Recycling Horticultural Films Handling and Marketing Lois Levitan

Recycling Horticultural Films: Handling and Marketing Lois Levitan Recycling Agricultural Plastics Program (RAPP) Dept Communication • Cornell University • Ithaca NY 14853 MID-ATLANTIC FRUIT & VEGETABLE CONVENTION, SMALL FRUITS – JANUARY 29, 2015

My Objectives • Convey that recycling horticultural film won’t all be smooth sailing, but is do-able • By end of talk, have a roomful of well informed recycling enthusiasts • ? w o n k u o y d i D LEVITAN, CORNELL UNIVERSITY 2

Topics • What is recycling? • Challenges to recycling horticultural plastics. • Overcoming the challenges. • Products made with recycled horticultural plastics. By whom? • What I hope to learn from growers. LEVITAN, CORNELL UNIVERSITY 3

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Plastics-to-Oil HEAT + PRESSSURE ( + catalyst) oil or wax + inorganic residue (e. g. , carbon black) PLASTICS RECYCLING CONFERENCE 2014 – LEVITAN, CORNELL UNIVERSITY 5

Waste-to-Energy ≠ RECYCLING ENERGY RECOVERY BY INCINERATION (COMBUSTION AT HIGH HEAT) Organic waste inorganic ash, flue gas + heat Graphic: SICK Sensor Intelligence. http: //www. sick. com/group/EN/home/solutions/industries/waste/Pages/waste. aspx United States: 67 large Municipal Solid Waste incinerators + several hundred industrial, medical and hazardous waste incinerators of all sizes (Source: Waste Incineration. Unites States Response to UNEP Questionnaire for Paragraph 29 Study, Enclosure 4 a, Rev. May 2010) LEVITAN, CORNELL UNIVERSITY 6

Fuel Pellets PLASTIC PELLETS or 10% PLASTIC + BIOMASS burns hotter, flows better LEVITAN, CORNELL UNIVERSITY 7

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Horticultural Plastics Many different film and rigid products. Many colors, multi-colored. Different resins, & mixes of resins, with additives. Mostly low density PE, but also HDPE, PP, PS. PVC used historically; some still used, particularly in imported products. Plant pots, flats, trays: PE, PP, PS Greenhouse & tunnel covers PP bulk bags Mulch film LEVITAN, CORNELL UNIVERSITY 9

Horticultural Plastics Challenges to recycling : s e i r o g e t 3 ca • characteristics inherent to these plastic products • characteristics of the products after use in fields & nurseries • cost and logistics of collection and transport from fields (or nurseries) to recycling markets Photo: Delta Planstics LEVITAN, CORNELL UNIVERSITY 10

Challenges to recycling: • characteristics inherent to complex, technical products Thin films with multiple extrusion layers, each with additives and colorants for specific agronomic or horticultural purposes: Block UV Repel insects Absorb or reflect heat EVOH O 2 barrier Hold moisture Reinforce structure Prevent backwash Stretchability Stickiness Tensile strength Flexibility Rigidity Longevity Degradability LEVITAN, CORNELL UNIVERSITY Jphn Deere Pro-Flat PVC drip tape John Deere Max-Flat PE irrigation drip tape 11

Plant pots, flats, seedling trays HDPE, PS, PP, blown, molded, thermo-formed Photo: Lois Levitan, RAPP LEVITAN, CORNELL UNIVERSITY

Maple syrup tubing Mostly LDPE tubing (some old PVC tubing) with fittings, connectors, and ball valves of nylon, polycarbonate, rubber Photoa: Lois Levitan, RAPP LEVITAN, CORNELL UNIVERSITY 13

Challenges to recycling: • characteristics of products after use (post-consumer) Photos: Lois Levitan, RAPP Used & stored outdoors, in mud, rain & snow Often with residues of soil, plant debris, moisture, stones & grit Possible or perceived pesticide residues & soil pathogens Bulky Photo: Lois Levitan, RAPP LEVITAN, CORNELL UNIVERSITY 14

Challenges to recycling: • characteristics of the products after use (post-consumer) Mulch film: strips of LDPE, typically ≤ 1 mil thick ( high surface: volume ratio). Lays on soil, gets very dirty. White, black, silver, occasionally clear or other colors. Sometimes 2+ color layers. Some with nylon or EVOH O 2 barrier layer. Baled mulch film Photo: Sky Plastics Photo: Lois Levitan, RAPP Delta Plastics (L)LDPE irrigation polytube, Photo: Delta Plastics LEVITAN, CORNELL UNIVERSITY 15

Pesticide containers, chemical drums. HDPE. Example of Extended Producer Responsibility (EPR): Ag Container Recycling Council (ACRC) financed by pesticide manufacturers and distributors. ACRC protocols require triple rinsing, special handling & approved end-uses that minimize exposure. ACRC oversees a national network of collectors, processors, end-product manufacturers. 10 million lb collected 2014; 150 million lb since began in early 1990 s. Photo: Lois Levitan, RAPP Photo: Nate Leonard, RAPP LEVITAN, CORNELL UNIVERSITY

New technologies & advances in processing equipment creating new recycling options Horticultural Mulch Film: Before & After Washing BEFORE WASHING 1 MINUTE LATER Photo: Lois Levitan, RAPP Paul Vanderpool: “Recyclers have learned how to recycle better” LEVITAN, CORNELL UNIVERSITY 18

F. Paul Vanderpool American Cierra Corporation 491 Grant Ave. Auburn, NY 13021 office 315 -252 -6630. m 315 -7306156 email: paul@cierrainc. net “Recyclers have learned how to recycle better” www. americancierraequipment. com Photo: Lois Levitan, RAPP

