With a focus on cross-contaminated polymers and industrial plastic scrap that many consider unusable, privately owned plastics separation company Butler-MacDonald Inc. has grown and prospered during the difficult economy of the past two years.
Our average revenue growth over the past seven years is 25 percent, said Grant Gilmore, business development specialist at Indianapolis-based Butler-MacDonald. We process 30 million to 35 million pounds annually.
In the last two years, Butler-MacDonald has expanded its manufacturing plant and upgraded processing capabilities by adding $2.3 million in equipment, including two new melt filtration systems to extrude pellets from regrind and a large shredder, Gilmore said. That has triggered a 50 percent increase in its workforce in the last year.
We were already doing size reduction and plastics separation, Gilmore said. This [new equipment] enabled us to deal with a wider range of plastic feed streams to provide clean regrind or pellets. Having all of our processes under one roof allows us to be a one-stop shop.
If we can recover a higher-purity polymer, our customers can better use the scrap they generate and that will translate to a significant cost savings for them.
The company uses proprietary separation processes developed by President and CEO J. Scott Johnson, whose father founded the firm 27 years ago. The technology is designed to remove contaminants such as commingled resins, color defects, ferrous and non-ferrous metals and dirt.
The firm processes more polystyrene than other plastics, but it also does significant amounts of polyethylene, polypropylene, polycarbonate, PET, PVC, ABS and nylon. Gilmore said 90 percent of business is toll processing for original equipment manufacturers with which it has closed-loop recovery partnerships.
Butler-MacDonald focuses on separating mixed plastics, hard-to-recycle materials and recovering plastic from packaged assemblies, housings, vinyl window profiles, auto parts, startup scrap, ground spill, silo contamination, manufacturing rejects and end-of-life products.
We want to help our customers better utilize their material, achieve sustainability initiatives and offset their prime resin expenditures, Gilmore said.