high precision
intelligent
custom made
PRA‘s 2013 Green Packaging Conference 21 November 2013 – Jakarta, Indonesia
Optical Sensor based Automatic Sorting Technologies to Promote Sustainability & Increase Profitability Lee Chee Kiong Sales Director, Asia – Sorting Division
high precision
intelligent
custom made
PRA‘s 2013 Green Packaging Conference 21 November 2013 – Jakarta, Indonesia
We are privileged to be part of this CSR (Corporate Social Responsibility) initiative from PRA and Tara Media & Communications.
high precision
intelligent
custom made
Optical Sensor based Automatic Sorting Technologies to Promote Sustainability & Increase Profitability
Sharing •
Introduction of S+S
•
The Reality
•
The Roles of Automatic Sorting
•
Available Sorting Technologies
•
Application based Sorting Technologies
•
Conclusion
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Company Profile
• Founded in 1976 as S+S
Elektronik KG • Corporate headquarter, R&D and manufacturing facility located in Schoenberg, Germany, about 150 km North East of Munich in Bavaria state
high precision
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custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Company Profile •
•
Wholly owned world wide subsidiaries: - United States of America - France - United Kingdom - Singapore - China - India - Italy - Turkey
350 staffs world wide
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Company Profile
• Asia Pacific Service & Sales Offices: - Singapore (Asia HQ) - Thailand - The Philippines - Indonesia
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Company Profile Approximately 1,300 automatic sorting installations worldwide, in different industries:
Plastics Recycling Glass Recycling Wood Recycling Metal Scrap Recycling Electronics Scrap Recycling
More than 250 installations in plastics recycling since 2001
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
The Reality
REALITY
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custom made
19 November 2011
Source: http://www.thejakartaglobe.com/archive/workers-threaten-strike-over-minimum-wage-rise/
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REALITY
06 February 2013
Source: http://www.aljazeera.com/news/asia-pacific/2013/02/20132675333828387.html/
REALITY
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custom made
05 September 2013
Source: http://www.bloomberg.com/news/2013-09-05/indonesian-workers-rally-in-java-to-demand-50-percent-pay-rise.html
REALITY
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intelligent
custom made
29 October 2013
Source: http://www.indonesia-investments.com/news/todays-headlines/demand-for-higher-minimum-wages-hurts-indonesias-investment-climate/item1261
high precision
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custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
REALITY
The Reality
Source: http://www.oecd.org/eco/surveys/2012%20Indonesia%20Overview.pdf
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intelligent
custom made
REALITY
Indonesia is not alone in this reality landscape
According to a report by French bank published on 29 July 2012: China’s labour costs will match those in the US in 4 years’ time catch up with Eurozone in 5 years’ time be similar to Japan in 7 years’ time Source: http://www.news.com.au/business/worklife/china-labour-costs-like-us-withinyears/story-e6frfm9r-1226438065496
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UNSUSTAINABLE!
11/29/2013
Page 5
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UNSUSTAINABLE!
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UNSTOPPABLE! We are very sure you would rather have
Let’s Explore .......
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The Good News! Innovative technologies are available to promote sustainability and increase profitability
high precision
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custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
A Cruel Fact on Plastic Packaging
Plastic packaging will take up to 450 years to decompose!
high precision
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custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
A Cruel Fact on Plastic Packaging
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
A Cruel Fact on Plastic Packaging
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
A Cruel Fact on Plastic Packaging
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Opportunities in Recycling of Rigid Plastics Packaging
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Opportunities in Recycling of Rigid Plastics Packaging
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Opportunities in Plastic Packaging 3R
high precision
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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Opportunities in Plastic Packaging 3R
o o o o o o
EcoARK in Taiwan By Far Eastern Group 1.5 million PET bottles 3 stories tall One amphitheater One exhibition hall
Source: http://www.treehugger.com/sustainable-product-design/massive-plastic-bottle-building-unveiled-in-taiwan.html
high precision
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custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Opportunities in Plastic Packaging 3R Weight of Packaging
Year
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custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Opportunities in Plastic Packaging 3R
o o o o o
2010 World Cup Up to 8 recycled PET bottles ďƒ† 1 shirt About 13 million PET bottles recycled Bottles laid end to end = 3,000 km Enough to cover 29 football fields
Source: http://www.ecouterre.com/nike-outfits-world-cup-teams-in-jerseys-made-from-recycled-bottles/
high precision
intelligent
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Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Opportunities in Plastic Packaging 3R
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custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Opportunities in Plastic Packaging 3R Many other opportunities in the recycling of plastics
Recycled PET Punnet
Recycled PP Flower Pots
Recycled HDPE Milk Bottles
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Typical Recycling Process for Plastics
Industrial Waste
Extrusion Extrusion
Commercial Waste
Pelletizing Blown Film
Collection / Baling
Sorting / Separation
Size Reduction
Pipes, sheet Tube Bags, film
Cleaning / Washing
Agricultural Waste
Injection Molding
Various Items
Municipal Waste
Blow Molding
Bottles Containers
Pelletizing
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Typical Recycling Process for Plastics
Industrial Waste
Extrusion Extrusion
Commercial Waste
Pelletizing Blown Film
Collection / Baling
Sorting / Separation
Size Reduction
Pipes, sheet Tube Bags, film
Cleaning / Washing
Agricultural Waste
Injection Molding
Various Items
Municipal Waste
Blow Molding
Bottles Containers
Sorting / Separation
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Manual Sorting
Increasing Labour Costs Difficulties to Employ Workers Inconsistent Quality
Low Sustainability!
