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.

Cap and Closure Scrap: Polymer Recovery Achieved

Cap and Closure Scrap: Polymer Recovery Achieved

One of the world’s leading manufacturers of PP caps and closures was generating scrap at their manufacturing facilities. This material was generated as whole closures (i.e. caps) or could be ground for destruction and freight savings purposes at their facility. In both cases the material was not suitable for use in the manufacturing of new caps and closures because of the paper/foil cap liners.

Consumer Returns - Polymer Recovered

Consumer Returns - Polymer Recovered

A multi-national producer of toner cartridges needed a solution to the growing problem of consumer returns and the rising costs of HIPS resin. The returned material contains ABS, HIPS, Acetal (plus several other polymers), urethane and silicone rubber, foam and both ferrous and non-ferrous metal.

e-Waste Solutions

e-Waste Solutions

Literally - for years - recovering an ongoing and sustainable plastic value derived from end-of-life dismantled electronics has been questionable at best. Almost always, export becomes the outlet - and that is not always available and only at minimal value.

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.

Ground Spill Scrap: Usable Plastic Recovered

Ground Spill Scrap: Usable Plastic Recovered

54,000 lbs. of dark gray/black ABS virgin pellets had been contaminated with wood, cardboard, dirt and rocks from a ground spill.

Irrigation Dripline Scrap: PE Polymer Recovered - Silicone Removed

Irrigation Dripline Scrap: PE Polymer Recovered - Silicone Removed

Major manufacturers of irrigation products and services wanted an alternative to sending their otherwise unusable production scrap to a landfill. Irrigation dripline scrap cannot be reused “as is” because of imbedded thermoset silicone emitters and incompatible polymers. In addition to landfill avoidance, our customers also wanted to recover the valuable PE from their dripline scrap and use it for manufacturing new irrigation tubing.

Label Scrap (L-Scrap): Paper Is Out – Plastic Is In

Label Scrap (L-Scrap): Paper Is Out – Plastic Is In

A PET bottle manufacturer generates defect bottles with adhered labels. The labels cannot go back into the melt stream.

Metal Detector Rejects

Metal Detector Rejects

A few of our customers specialize in recycling PVC window and siding. To remove metal generated during granulation, they rely upon a metal detector and a magnet. While magnets can remove the ferrous metal (attracted to a magnetic), a metal detector was used to detect and remove the non-ferrous metal. Due to the way metal detectors function, unfortunately they reject several hundred times more plastic materials along with the metal every time they detect the presence of metal.

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