5955 W. 80th Street
Indianapolis, IN 46278
Phone: 317-872-5115

Turning Plastic Scrap
Into Usable PlasticTM - Case Studies

caseIn our 30+ year history, we've faced a lot of challenges that other recyclers have avoided. In doing so we've gained a wealth of knowledge and a level of experience that is second to none. Our willingness to develop creative solutions to the tough projects has allowed us to deliver excellent results. 

 

A picture is worth a thousand words, and maybe more. This is why we have developed several real world case studies to aid in understanding what we can do at Butler-MacDonald as well as the type of result you can expect when you chose to work with us.

Automotive Intake Manifolds Nylon (PA) Recovered - Metal Free/Gasket Free

Automotive Intake Manifolds Nylon (PA) Recovered - Metal Free/Gasket Free

Automotive intake manifolds made of 30% GF nylon were being sold by a Tier 1 supplier to another recycler as unusable plastic scrap because they had ferrous and non-ferrous (non-magnetic) metal inserts. Because they had been through the initial phases of manufacturing, they also had rubber gaskets attached to the housings. Sending the scrap parts to a landfill did not fit the enviromental profile for this Tier1 manufacturer. Export was considered but would have returned minimal value.

Coextruded PET Preforms Nylon Barrier Liberated - Both Plastics Recovered

Coextruded PET Preforms Nylon Barrier Liberated - Both Plastics Recovered

We were approached to find a way to separate Nylon from PET to recover PET. Bottle preforms can be coextruded with a Nylon barrier (above) sandwiched between two layers of PET.

Coextruded Window Profiles: Coextruded Parts

Coextruded Window Profiles: Coextruded Parts

A custom profile extrusion manufacturer generated scrap coextruded profiles on a monthly basis. The two polymers, rigid PVC (white) and flexible PVC (black), are not compatible in the melt stream.

Color Separation Sometimes It Doesn’t Work

Color Separation Sometimes It Doesn’t Work

A company called us in search of someone who had a color sorter thinking that a color sort was the answer to a problem they were having. A bulk truck receiving error had resulted in 110,000 pounds of PP being erroneously blown into the PVC silo - resulting in a major cross-contamination problem. With the material now commingled with an estimated 60% of the PP in the PVC, what they did not understand was that color separators do not give high yields when the contamination level is over 10% by volume.

Contaminated PET Pellets: PVC Commingled

Contaminated PET Pellets: PVC Commingled

A multinational custom compounder had four truck loads of black PVC pellets that had been contaminated with white PET pellets (pepper and salt). Had it all been PVC, they would color over the white with the black. But in this case, the white was PET.

Contaminated Resins: ABS & PP Raw Material Bargains

Contaminated Resins: ABS & PP Raw Material Bargains

A silo with natural ABS prime resin had been cross-contaminated and time was of the essence. The source needed to get the material removed from their silo immediately (via bulk truck) so that  replacement material could be received.

Contamination Not Seen Commingled PC, GPPS & PVC

Contamination Not Seen Commingled PC, GPPS & PVC

A compounder acquired what they believed to be clean, clear PC regrind contaminated with off-colored pieces. Thinking they could use the material as received, they blended the material so it could be used in production.


Unfortunately, after the company blended the material they found the material was contaminated with other resins (clear GPPS and clear PVC). None of the contaminants were visually apparent upon receipt.

EVA Lined Closures: Commingled Polymer Contaminant

EVA Lined Closures: Commingled Polymer Contaminant

A closure manufacturer was not able to reuse scrap closures because of the EVA lining that is adhered to the interior of the cap. In an effort to reuse some of the material, the manufacturer had a company grind and repelletize the EVA lined closures but found the residual EVA caused failure in the white application.

Floor Sweeps & Waste: A Usable Plastic Resource

Floor Sweeps & Waste: A Usable Plastic Resource

A customer had an opportunity to purchase 40,000 lbs. of natural HIPS pellets contaminated with rocks and dirt from a ground spill at a very low price “as is.”  This material also contained wire, metal, wood and several other commingled polymers that made it unusable.

Foil lined closures: Green Is In

Foil lined closures: Green Is In

A closure manufacturer was not able to reuse scrap closures because of the foil lining. They did not want to grind the scrap closures and introduce foil into the system. They tried other recyclers that do grinding, extrusion, melt filtering and pelletizing in the past, but the effort resulted in residual foil that plugged the gates in the mold. Moreover, the metal detector fired constantly. The manufacturer’s belief was that the foil lined closures could not be recycled to a purity acceptable to their quality standards.

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