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
The Roles of Automatic Sorting To improve quality To increase output To reduce costs
Higher Profits
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
The Roles of Automatic Sorting
Automatic PET Bottle Sorting
ďƒź Higher Profits
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
The Roles of Automatic Sorting
Automatic PET Flake Sorting
ďƒź Higher Profits
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Available Automatic Sorting Technologies – PET Bottles
High Resolution CCD Colour Sensor Separation of coloured and nontransparent bottles from clear PET bottle stream Near Infra-Red Sensor Separation of non-PET plastics (e.g. PLA, PVC and PET-G) from the PET bottle stream
High Frequency Electromagnetic Sensor Removal of ferrous and non-ferrous metal contamination from the PET stream Metal Cans
Metal Parts
Metal Caps
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Available Automatic Sorting Technologies – PET Bottles
High Resolution CCD Colour Sensor Separation of coloured and nontransparent bottles from clear PET bottle stream
High Frequency Electromagnetic Sensor Removal of ferrous and non-ferrous metal contamination from the PET stream
Near Infra-Red Sensor Separation of non-PET plastics (e.g. PLA, PVC and PET-G) from the PET bottle stream
The selection of the sensor type depends on the incoming materials and sorting objectives. It can be a single sensor, or a combination of two or all three sensors
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Available Automatic Sorting Technologies – PET Bottles
Digital signal processing
CCD camera
Valve control
Air blast ejection system Illumination unit
Diverter shield Multispectral NIR sensor incl. Illumination unit Conveyor belt Metal detection coil Output fraction 3, e.g. Colored PET bottles
Output fraction 2, e.g. clear PET bottles
Output fraction 1, e.g. offpolymers like PVC & metal
high precision
intelligent
custom made
Application Based Automatic Optical Sensor Sorting for the PET Recycling Industry
Available Automatic Sorting Technologies – PET Bottles
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Available Automatic Sorting Technologies – PET Flakes
High Resolution CCD Colour Sensor Separation of coloured and nontransparent flakes from clear PET flakes stream
PVC
PET Near Infra-Red Sensor Separation of non-PET (e.g. PLA, PVC and PET-G) flakes from the PET flakes stream
High Frequency Electromagnetic Sensor Removal of ferrous and non-ferrous metal contamination from the PET stream
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Available Automatic Sorting Technologies – PET Flakes
High Resolution CCD Colour Sensor Separation of coloured and nontransparent flakes from clear PET flakes stream
High Frequency Electromagnetic Sensor Removal of ferrous and non-ferrous metal contamination from the PET stream
Near Infra-Red Sensor Separation of non-PET (e.g. PLA, PVC and PET-G) flakes from the PET flakes stream
The selection of the sensor type depends on the incoming materials and sorting objectives. It can be a single sensor, or a combination of two or all three sensors
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Available Automatic Sorting Technologies – PET Flakes
Flake infeed
Multi-spectral NIR sensor CCD camera
Illumination unit
Metal detection coil Air blast ejection system Diverter shield Ejected impurity material Cleaned accept material
high precision
intelligent
custom made
Application Based Automatic Optical Sensor Sorting for the PET Recycling Industry
Available Automatic Sorting Technologies – PET Flakes
