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Description
Polska Korporacja Recyklingu (Polish Recycling Corporation) operates in the field of household waste management, mainly waste electrical and electronic equipment and waste batteries (including car batteries). The project objective is to manage process waste generated in our company and to create a product with high commercial potential. We plan to introduce an automatic sorting process and an intelligent regranulation system for plastic waste from the processing of waste cooling equipment. The project will result in the implementation of an innovative product - plastic regranulate (mainly from polystyrene), which has so far been a waste product in our business.
The project is in line with the zero-waste principle. About 185.5 tons of regranulate will be obtained monthly, i.e. 2,226 tons per year. The project will also reduce electricity consumption by 0.45 GWh and reduce annual CO2 emissions by 328.05 tons.
We will implement the project in cooperation with the Norwegian company TOMRA Sorting, which is the world leader in sensor-aided sorting. Our cooperation will result in exchange of experience and know-how, including evaluation of waste data, verification of the concept and conducting tests of waste sorting.
Summary of project results
The challenge taken up as part of the project was to reduce the amount of waste generated in the company of the Beneficiary – Polska Korporacja Recyklingu Sp. z o.o. (Home - Polska Korporacja Recyklingu). The aim was to manage a significant part of the waste fraction of mixed plastics, which is generated in the plant in the process of processing used refrigeration equipment (refrigerators, freezers) and to produce high-quality polystyrene regranulate from it. Regranulate is a product (under the trade name of "Greenway polymer"), created in the raw material recycling process in the form of standardized granules, which is a valuable material for the production of products by injection molding. This recycled product can be used directly in plants dealing with plastics processing and can successfully replace the original material. New industrial packaging, electronic components or household products can be created from it.
The implementation of the project (Watch here) enabled the Beneficiary to manage the waste fraction of plastics, which so far had been stored or constituted a fraction of alternative fuel. The important part of the project was an evaluation of data on the composition, morphology and the type of waste which was carried out with the Norwegian project partner TOMRA Sorting AS. This evaluation was conducted to determine the types of plastics contained in the mixture and their generic structure. The research tests were carried out to identify the possibilities of the plastic sorting process in terms of their type and the separation of metals in the form of a printed circuit board and electrical wires.
As a result of the project, the waste is turned into a product of valuable raw material that is an input material for further processing. The implementation of innovative separation and regranulation technologies allows the conversion of the waste polymer fraction into a re-raw material which is reintroduced into the production cycle in the form of regranulate. In this way, the life cycle of the material is extended, and the carbon footprint is significantly reduced. The product can be repeatedly returned to circulation which means the transformation from the linear economy into a circular economy.
The implementation of advanced technological processes required equipping the plant''s machinery park with modern devices which was also implemented as part of the project.
In addition, during the implementation of the project the Beneficiary has developed international cooperation with a Norwegian company - TOMRA Sorting AS. The intention of both parties is to continue this cooperation.
The implementation of the project contributed to the development of the Beneficiary''s plant and company. It allowed for the introduction of an innovative recycled product in the form of regranulate with properties like the original material.
The project has significant environmental results and importance. Due to the implementation of appropriate separation and regranulation technologies, the amount of waste generated in the plant was reduced. Moreover, the production of regranulate from post-consumer polymer fractions emits much less CO2 into the environment than the production of these polymers from primary material. The use of regranulate in the production process results in much lower carbon footprint.
The machines purchased within the project are characterized by high energy efficiency, therefore the process of producing regranulate is more ecological due to the lower demand for electricity. The Beneficiary gained a technological benefit by implementing advanced sorting and regranulation processes, through the purchase of modern equipment from renowned companies.
The implementation of the project has strengthened the company’s position in the market as one of the largest modern plants in Poland for processing waste electrical and electronic equipment. It was another step in the transformation into a mature manufacturer of products based on obtained plastic fractions.
The introduction of innovative regranulate to the market is an alternative to the production of primary material, which will become a legal requirement in the next few years. This is an undoubted benefit for all plants involved in plastic processing, because they can now choose a more ecological and environmentally friendly solution and adapt their production processes to it. An additional benefit will also be the image effect of the company building a pro-ecological brand.
The achievements of the project also fit directly into the market trends. Consumers consciously choose products made with the use of recycled materials, so they are also a group which indirectly benefit from the introduction of regranulate to the market.
Summary of bilateral results
Thanks to the partnership with the Norwegian company, PKR gained access to a base of specialized knowledge, many years of experience and know-how, as well as to specialized research equipment within the test center - representatives of the Beneficiary took part in tests performed at the test center. Thanks to the partnership with Tomra Sorting AS, it was possible to scale the technology from the laboratory scale to the industrial scale - it became possible to transfer innovative solutions to practical application. The partner not only provided a high-end device and trained the Beneficiary''s staff, but also participated in the work of optimizing the technology for PKR''s needs. Combined with the internal analyses performed, we were able to effectively optimize the machine settings for separated materials, debris removal and throughput control. After the tests were performed, we received a comprehensive report describing all the performance with photos.The main result of the bilateral cooperation was an exchange of knowledge and experience that allowed two different perspectives, skills and experiences to be juxtaposed, contributing to a better understanding of the technology and aspects of its implementation. As part of the bilateral cooperation, Tomra Sorting AS participated in studies that helped optimize the technology strictly for PKR''s needs, providing valuable information and suggestions for improvements and adjustments. Another aspect is risk reduction - bilateral cooperation has reduced the risks associated with implementing new technology by combining the years of experience of two specialized entities. In addition, the partnership with the Norwegian entity undoubtedly contributed to greater interest in PKR''s business environment in the implemented project and its results.