sites. 

Total Recycling is a Material Recovery Facility plant that separates and prepares single-stream recycling materials to be sold to end buyers. “J.P. Mascaro & Sons is proud to open TotalRecycle, Inc. This groundbreaking, state-of-the-art single-stream recycle facility further advances our steadfast commitment to a greener environment. TotalRecycle contains cutting-edge technology that allows for the precise sorting and processing of recyclable materials.”

Introduction

October 20th 2023, George School held a tour trip to the J.P. Mascaro & Sons total recycle Inc. During the Facility Tour, one of the staff members, Robert K, welcomed the students and gave them a detailed explanation of the mission of the TotalRecycling plant.

What happens to your recyclables after you throw them away?

Operational Process and Efficiency

• Can you walk me through the step-by-step process from the moment recyclables enter the facility until they are shipped out?

  • Step 1: The total recycling plant takes all of the recyclables and loads them into a pile of items waiting to be put into the machine by a forklift.

  • Step 2: The items are first put into a manual sort where items that are too big (eg. bulk metal and bigger plastic items) for the plant will be put into bins for sale.

  • Step 3: The screening process is conducted by four different screens. The first screen takes out glass; The next screen sorts out cardboard; Next one sorts out paper (newspaper, office paper, and mail); The last screening machine takes out r-flex (i.e. what chip bags and candy wrappers are made of), which is a new advancement in the world of recycling that can be turned into roofing. 

    1. Common roofing materials include asphalt shingles, metal sheets, tiles, and various types of membranes. For example, recycled plastic or rubber materials can be processed and molded into shingles or tiles for use in roofing.

• How do you recycle chip bags? 

We don’t do the physical recycling. We collect the flexible plastics and bale them for  the commodities market.  

• Step 4: This step includes the Optical Sorters, utilized for identifying and separating materials based on optical properties. The first optical scanner searches for paper missed during the screening processes. Before the second optical scanner, a magnet is used to remove steel and tin. 

Magnets: For extracting ferrous metals from the recycling stream.

• Step 5: Plastics are classified into 7 categories by the chemical structure of the polymer's backbone and side chains. The second optical scanner removes #1 (eg. water bottles) then #2 (eg. shampoo bottles) plastics.

• Step 6: A manual sort is performed to remove aseptic cartons. The remaining plastics #3-#7 (this is all the remaining types) are removed as well. 

• Step 7: An eddy current is sent out to sort aluminum products. 

• How do eddy currents work? 

I don’t know how this technology works either. Sorry. I think there is a tour being offered to the students at our recycling facility, this would be a good question at the tour. 

“An eddy current separator (ECS) is a machine that uses a powerful magnetic field to separate non-ferrous metals from an input waste or ore stream. Non-ferrous metals typically separated by an ECS include aluminum, copper and die-cast metals.” (Wikipedia). For more detailed explanation: please visit Eddy Current Separator Aluminum Recovery

• Step 8: The remaining items are sent to the last person who saves any remaining recyclables from going to the landfill.

• Step 9: Each of the sorted recyclables are baled into boxes of a given material.

Balers: Machines used to compress recyclables into compact bales for transportation.

What happens to the recyclables once they are baled and ready to be shipped?

Introduction

Total Recycle, just like other single-stream material recovery facilities (MRFs), does not perform any recycling, at least according to the definition of recycling, or the conversion of waste into some form of useable product or material. Instead, such plants are better likened to processing plants where regional single-stream recycling is merged, sorted, and baled to be re-distributed. In no part of this process is any material cleaned or transformed (unless we count compressing during the baling process). In an ideal world, if all waste is sorted correctly and contaminant-free, there will be little use for MRFs. Unfortunately, such standards are not achievable as is impractical to enforce accurate and contaminant-free recycling for all individuals. What must be done instead is to maintain a fine balance between maximizing garbage and ensuring the quality of recyclables. This is where single-stream recycling comes into play; this system ensures a high supply of available waste and employs automation to select high-quality recyclables. The need for processing plants to produce and distribute bales will therefore continue to exist. This means that when evaluating the environmental impact of recycling, it is necessary to continue to track the movement of trash to the next stage of its life journey, namely end markets. This portion of our case study of J. P. Mascaro’s Total Recycle plant aims to provide a more comprehensive understanding of where trash ends up after it leaves the plant and how this shapes our view on recycling and consumer habits. 

