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.

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.

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.

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.

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.

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