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Application Based Sorting Technologies
PET Recycling – from Bottles to Flakes
Long Fiber
Strapping Band PSF
Food Packaging
Bottle to Bottle
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Application Based Sorting Technologies
PET Recycling – from Bottles to Flakes
Long Fiber
Strapping Band PSF
Food Packaging
Bottle to Bottle
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Application Based Sorting Technologies
Incoming Material Composition
Mechanical & Washing Processes
Sensor Based Auto Sorting
The selection and configuration of the sorting systems depend on the incoming material and the output flake quality requirements
Output Material Quality
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Application Based Sorting Technologies – Example 1 Sample Input Material Type: Compacted Bottles Input: 2,000 kg/hr - PET Clear: 98% - PVC: 2% (20,000ppm)
Solution One unit of Varisort N 1920 (2 outlet chutes) with re-sort tracks
Sorting Objectives: To remove PVC to below 150ppm
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Application Based Sorting Technologies – Example 2 Sample Input Material Type: Compacted Bottles Input: 2,000 kg/hr - PET Clear: 98% - PVC: 2% (20,000ppm)
Solution One unit of Varisort N 1920 (2 outlet chutes) with re-sort tracks And one unit of Flake Purifier N 1024 (2 outlet chutes
Sorting Objectives: To remove PVC to below 25ppm
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Case Study – Reduction of Manual Sorting Possibility 1 – Sorting of non PET Plastics such as PVC Bottles Bottles ① ③ ⑤ ⑦ ⑨ ⑪ De-Bale
Manual Sorting Station
① ③ Pre-Washing
① ③ ⑤
Manual
Label
Manual
Sorting
Stripper
Sorting
① ③ Crusher
② ④ ⑥ ⑧ ⑩ ⑫
② ④
② ④ ⑥
12 workers per shift
4 workers per shift
6 workers per shift
Flakes
Flakes
Washing
Drying
Zig Zag Shifter
Manual Sorting
Flakes Packing
② ④ Flakes
4 workers per shift
Bottles ① ③ ⑤ De-Bale
Label
Vibratory
Sorter # 1
Sorter # 2
Manual
Stripper
Feeder
Varisort N 1536
Varisort N 1536
Sorting
① ③ Crusher
Flakes
Flakes
Washing
Drying
② ④ ⑥ 6 workers per shift
Zig Zag Shifter
Manual Sorting
Flakes Packing
② ④ Flakes
4 workers per shift
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Case Study – Reduction of Manual Sorting Possibility 1 – Sorting of non PET Plastics such as PVC Bottles Bottles ① ③ ⑤ ⑦ ⑨ ⑪ De-Bale
Manual Sorting Station
① ③ Pre-Washing
① ③ ⑤
Manual
Label
Manual
Sorting
Stripper
Sorting
① ③ Crusher
② ④ ⑥ ⑧ ⑩ ⑫
② ④
② ④ ⑥
12 workers per shift
4 workers per shift
6 workers per shift
Flakes
Flakes
Washing
Drying
Zig Zag Shifter
Manual Sorting
Flakes Packing
② ④ Flakes
4 workers per shift
Bottles ① ③ ⑤ De-Bale
Label
Vibratory
Sorter # 1
Sorter # 2
Manual
Stripper
Feeder
Varisort N 1536
Varisort N 1536
Sorting
① ③ Crusher
Flakes
Flakes
Washing
Drying
② ④ ⑥ 6 workers per shift
Zig Zag Shifter
Manual Sorting
Flakes Packing
② ④ Flakes
Saving of 48 workers / day
4 workers per shift
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Case Study – Reduction of Manual Sorting Possibility 2 – Sorting of non PET Plastics such as PVC and Coloured PET Bottles Bottles ① ③ ⑤ ⑦ ⑨ ⑪ De-Bale
Manual Sorting Station
① ③ Pre-Washing
① ③ ⑤
Manual
Label
Manual
Sorting
Stripper
Sorting
① ③ Crusher
② ④ ⑥ ⑧ ⑩ ⑫
② ④
② ④ ⑥
12 workers per shift
4 workers per shift
6 workers per shift
Flakes
Flakes
Washing
Drying
Zig Zag Shifter
Manual Sorting
Flakes Packing
② ④ Flakes
4 workers per shift
Bottles ① ③ De-Bale
Label
Vibratory
Sorter # 1
Sorter # 2
Manual
Stripper
Feeder
Varisort CN 1536
Varisort CN 1536
Sorting
① ③ Crusher
Flakes
Flakes
Washing
Drying
② ④ 4 workers per shift
Zig Zag Shifter
Manual Sorting
Flakes Packing
② ④ Flakes