Downcycling and upcycling: not all recyclables end up the same 

Since recycling is not a linear process (the word itself implies that the process is a loop), it is insufficient to only consider a product’s current lifecycle and instead analyze how its recyclability changes over time. Downcycling is the way through which most recycled products degrade in quality over time and become less recyclable and is an effort to partially preserve a product’s embodied value - the natural resources, energy, labor, and time that went into its production. It may also be the case that some materials become more costly to recycle over time, causing a reduction in economic incentive for their continued reuse. Materials like aluminum, glass, and paper are all easily broken down with minimal changes in their durability or useability. Plastics, on the other hand, degrade in quality over time; most plastics are only suitable for recycling once and only a mere 1% has been recycled twice [1]. Products we often see advertised as being manufactured from 100% recycling plastics, such as carpeting, clothing, and shoes, are rarely recyclable for a second cycle. From this view, recycling is simply a delay before the plastic eventually ends up in a landfill - recycling doesn’t reconnect the end to the beginning of a plastic product’s life, merely extending a finite chain [2]. Continued recycling and downgrading of plastics contributes to the formation of microplastics, as plastics don’t biodegrade or decompose; they turn into tiny pieces that are almost invisible to the naked eye. This can be problematic as they are not only difficult to detect but also mix into rivers and groundwater supply which may in turn impact marine life and humans who consume them [3]. Similar disadvantages can be said about the recycling of paper. The quality of paper is rarely preserved after each recycling cycle, during which paper fibers become shorter and less useable. Most high-quality writing paper is used for cruder paper products like cardboard packaging and toilet paper, and we observe the same scenario as plastic where the lifespan of paper products is only lengthened for a limited period. Contrary to plastic, however, paper is biodegradable and does not produce the same degree of environmental repercussions when dumped into a landfill. 

On the other hand, upcycling is the creation of a new, high-value product from low-value recyclables. This not only preserves the embodied value of the raw material but also avoids breaking down the original product into constituent components of inferior quality thus ensuring recyclability for the product’s nest lifecycle. This method of recycling is generally associated with larger goods, such as turning old bicycles into lamps and furniture or tires into belts. Such a process may be labor and energy-intensive, but unlike downcycled products, the resulting produce is often of higher practical value that, combined with consumers channeling their societal desire for recycling into purchasing decisions (and thus willing to pay a premium), helps compensate for the higher cost of production [2]. Claiming to be the only MRF of its kind to accept rFlex, the Total Recycle plant bales packaging like chip bags, plastic bags, bubble wraps, and heat shrink films [4]. This material isn’t broken down further (which would also be difficult as most rFlex are made from composite materials) but instead manufactured into roofing materials that are stronger than conventional composite wood boards. However, more is to be uncovered if we ask ourselves the question of why this isn’t being done on a larger scale. One of the most apparent answers is that there are very few existing examples of cooperatives between recycling plants and upcycling facilities, and since most MRFs don’t process flexible packaging, there is a lack in supply and incentive for similar enterprises to take on upcycling rFlex. This case also helps illustrate one of the disadvantages of upcycling: it simply has a smaller market and demand that cannot accommodate the sheer volume of waste produced and processed by MRFs. Moreover, a consistent demand for basic downcycled goods like cardboard and plastic bottles ensures a higher profit margin that gives little financial incentive. At the end of the day, recycling is still a business, and environmental motivations often remain secondary to economic ones. 

End-market recycling by the numbers 

        The previous case with downcycling and upcycling illustrates how the same recyclable waste can be processed in vastly different ways that have varying degrees of environmental impact. The waste themselves, however, are not equal either. Aluminum is currently the most recyclable material in packaging; nearly 75% of all aluminum ever produced is still in use today, while this figure is only 9% for plastic [5]. This is because aluminum in cans has a very high degree of purity and low alloy content, allowing it to almost be recycled in a true indefinite loop. Furthermore, the melting of aluminum requires lower temperatures than other metals that, combined with the fact that most cans are very thin and easily melted, makes the recycling process of aluminum less energy-intensive than plastics; in fact, only 5% of the energy required to manufacture new aluminum is needed to recycle it, while this increases to 24% for recycling plastics [6]. Therefore, when we observe bales of plastic bottles and crushed aluminum cans being shipped out of MRFs, they are far from equal; those bales of plastic may end up in a landfill in the next 10 years, or worse in the environment if not properly managed, while a much larger portion of the aluminum may be looped in the recycling process for a much longer time. This is not to suggest that recycling plastics is not worthwhile. Plastic consumption in the United States in 2021 was an overwhelming 40 million tons compared to 4.3 million tons for aluminum, but only 6% of the plastic was recycled while only 1% of aluminum waste ended in the waste stream [6]. Thus, recycling and maximizing the life cycle of plastics that are currently in circulation is necessary, but these statistics suggest that aluminum would be the better option moving forward if we consider materials that are truly renewable. 

