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.

Rejection Does Not Mean Sell Cheap Or Export

Rejection Does Not Mean Sell Cheap Or Export

A company that sells TPO needed a solution to fix 80,000 lbs. of mixed-color material that was rejected by their customer due to the presence of both nylon and TPU (urethane) contamination. Facing a significant loss in material value, the company was looking for options other than trashing the material or selling “as is” for export.

Silo Contamination: Polymers Get Recovered

Silo Contamination: Polymers Get Recovered

50,000 lbs. of natural ABS virgin pellets had been contaminated with PVC pellets (square) and a trace amount of yellow concentrate and black resin - a result of silo cross-contamination. The material required immediate removal from the silo in order for the customer to get a replacement load of ABS pellets and maintain production.

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.

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.

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.

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.

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.

Security Devices Source of Raw Materials

Security Devices Source of Raw Materials

Security devices cannot be reused and require secured destruction. A North American department store chain needed a solution for handling millions of clothing security devices without having to send them to a landfill and that would allow them to recoup some value for them.

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.

Metal In Parts & Assemblies: Plastic Can Be Recovered

Metal In Parts & Assemblies: Plastic Can Be Recovered

Inherent in the process of manufacturing parts is the need to include metal. The metal can be of various forms, weight and thickness. It’s required to make the part function. Most recycling efforts call for the use of manual labor to remove the metal part or assembly prior to grinding. The problem is valuable plastic is lost.

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.