4 workers per shift
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Case Study – Reduction of Manual Sorting Possibility 2 – Sorting of non PET Plastics such as PVC and Coloured PET Bottles Bottles ① ③ ⑤ ⑦ ⑨ ⑪ De-Bale
Manual Sorting Station
① ③ Pre-Washing
① ③ ⑤
Manual
Label
Manual
Sorting
Stripper
Sorting
① ③ Crusher
② ④ ⑥ ⑧ ⑩ ⑫
② ④
② ④ ⑥
12 workers per shift
4 workers per shift
6 workers per shift
Flakes
Flakes
Washing
Drying
Zig Zag Shifter
Manual Sorting
Flakes Packing
② ④ Flakes
4 workers per shift
Bottles ① ③ De-Bale
Label
Vibratory
Sorter # 1
Sorter # 2
Manual
Stripper
Feeder
Varisort CN 1536
Varisort CN 1536
Sorting
① ③ Crusher
Flakes
Flakes
Washing
Drying
② ④ 4 workers per shift
Zig Zag Shifter
Manual Sorting
Flakes Packing
② ④ Flakes
Saving of 54 workers / day
4 workers per shift
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Case Study – Reduction of Manual Sorting Possibility 3 – Sorting of non PET Plastics such as PVC and Coloured PET Bottles and Sorting of PET Flakes Bottles ① ③ ⑤ ⑦ ⑨ ⑪ De-Bale
Manual Sorting Station
① ③ Pre-Washing
① ③ ⑤
Manual
Label
Manual
Sorting
Stripper
Sorting
① ③ Crusher
② ④ ⑥ ⑧ ⑩ ⑫
② ④
② ④ ⑥
12 workers per shift
4 workers per shift
6 workers per shift
Flakes
Flakes
Washing
Drying
Zig Zag Shifter
Manual Sorting
Flakes Packing
② ④ Flakes
4 workers per shift
Bottles ① ③ De-Bale
Label
Vibratory
Sorter # 1
Sorter # 2
Manual
Stripper
Feeder
Varisort CN 1536
Varisort CN 1536
Sorting
Crusher
Flakes
Flakes
Washing
Drying
② ④ 4 workers per shift
Flakes
Zig Zag Shifter
Flake Purifier
Flakes Packing
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Case Study – Reduction of Manual Sorting Possibility 3 – Sorting of non PET Plastics such as PVC and Coloured PET Bottles and Sorting of PET Flakes Bottles ① ③ ⑤ ⑦ ⑨ ⑪ De-Bale
Manual Sorting Station
① ③ Pre-Washing
① ③ ⑤
Manual
Label
Manual
Sorting
Stripper
Sorting
① ③ Crusher
② ④ ⑥ ⑧ ⑩ ⑫
② ④
② ④ ⑥
12 workers per shift
4 workers per shift
6 workers per shift
Flakes
Flakes
Washing
Drying
Zig Zag Shifter
Manual Sorting
Flakes Packing
② ④ Flakes
4 workers per shift
Bottles ① ③ De-Bale
Label
Vibratory
Sorter # 1
Sorter # 2
Manual
Stripper
Feeder
Varisort CN 1536
Varisort CN 1536
Sorting
Crusher
Flakes
Flakes
Washing
Drying
② ④ 4 workers per shift
Flakes
Saving of 66 workers / day
Zig Zag Shifter
Flake Purifier
Flakes Packing
high precision
intelligent
custom made
8th China International Recycled Polyester Conference 13 ~ 14 September 2012
Sorting is NOT Magic
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Conclusion
Automatic Sorting is Magical but NOT Magic
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Conclusion It is possible to move from labour intensive manual sorting‌.
To highly efficient automatic sorting with - Improved quality - Increased processing output - Lower costs - Better efficiency
- Higher Profit Margin with Sustainability
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Conclusion – 3R’s
Rethink
• Future Rising Labour Costs • Approach to Sorting
Retool
• Technologies are available • Work with Partners
Recover
• Valuable Recyclables • Eroding Profits
high precision
intelligent
custom made
Optical Sensor Based Automatic Sorting for the Packaging Recycling Industry
Conclusion – 3R’s
Rest
• You DESERVE It!
Relax
• You DESERVE It!
Rejoice
• You DESERVE It!
high precision
intelligent
custom made
PRA‘s 2013 Green Packaging Conference 21 November 2013 – Jakarta, Indonesia
Thank You Very Much!
Contact: Mr. Dharmawan Putra - Indonesia +62-811-816-342 dharmawan.putra@sesotec.com.sg
Mr. Lee Chee Kiong – Asia Pacific +65-9088-3758 cheekiong.lee@sesotec.com.sg
www.sesotec.com & www.pet-recycling.com