        Another important factor to consider is the carbon footprint associated with bale transportation. Robert, the manager of the Total Recycle plant, explained that while a small percentage of baled recyclables are shipped off to India and other Asian countries, they strive to direct most bales towards domestic markets, specifically buyers on the East Coast, to prioritize demands of more regional markets. Although transportation costs are likely the main motivator in this decision, concentrating on nearby markets also has the double benefit of reducing the ecological footprint associated with bale distribution. If we consider the economics of recycling, however, we see that directing bales to local markets may not be as simple as it appears; following China’s ban on imported plastic in 2017 [1], global exporters of plastic waste like the United States have been unable to handle domestic plastic recycling demand due to a lack of recycling facilities. This surplus in plastic waste, as a result, has been directed to the landfill. 

        As mitigating pollution and ecological impact is a major incentive for recycling (other than limited landfill space and economic interests), we must not only seek to maximize recycling volume but also consider the environmental repercussions associated with recycling processes. Here we are going to utilize two benchmarks: total energy use (TEU) and global warming potential (GWP). Although it is generally true that recycling requires less energy than producing new material as it bypasses having to extract, transport, and process raw materials, there are exceptions. Studies have shown that plastics including polyethylene (PE), polypropylenes (PP), polystyrene (PS, commonly known as Styrofoam), PET, and PVC have a higher TEU and GWP than both incineration and landfilling, while non-recyclable plastics (in the conventional sense of downcycling which includes rFlex) also have a higher GWP than landfilling [8]. Energy usage only serves as a guideline, however, as the optimal choice may depend on local contexts; recycling may be less environmentally damaging in areas where poorly managed landfills may lead to potential risks like water contamination, while incineration may be favorable in places where fossil fuels are dominant and energy demand is high [1]. 

Conclusion

        To gain a sense of the large picture and awareness of potential pitfalls with single-stream recycling, let us remind ourselves of the purpose of recycling: to divert more materials from ending up in the landfill or the environment and extend the lifecycle of products as close to indefinitely as possible. Only considering the percentage of waste recycled or the volume of bales produced by an MRF provides a lacking picture when evaluating whether current single-stream recycling systems meet this goal. Addressing where materials end up and their projected lifespan after more than one recycling cycle, along with energy consumption, impact on raw material extraction, and ratios of recycled material categories uncover the complexities in the process. Current focuses on downcycling which lends a false public perception of sustainability and the shortage of upcycling infrastructure and incentives. Total Recycle is moving in this direction with its roofing material and rFlex program, but there is much more to be done, including applying upcycling to a wider range of mass-produced consumer products and reducing contamination rates. More importantly, however, are consumer preferences and purchase habits, which may in turn shape policies on recycling. A conscious choice in purchasing products packaged that are more recyclable (opting for aluminum and paper over plastics) and reducing overall consumption can have significant influences on material flow and recycling dynamics. Furthermore, reusing materials (such as using a grocery bag as a garbage bag or old newspapers as wrapping paper). Focusing on “reduce” and “reuse” alleviates pressures on “recycle” and prevents unnecessary waste from entering waste management systems. 

References

[1] Ritchie, Hannah. “FAQs on Plastics.” Our World in Data, 2 Sept. 2018, https://ourworldindata.org/faq-on-plastics.

[2] Weber, Agnes, and Mathieu Dasnois. “Recycling, Downcycling and the Need for a Circular Economy.” Metabolic, 3 Feb. 2021, https://www.metabolic.nl/news/recycling-downcycling-and-the-need-for-a-circular-economy/.

[3] GreenMatters. What Are Microplastics? https://www.greenmatters.com/t/microplastics.

[4] Biotef. Flexible Packaging vs. Rigid Packaging. https://www.biotef.com/labels-guides/flexible-vs-rigid-packaging.

[5] Calma, Justine. “Aluminum Is Recycling’s New Best Friend, but It’s Complicated.” The Verge, 21 Jan. 2020, https://www.theverge.com/2019/9/12/20862775/aluminum-recycling-water-tech-plastic-manufacturing-cocacola-pepsi-apple.

[6] The Aluminum Association. “Infinitely Recyclable.” https://www.aluminum.org/Recycling.

[7] Wakefield, Faith. “Top 25 Recycling Facts and Statistics for 2022.” EcoWatch, 19 June 2022, https://www.ecowatch.com/recycling-stats.html.

