QUESTION 1

A significant global concern in plastics is recyclability and disposability. Give examples

and explain briefly on the process involves. Write a report to discuss on the issues.

The world's annual consumption of plastic materials has increased from around 5

million tonnes in the 1950s to nearly 100 million tonnes today. Packaging represents the

largest single sector of plastics use in Malaysia. Plastic is the material of choice in nearly half

of all packaged goods. Plastics do not degrade naturally and when they are disposed in an ad

hoc manner, it creates numerous environmental problems that can deteriorate the life of flora

and fauna. There are about 50 different groups of plastics, with hundreds of different

varieties. All types of plastic are recyclable.

Recycling of plastics will definitely reduce the waste material at waste disposal while

reducing the piling up of plastic virgin material on the earth. At the same time it will reduce

the energy and water consumption and emission of toxic gases and chemicals in the virgin

material production process. When all these factors are taken into account the overall impact

of waste plastic recycling would be very high. In plastic recycling, the end product can be

replaced for virgin material and will generate the above mentioned environ-economic

benefits. Plastic recycling can be done in two ways namely,

i. Mechanical recycling and

ii. Chemical or feedstock recycling.

This report will be covered only on mechanical recycling. Mechanical recycling of

plastics refers to processes which involve the melting, shredding or granulation of waste

plastics. Plastics must be sorted prior to mechanical recycling. At the moment, most sorting

for mechanical recycling is done by trained staffs who manually sort the plastics into polymer

type and colour. Technology is being introduced to sort plastics automatically, using various

techniques such as X-ray fluorescence, infrared and near infrared spectroscopy, electrostatics
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and flotation. Following sorting, the plastic is either melted down directly and moulded into a

new shape, or melted down after being shredded into flakes and then processed into granules

called regranulate. The steps in mechanical waste plastic recycling are shown in the figure 1

that given below.

Reintroductio
Reintroductio
Collection
Collection Sorting
Sorting Grinding
Grinding Washing
Washing Drying
Drying Pelleticizing
Pelleticizing nn into
into
Manufacturing
Manufacturing

Figure 1 : Mechanical Recycling of Plastic Process Flow

Plastic bottles and containers are collected with other items made of glass and paper.

Corporations that use plastic in their normal operations set aside plastic items for recycling

like ink cartridges, plastic buckets, and packaging peanuts, to name a few. Mass collection

processes happen every day all over the world as people become more aware of the

importance of recycling, especially a non-biodegradable substance like plastic. Put

recyclables into the suitable colour-coded recycling bins. These bins like in figure 2 can be

found in public places, schools and some government buildings. Recycle bins are available to

accommodate waste in the small to medium amount. Waste in big volume need to be sent to

recycling centre.

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 Figure 2 : Recycle bins and recycling centre
Currently plastics must be sorted into seven different groups (figure 3) before they

can be recycled as they are not the same substance, even though they are all called plastics. If

they were melted together, they would not blend as they are made of different substances.

Each plastic item should have a number on it to identify it for sorting.

Figure 3 : Recycling code and acronym

Once the plastics are sorted, they get ground or shredded by large machines (figure

4). This process is difficult as the plastic is not easily cut and is actually an abrasive to the

cutting blades. They are often dulled quickly and have to be changed several times in a day.

Figure 4 : Shredding Machine

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 The plastic shreds have to go through a washing process (figure 5) that can become

quite complicated as there are contaminates like glue from labels and dirt and grease from

food that can change the end product if it is not removed. Special detergents and rinses are

used to prepare the plastics for the next step.

Figure 5 : Plastic Washing Recycling Line

Special machines (figure 6) are designed to dry plastic shreds before they are

pelletized. Most use centrifugal spin cycles to manually lower the moisture content. Care is

taken not to let stored shreds collect humidity by keeping the storage area very dry.

Figure 6 : Recycling Plastic Drying Machine

Each of the different kinds of plastic shreds is treated a little differently and some are

almost impossible to recycle in pelleticizing process. The ones that have gone through the

shredding process are then fed into machines that use pressure and heat to compress the

plastics into a solid that is then extruded into pellets.

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 Figure 7 : Pelleticizing Machine

Lastly, the pellets are then sold on the market to manufacturers who use them for a

growing number of applications. The number 1 is made into fibres and carpets; number 2 is

formed into floor tiles, outdoor lumber, and laundry bottles; number 3 go into mats and

flooring while number 4 can't be used in this process. Customers can buy the pellets by the

truckload, thereby bypassing the need to use oil to make the raw materials.

Plastic recycling is a newly emerging industry and it has already been identified that

there is a good potential to this sector. The recycled plastics can be shared with both small and

large scale industries to produce new plastic items. Further, recycled plastics can replace pure

material being imported from other countries and this will create many job opportunities

among the people. Recycling of plastics therefore, is a resource that one could obtain

maximum benefit out of it and helps minimize environmental degradation. Therefore, plastic

material should not be disposed or buried without a proper disposal mechanism.