Starting a Plastic Recycling Business
Starting a Plastic Recycling Business
STARTING A BUSINESS
Introduction
Sooner or later, everything we use and consume
becomes waste, including all these nice plastic items
and plastic bags we use every day. Plastic
consumption is rising and with it the amount of plastic
ending up as waste. Managing plastic waste is a global
problem with increasing amounts of waste in
developing countries as well as industrialised nations.
These developments offer opportunities to people in Bowls made form recycled plastic,
developing countries enabling new economic activities Galle, Sri Lanka. (Zul / Practical Action)
through the collection, sorting and recycling of plastic
waste material. This technical brief gives an overview
of technical and economical aspects involved in these activities; it is intended primarily for
entrepreneurs thinking of setting up their own plastic recycling business and for organisations
dealing with communities in urban low-income areas and who seek opportunities either to
create or to increase employment.
Practical Action, The Schumacher Centre for Technology and Development, Bourton on Dunsmore, Rugby,
Warwickshire, CV23 9QZ, UK
T +44 (0)1926 634400 | F +44 (0)1926 634401 | E [email protected] | W www.practicalaction.org
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Patron HRH The Prince of Wales, KG, KT, GCB
Recycling of plastics Practical Action
The disposal of plastics products also contributes significantly to their environmental impact.
Most plastics are not biodegradable and can persist in the environment for many years.
Plastics can cause blockage of drainage and sewage systems resulting in water logging,
flooding and spread of water born diseases. With more and more plastics products,
particularly packaging, being disposed of soon after their purchase, the landfill space
required by plastics waste is a growing concern.
Although there is also a rapid growth in plastics consumption in the developing world,
particularly due to the increasing demand for plastics from Asia, plastics consumption per
capita in developing countries is much lower than in the industrialised countries. However,
there is a much wider scope for recycling in developing countries due to several factors:
• Labour costs are lower.
• In many countries there is an existing culture of reuse and recycling, with the associated
system of collection, sorting, cleaning and reuse of ‘waste’ or used materials.
• There is often an ‘informal sector’ which is ideally suited to taking on small-scale
recycling activities. Such opportunities to earn a small income are rarely missed by
members of the urban poor.
• There are fewer laws to control the standards of recycled materials. (This is not to say
that standards can be low – the consumer will always demand a certain level of quality).
• Transportation costs are often lower, with hand or ox carts often being used.
• Low cost raw materials give an edge in the competitive manufacturing world.
• Innovative use of scrap machinery often leads to low entry costs for processing or
manufacture.
In developing countries the scope for recycling of plastics is growing as the amount of plastic
being consumed increases. Collecting, sorting and recycling plastic waste becomes a viable
activity.
Types of plastics
The six most common types of plastic can easily be recycled. The plastics industry has
voluntarily devised a coding system which makes recycling plastics easier. Table 1 shows
these 6 types of plastics with their identification code, general properties and common uses.
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Recycling of plastics Practical Action
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Recycling of plastics Practical Action
It is recommended to make a business plan as it brings ideas and information gathered into a
structured format. Furthermore, A Business Plan helps you to
• decide if you should start your business or not
• organize your ideas so that you will start and run your business in the best way
• present your business idea to a lending institution such as a bank to get a loan for your
business.
The following manual helps to prepare a business plan for the proposed business:
http://www.ilo.org/public/english/employment/recon/eiip/download/waste_recycle/business_ma
nual.pdf
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Recycling of plastics Practical Action
As a result of this intensive marketing and promotional campaign, more than 100 contracts
were established with suppliers of plastic waste materials like hotels, restaurants, schools,
NGO’s, garbage collectors, petrol stations, supermarkets, etc. Apart from these agreements,
many small companies started collecting and selling plastic waste material to PRI.
The impact of these activities is enormous, next to the creation of hundreds of jobs in the
collection and transportation of plastic waste, also a great impact on environment is
noticeable. Plastic waste lying around in streets is less and it is also noticed that the burning
of plastic has decreased in many areas of the city.