[8] Bernardo, C. A., et al. Environmental and Economic Life Cycle Analysis of Plastic Waste Management Options. A Review. 2016, p. 140001, https://doi.org/10.1063/1.4965581.

• Why have more materials become recyclable? 

It’s not that they were not recyclable in the past. The cost to bale and store the product was not profitable for most companies. For lots of manufacturers it was cheaper to make a new product from fresh materials. Metal, Glass, and paper have been recycled for decades. With the introduction of plastic bottles and the cost benefit for companies they saw profits increase. This is why more companies use plastic instead of glass and metal.

More information on TotalRecycling 

Technology 

• What specific sorting technologies are currently in use at this facility?

Eddie Current

Bottle 

Van Dyk manufacturer

Conveyors and Feeders: For moving materials through the facility.

Glass Crushers or Pulverizers: For processing glass into cullets.

Air Classifiers: To separate materials by weight or density.

• Are there any technologies here that are unique to your facility compared to other similar recycling plants?

No, nothing proprietary. Planning for styrofoam. 

• Why can you not recycle Styrofoam?  

Styrofoam can be easily recycled but we do not get enough of this material. There are other factors that go into recycling Styrofoam. Quantity is the first and we don’t have enough customers to generate the volume it would take to get another manufacturer to purchase the material. We would have to dedicate space to house the material so we could sell a trailer full of this product. The transportation of the product would cost more than the value of the product.

Capacity and Throughput

• What is the maximum processing capacity of the facility, and how close does the facility operate to this capacity regularly?

Current operating hours are Thursday and Friday from 12pm-5pm and Saturday from 7am- noon. 100-120 people per day

Environmental Impact

• What systems are in place for energy recovery or water reuse within the facility?

Collect methane: gas to electric power plants

Contamination Management

• What are the most common contaminants, and how do they impact the recycling process?

Mayonnaise, peanut butter

Seasonal: Xmas tree lights, animal bodies, garden hoses, chords, rocks, blocks, balls, pots & pans, rechargeable batteries (causes fires1

Different outlets, they could be recycled, but they go in landfill

Goal is to have precise separation for each type of recycle and bail them accordingly

Market Dynamics

• How does the fluctuation in commodity prices for recyclable materials affect your operations?

Hard to figure out prices, 

Mostly 95% stay in the US, less than 3% go intl, plan for next spring to reduce to 0. 

Plastics may be main profit

• What happens to materials that are not currently profitable to recycle?

Septic cartons: 

Carton council: extended producer responsibility, leading manufacturers decided to standardize production, 

Plastic 1-7: 1,2 easy, 3-7 difficult 

Plastics other than 1-7: styrofoam, not recycled, treated as trash. 

(R-flex) flexible packaging: only facility that processes in NA, used for roofing boards, claim to be better performance

Pressure molded by aseptic cartons and r flex

Indifference to recycling materials

Litter free landfill, 1 violation

Community Engagement

• How do you work with the local community to improve recycling rates and education?

5*20h

Comparison to multi-stream: Single stream makes it easier for community 

• Are there any community outreach programs or incentives to encourage proper recycling habits?

Make it easier for recycling, pioneer crossing landfill has valuable space

• How can we improve recycling? 

Simply placing the recyclable items in the correct receptacle. It’s the smallest step that makes the difference.

Future Developments

• Are there any new developments in recycling technology on the way? 

I think the better question is what can we create from the materials we have already collected. What can scientists create with all the plastics we generate every day. I would have to research what the cutting edge is in recycled plastics.

Challenges and Adaptations

• What are the biggest challenges the facility faces today in terms of recycling 

efficiency and sustainability?

• How does your plant avoid being broken by trash items? 

From time to time our equipment needs maintenance and we have a team of skilled technicians who take care of our recycling machine. We will hand pick items out of the recycling and send it over to our landfill for proper disposal.

• What happens if something breaks within the plant? 

Our tech staff must shut the machine down to fix the issue. There are times where the machine is shut down all day. You can imagine how much recycling gets backed up while we are fixing the machine. We can run at speeds up to 50 tons per hour, so a malfunctioning machine is not what we want to see during the day when our trucks are unloading all the recycling they have collected.

• How has the facility adapted to changes in recycling streams over the past years (for example, changes in the types or volumes of materials received)?

Cardboard skyrocket through Covid

• How is smart packaging recycled compared to regular recyclables? 

Sorry we don’t turn the recycling we collect into another product. We are the middleman in the supply chain for recycled materials.