How

Flake sorting is the answer.
MDS is our trick.
Very pure plastics is the outcome.

Disruptive approach

Less than 10% of all plastics ever produced are recycled. Common recycling technologies fall short to have an answer to the plastic challenge. A disruptive approach is necessary to untangle the ever-growing plastic waste pile. 
 
Almost half of all plastics are used for packaging. Household waste is a rich plastic source, but different types of plastic are mixed. Umincorp has developed a unique process of turning plastic packaging waste into a high-quality resource. 
 

Object sorting versus flake sorting

Most recycling processes sort object by object, so shampoo bottles in one box and buttercups in another. But a simple bottle is not that simple: the lid is often from another plastic than the bottle and the wrapping is from another plastic-type again. So using object sorting makes it hard to reach pure end- products. Common recyclers therefore constantly balance between high losses for higher purity versus lower losses but lower purity.  
 
On the other hand, Umincorp’s process is based on flake sorting. In an early stage of the process, we cut all incoming plastics into small pieces (flakes).  Each flake consists of one type of plastic. The MDS enables an accurate separation of the flakes per type of plastic. This enables a high recovery and high purity.
 




Reducing CO2 emission by 80%!

MDS principle

The Magnetic Density Separation (MDS) application, with a capacity of
10.000t/yr, makes use of specially designed magnets in combination with
a unique water-based 
process fluid to separate heterogeneous input flows
on density levels of each individual particle in one step. The magneto-
responsive fluid, also produced in-house, together with the permanent
magnet creates the required density gradient so that there are different
densities at different heights in the machine.

Particles flow through the density field, with light particles floating on the
surface while heavier particles are suspended in the liquid below at different
depths according to their density. The separation for the production of pure
material fractions of equal densities are combined into one process by setting
splitters in the right positions.     
  

The use of MDS in the plastics industry results in high purity PP, HDPE, PS,
PET, ABS, PVC, or other plastics fractions that can be used directly in new
high-quality end products. We have the unique expertise to improve material
recovery at higher product purity while reducing the cost compared
to current alternatives.



MDS lowers the costs of the plastic recycling chain

Umincorp plant

Using the MDS, the whole plastic chain can be made more efficient. An Umincorp plant receives plastic waste in object form directly from waste processors and municipalities. We use the Magnetic Density Separation technique to process this waste, but in addition, we are realizing shredding, washing, and cutting processes before the materials enter the MDS installation. This enables savings on both transportation costs and CO2 emissions. The dropout rate - the percentage of plastic waste that is still unsuitable for reuse after processing - is also considerably lower than the 40 percent in conventional recycling processes.

The total chain of plastics can be up to 75% more cost-effective than current methods of recycling. The end product is of such quality and purity that it can be used as an alternative to virgin (new) plastic.


Our benefits are challenging the current plastic chain

Benefits

               

    99% Product purity                          90% Plastic recovery

     

                                           

   75% Cost reduction                                    90% Reduction of CO2

Our end fractions can be used directly in new products

New developments


Umincorp’s research and development program enables us to continuously improve our ability to convert complex material mixtures into high-grade products. We are currently developing, in the field of packaging waste recycling, a high-frequency color sorter for small polymer flakes. In the future, this will enable us to provide high product grades in terms of polymer type (e.g. PE) and to deliver on specific color requirements.


The business card holders/dispensers below are directly produced from color-sorted Umincorp PP flakes, without any additions or compounding. An example clearly showing the potential of low-cost, high-grade color sorting at flake level.



Contact us for more information