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Recycling of plastics Practical Action
Plastic Waste
Collection
Storage
Sorting (identification)
Baling (optional)
Value added
Washing
Drying
Cutting
Shredding
Agglomerating
(for film sheet)
Storage
Extruding/compounding
Pelletizing
Selling of pellets
Further processing
(injection moulding,
blow moulding, film blowing)
Selling of products
Storage
The plastic recycling enterprise needs quite a large storage space in order to store all
collected waste items, processed materials and finessed products. Plastic waste items,
especially bottles, have a large volume and therefore a large storage place is necessary.
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Recycling of plastics Practical Action
Burning test.
Hold a piece of the plastic in a tweezers or on the back of a knife and apply a flame. Dose
the plastic burn? If so, what colour?
Fingernail test.
Can a sample of the plastic be scratched with a fingernail?
Test PE PP PS PVC*
Water Floats Floats Sinks Sinks
Burning Blue flame with Yellow flame Yellow, sooty Yellow, sooty
yellow tip, melts with blue base. flame – drips. smoke. Does
and drips. not continue
to burn if
flame is
removed
Smell after Like candle wax. Like candle wax Sweet Hydrochloric
burning – less strong acid
than PE
Scratch Yes No No No
Baling
After collecting and sorting the plastic material the option
exist to sell the material to (other)
processing units. Especially when transporting distances are
considerably, it is important to compact the waste to improve
handling and save costs during transport. In order to obtain a
Washing
If the plastic is dirty, cleaning is necessary. The main
cleaning steps are:
- Draining of remaining fluids from containers into
prepared collection barrels.
When plastic waste is sorted to type, the price per kilo increases substantially.
When the plastics are further sorted to colour, the price increases more.
When the plastics are baled, the price increases more.
Large quantities give better negotiation positions.
Cutting
Cutting is usually carried out for initial size reduction of large objects. It can be carried out
with scissors, shears, saw, etc.
Shredding
Shredding is suitable for smaller pieces. A typical shredder has a series of rotating blades
driven by an electric motor, some form of grid for size grading and a collection bin. Materials
are fed into the shredder via a hopper which is sited above the blade rotor. The product of
shredding is a pile of coarse irregularly shaped plastic flakes which can then be further
processed.
Agglomeration
Clean film sheet is processed in an
agglomerator. The agglomerator consists of a
vertical crum with a set of fast moving blades in
the bottom. The agglomerator chops the sheets
into thin film flakes. Due to the cutting and
friction energy of the process, the flakes are
heated until they start to melt and form crumbs
or agglomerate. This will increase the bulk
density of the material which is now fit to be
feed directly into the extruder.
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Recycling of plastics Practical Action
Pelletizing
For many purposes it is recommended to convert plastic flakes or agglomerate (crumbs) into
pellets before processing. The plastic pieces are fed into the extruder, are heated and then
forced through a die to form a plastic spaghetti which can then be cooled in a water bath
before being chopped into pellets.
Further processing
Extrusion. The extrusion process used for manufacturing new products is similar to that
outlined above for the process preceding pelletisation, except that the product is usually in
the form of a continuous ‘tube’ of plastic such as piping or hose. The main components of the
extrusion machine are shown in Figure 2 below. The reclaimed plastic is forced along the
heated tube by an Archimedes screw and the plastic polymer is shaped around a die. The die
is designed to give the required dimensions to the product and can be interchanged.
Injection moulding. The first stage of this manufacturing process is identical to that of
extrusion, but then the plastic polymer emerges through a nozzle into a split mould. The
quantity of polymer being forced out is carefully controlled, usually by moving the screw
forward in the heated barrel. A series of moulds would be used to allow continual production
while cooling takes place. See Figure 2 below. This type of production technique is used to
produce moulded products such as plates, bowls, buckets, etc.
Blow moulding. Again the spiral screw forces the plasticised polymer through a die. A short
piece of tube, or ‘parison’ is then enclosed between a split die -which is the final shape of the
product - and compressed air is used to expand the parison until it fills the mould and
achieves its required shape. This manufacturing technique is used for manufacturing closed
vessels such as bottles and other containers. See Figure 2 below.
