Industrial recycler adds capacity in North Carolina

Mike Verespej

Published: November 28, 2012 6:00 am ET

Related to this story

Topics Materials, Suppliers, Sustainability, Recycling

ERIE, PA. (Nov. 28, 3:50 p.m. ET) — Pennsylvania-based EPI Recycling Solutions has begun pellet production at its industrial plastics recycling plant in Sanford, N.C.

The pellets are being produced with an S:GRAN 125 recycling machine that can reprocess 1,500 pounds of material per hour, increasing the plant’s capacity to 1 million pounds per month, said Kurt Duska, president of both EPI Recycling Solutions of Erie, Pa., and sister company injection molding contract manufacturer Engineered Plastics LLC, whose molding plant is in Lake City, Pa.

The 30,000 square foot plant in Sanford — the first recycling plant for EPI outside of its headquarters plant in Erie — represents an investment of more $1.1 million. It opened in April with a single granulator and baler.

“To service our existing national customers, increase our customer base, and to offer service to multiple locations, it was necessary to open an additional facility,” Duska told Plastics News. “Recycling facilities are typically limited due to incoming freight cost. Our model is a 300-mile radius for incoming material, and the Sanford facility is 600 miles from our primary facility in Erie.

“Opening a facility in Sanford [gives us] the capability to handle large sections of the country [as the] North Carolina area has many customers that are looking for our capabilities and recycling concepts.

“The NGR shredder/densifier/pelletizer offers us one machine that can process multiple materials in various forms,” he said. “We need to be able to process everything from 150-pound ABS purges to polystyrene and polyethylene foam, and molding scrap to thermoform trays.”

Duska expects the shredder, made by Austrian-based Next Generation Recyclingmaschinen GmbH, to be operating on three shifts in January, just as its Erie plant that already operates around the clock.

“We are excited to add the NGR equipment to our offering of services and see this as a long-term investment in North Carolina,” he said. “We believe that coupling the latest design in recycling equipment with our creative recycling concepts will allow companies to convert waste-plastic cost to revenue and improve their environmental position.

“Our main focus is post-industrial plastics,” said Duska. “The majority of our work is in packaging and process scrap. We handle flexible films on rolls and bulk including [polyethylene], polypropylene, biaxially oriented polypropylene film, as well as bags and stretch film.”

He said the company also reprocesses some multi-layer materials and all rigid plastics including engineered grades and filled material from injection, blow and extrusion applications.

In addition, he said the company works with hospitals and other non-manufacturing businesses on clean packaging and sustainability as Engineered Plastics was one of the eight founding members of the now 18-month-old Healthcare Plastics Recycling Council.

Duska said the company strives to provide creative solutions to customers at both of its recycling plants.

“We have developed a post-industrial single-stream program for customers that we manage,” he said. “Our post-industrial stream is focused on plastics, but it also offers mixed trailer solutions for cardboard, metal, paper and other items.”

That approach, said Duska, provides customers with a solution for low to high volume products. On one truck, there may be blow molded bottles, rolls of film, baled cardboard, scrap injection parts, and 100-pound purges.

“The process starts with a waste audit, but it never really ends,” Duska said. “We look at process scrap, and internal and external logistics. In addition, we design changes in systems and materials to improve recycling and eliminate waste.

“Often, we participate up and down stream to provide a complete recycling solution,” he said “We can offer unique disassembly and sorting programs geared to specific customers needs.” A case in point: it recently helped divert more than 175,000 lbs. of thermoset plastics from landfills.

“This is an opportunity for the state to improve its post industrial recycling and help reduce bottom line spending,” explained Bob Heuts, director of the Lee County Economic Development Corp. “Companies won’t have to pay to dispose of their materials and it will reduce” costs companies incur when they send materials to landfills.


Comments

Industrial recycler adds capacity in North Carolina

Mike Verespej

Published: November 28, 2012 6:00 am ET

Post Your Comments


Back to story


More stories

Image

'Thermoforming has nearly limitless possibilities'

April 18, 2014 12:54 pm ET

Julie McAlindon of PolyOne Corp. speaks about the future of thermoforming and the integration of Spartech Corp.    More

Image

Ascend targets nylon for auto applications, opening propylene monomer unit in Texas

April 18, 2014 10:57 am ET

Materials firm Ascend Performance Materials Inc. is in full operation at its new nylon 6/6 compounding line in Florida and will break ground by the...    More

Dutch company launching $100 million PP, PE recycling plant

April 18, 2014 10:42 am ET

Quality Circular Polymers is building a new plastics recycling operation in Geleen, the Netherlands' Chemelot industrial chemical site, with a...    More

Lumena suspends trading, delays report amid claims of 'misrepresenting' financials

April 18, 2014 10:19 am ET

China Lumena New Materials Corp., which says it has the world's largest manufacturing capacity for polyphenylene sulfide resin, has suspended its...    More

PolyQuest spins off FiberQuest unit

April 18, 2014 10:14 am ET

PolyQuest Inc. has spun off its FiberQuest unit — which distributes polyester staple fibers and cotton — as a separate company.    More

Market Reports

Thermoformed Packaging 2014 Market Review & Outlook North America

This in-depth report provides analysis and discussions of economic and political conditions, market trends, legislative/regulatory activity impacting supply and demand, business opportunities and threats, materials pricing, manufacturing technology, as well as strategies being implemented by thermoformed packaging companies. In addition, there are reviews of 25 leading thermoformers in the packaging segment, assessing their growth initiatives and performance metrics over 10 years.

Learn more

Automotive Market Review and Outlook 2014 The Americas

This 75-page report features in-depth analysis of the automotive industry for the Americas. It includes discussions of market trends, legislative/regulatory activity impacting production and threats as well as design strategies being implemented by the major automakers. Detailed charts and data tables outline North American automotive production over the last five years.

Learn more

Plastics Building & Construction Market Review and Outlook 2014 with MS Excel chart data

This report provides in-depth analysis of the plastic building and construction market for North America, including discussions of trends, opportunities, threats and the latest developments in construction trends that impact plastics processors.

Learn more

Upcoming Plastics News Events

May 6, 2014 - May 8, 2014Plastics in Medical Devices 2014

May 12, 2014 - May 12, 2014Plastics News Brazil Pharma Summit

September 10, 2014 - September 12, 2014Plastics Caps & Closures 2014

February 3, 2015 - February 7, 2015Plastics News Executive Forum 2015

More Events