Mobile cleaning, baling, grinding equipment Photo: Romall Ind • Mobile film reclamation system • Cleans film ON-SITE, allowing flexibility in scheduling • Bales film for shipment ON-SITE • Self-contained, small footprint • Meets all California power plant restrictions • Cleans film with proprietary non– water processes • High volume capacity LEVITAN, CORNELL UNIVERSITY Contact: Lloyd Gleaves, CEO 209 495 -1282, <lloyd@romallindustries. com>

Best Management Practices (BMPs) • Keep plastic clean and dry as possible • Shake out pebbles & clumps of soil • Roll or fold into pillow-sized bundles • Store off ground, out of mud, grit, gravel • Separate plastic by color and type Photo: Jim Zecca. Madison Co What not to do! LEVITAN, CORNELL UNIVERSITY 21

Greenhouse, hoophouse, high tunnel covers Clear or white sheets of (L)LDPE. Excellent quality for recycling. Challenge: Keep clean & remove efficiently, meeting needs of growers & recyclers Photo: Lois Levitan, RAPP LEVITAN, CORNELL UNIVERSITY

Without prep for baling: 1. 2. 4. 3. Photo: Jim Zecca. Madison Co LEVITAN, CORNELL UNIVERSITY 4 hrs to finish bale, vs. ½ hr with plastic prepped in stacked bundles 23

Efficient compaction: LEVITAN, CORNELL UNIVERSITY 24

Challenges to recycling: • Cost & logistics of collection and transport from fields or nurseries, etc. to recycling markets • In most of the U. S. , agricultural plastics are dispersed acrosss the rural landscape high costs of collection Difficult to amass full 40, 000 lb truckloads LEVITAN, CORNELL UNIVERSITY 25

Why should society & recyclers care about this particular set of plastics? • Less than 2% of plastic discarded in US, but possibly 10% of film* lm fi Agr • Very visible 2 -10% • When left in the fields catches in bushes, ditches, ravines • Alternatives to recycling not pretty: burning, burying in fields bad for air & water quality • Landfilling costly to society *based on VT data calculated by Annie Macmillan, VT Agency of Agriculture. LEVITAN, CORNELL UNIVERSITY • Societal value of recycling >> economic value: All society benefits from conservation of resources & energy. 26

Agricultural Plastic Recycling Markets: Processors (Reclaimers) & Manufacturers • Domestic markets can & do process used horticultural plastic. • Location. More options, less costly to recycle where farms (& plastic use) are concentrated: FL, CA. • Smaller, regional recycling markets important for co-mingled supply from less concentrated areas. • Some recycling markets vertically integrate to guarantee supply & increase efficiency. • Some pick up & some require drop-off. • Only a few pay for material. • Some take-back products after use & give credit on purchases. Recycling markets typically put < value on difficult-to-recycle plastic than it costs to collect & transport. LEVITAN, CORNELL UNIVERSITY 27

http: //www. deltaplastics. com/ LEVITAN, CORNELL UNIVERSITY 28

Capacity to recycle 200 million lb/yr, with potential to double. Only (L)LDPE recycling@deltaplastics. com 800. 277. 9172 LEVITAN, CORNELL UNIVERSITY 29

• Recycling arm of Command Packaging. • Opened late 2013 • 100 million lb/yr capacity (CA uses 150 mm lb/), • Convert mulch film to 125 x reusable smarterbags™. http: //encore-recycling. com/ • $3 million CA grant Nov’ 14. LEVITAN, CORNELL UNIVERSITY 30

http: //www. flagplastics. com/ Opened 2014. Collect mulch film & drip tape from large Florida farms. Shred, clean, dry film. Sell to pelletizers worldwide. 40 million lb/yr at current site. LEVITAN, CORNELL UNIVERSITY 31

http: //www. netafimrecycling. com/ California collection area only. Pay based on dry weight polyethylene tubing, 8¢/lb towards new orders, 4¢/lb cash. LEVITAN, CORNELL UNIVERSITY 32

http: //www. bridoncordage. com/forage/revolver. htm l bridon cordage LEVITAN, CORNELL UNIVERSITY 33

The Blackmore Company http: //www. blackmoreco. com/ Call (800) 874 -8660 about recycling polystyrene trays. LEVITAN, CORNELL UNIVERSITY 34

http: //www. eastjordanplastics. com/recycling-program Manufacture & recycle plant containers: HDPE, PP, PS. 10 million lb/yr recycling capacity LEVITAN, CORNELL UNIVERSITY 35

NBF Plastics: plywood substitute, PIMS technology, anticipate 1 -2 million lbs/yr TERRECON Top skin: black & white silage bag film n drip tape Core: Irrigatio Top skin: blue boat wrap Top skin: maple tubing & fittings TERREWALKS® sidewalk pavers from agricultural bale wrap, thermokinetic processing info@terrecon. com Dishashish Plastic Manufacturers LLC: garbage bags, ~ 20% recycled b/w silage bags (1 million lb/yr). ashish@dishallc. us LEVITAN, CORNELL UNIVERSITY 36

QUESTIONS from YOUR EXPERIENCE: • Efficient methods/equipment that minimize dirt/debris in removing cover plastic & mulch? • Rollers, balers or other equipment that compact plastics tightly for transport? Please t contac me ! Lois Levitan, Ph. D Recycling Agricultural Plastics Program Dept Communication, Cornell University Ithaca NY 14853 lcl 3@cornell. edu 607 -592 -0356 Photo: Lois Levitan, RAPP LEVITAN, CORNELL UNIVERSITY