Film blowing. Film blowing is a process used to manufacture such items as garbage bags. It
is a technically more complex process than the others described in this brief and requires
high quality raw material input. The process involves blowing compressed air into a thin tube
of polymer to expand it to the point where it becomes a thin film tube. One end can then be
sealed and the bag or sack is formed. Sheet plastic can also be manufactured using a
variation of the process described.
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Recycling of plastics Practical Action
Environmental policy
The existence of government support schemes are very helpful to start a plastic recycling unit.
When laws and regulations are enforced promoting recycling, it often is much easier to obtain
the necessary permits needed for the company.
In developing countries, where standards are often lower and raw materials very expensive,
there is a wider scope for use of recycled plastic material. The range of products varies from
building materials to shoes, kitchen utensils to office equipment, sewage pipe to beauty aids.
Ragbags are fashionable products made from recycled plastic bags by deprived people in the
slums of Delhi. The production is done by Conserve, a Delhi based NGO. They work with rag
pickers, who collect the plastic waste, collection centers where they wash and clean the bags.
Then the bags are sorted on colours and pressed to thicker sheets. Finally they go to small
fabricators who make them into new products. The project is already creating jobs for more
than 100 ragpickers, people at collection centers and
fabricators in New Delhi, providing them and their
families ‘means of livelihood’ and gain access to more
opportunities.
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Recycling of plastics Practical Action
Useful addresses
RAPRA Technology Ltd. World Resource Foundation
Shawbury, Shrewsbury, Shropshire Heath House
SY4 4NR 133 High Street, Tonbridge
United Kingdom Kent TN9 1DH
Tel: +44 (0)1939 250 383 United Kingdom
Fax: +44 (0)1939 251 118 Tel +44 ( 0)1732 368333
Email: [email protected] Fax +44 (0)1732 368337
http://www.rapra.net E-mail: [email protected]
Rapra Technology is Europe’s leading http://www.wrf.org.uk
independent plastics and rubber specialist The Warmer Bulletin' published 4 times a
organisation, providing research, technology year (subscription required)
and information services for the polymer
industry and for industries using polymers in
their products or processes.
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Recycling of plastics Practical Action
www.pimcomachine.com
www.himalayagranulator.com
www.asianmachineryusa.com
For more manufacturers of recycling machinery all over the world, see www.alibaba.com
Used machinery:
www.plasplant.com
www.upm.nu
www.holzmag.de
Internet addresses
www.cwgnet.net Website of the Collaborative Working Group on Solid Waste
Management in Low- and Middle-Income Countries (the CWG). Has
access to articles, conference proceedings, networking information,
and a working group on the global informal sector in solid waste.
www.ilo.org Website of the International Labour Organization. The ILO has a wide
variety of very useful publications on solid waste services by and for
the poor, including “Start your own Waste Collection Service ;
Business Plan ”
www.iswa.org Website of the International Solid Waste Management Association.
ISWA publishes Waste Management World, www.waste-management-
world.com
www.skat.ch A Swiss NGO consultancy. Secretariat of the CWG, and specializes in
the Brown environmental agenda
www.worldbank.org/solid Website of the World Bank. Contains, has a great deal of very good
waste information on solid waste management in developing countries
www.unep.or.jp/ietc/issu Website of the former office of UN-International Environmental
es/Urban.asp Technology Center in Japan, publisher of the UN Solid Waste Source
Book.
This technical brief was updated in January 2009 by Sophie van den Berg for
Practical Action.
Practical Action
The Schumacher Centre for Technology and Development
Bourton-on-Dunsmore
Rugby, Warwickshire, CV23 9QZ
United Kingdom
Tel: +44 (0)1926 634400
Fax: +44 (0)1926 634401
E-mail: [email protected]
Website: http://practicalaction.org/practicalanswers/
Practical Action is a development charity with a difference. We know the simplest ideas can have the
most profound, life-changing effect on poor people across the world. For over 40 years, we have been
working closely with some of the world’s poorest people - using simple technology to fight poverty and
transform their lives for the better. We currently work in 15 countries in Africa, South Asia and Latin
America.
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