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Implementing a MRF project:

some helpful hints

by Jerry PowellResource Recycling

A variety of experts offerrecommendations on

designing and operating

the next generation of

materials recovery

facilities.

A now familiar recycling concept - thematerials recovery facility - is undergo-ing substantial refinement. Already manydevelopers are talking about second-and third-generation materials recoveryfacilities (MRFs).

These new facilities, which processcommingled recyclables collected fromresidents, were the topic of a major sym-

posium recently sponsored by the Uni-versity of Wisconsin Department of En-gineering Professional Development.The panelists at this seminar had manypithy prognostications to offer about howthese New Age MRFs will operate.

Also in this issue, we offer a directoryof MRF operators and equipment ven-dors.

Some numbersBefore we summarize the experience ofMRF development in recent years, wewill review current data on MRF opera-tions, which reveal many interesting

findings.Resource Recycling maintains adatabase on over 70 commingled recy-clables sorting plants. These facilities,located- in 20 states and one Canadianprovince, are either operating or underconstruction. Nine of the plants areowned and operated by the sponsoringgovernment, while the others are oper-ated by 26 different private firms.

From these data, we can summarizeMRF implementation trends in the fol-lowing manner:

Facility cost. A typical MRF is builtand equipped at a cost of approximately

$22,100 per ton of daily processing ca-pacity, with capacity being figured on atwo-shift-per-day basis. Smaller MRFs- under 100 tons per day of capacity -cost more than $30,000 per ton. MRFsare also becoming more expensive; thedata indicate that the average per-toncost to bring a MRF on-line is rising.

Facility size. Although the typicalMRF requires about 177 square feet of

covered space per ton of daily process-ing capacity (two-shift basis), the spacerequirement varies among differenttypes of MRFs. Those facilities designedto process less than 100 tons per day ofcommingled recyclables require about320 square feet per ton of daily capacity(or about 10,000 to 20,000 square feetin total). The big MRFs - with

throughputs over 200 tons per day - re-quire only 153 square feet per ton ofdaily capacity (or 30,000 to 50,000square feet).

Staffing needs. On average, the per-worker productivity at a MRF is 6.8 tonsper day. The small facilities of under 100tons per day have low productivity (3.3tons per worker day), compared to thelarge plants of over 200 tons per daywith productivity of 10.2 tons per workerday.

Much of the differences noted for facil-ity cost and staffing are explained by thelevel of mechanical sorting in a particu-

lar MRF. The smaller MRFs tend to relymore on manual sorting techniques,which require more space and havelower productivity. The larger MRFs aremore mechanized, requiring less spaceand thus less capitalization per ton ofcapacity and resulting in greater produc-tivity.

Location. MRFs are predominantly anEast Coast phenomenon. Nearly half theoperating or planned MRFs are in theNortheast; many new facilities are com-ing on-line in the Southeast. Relativelyfew commingled recyclables sortingplants are or will be located in the West.

The mini- and mega-MRF. The dataindicate that few medium-sized MRFs(100 to 200 tons per day of capacity) areunder construction. The market seemsto be heading in two directions, with sev-eral large cities or counties buildingmega-MRFs (over 200 tons per day ofcapacity) and numerous smaller com-munities constructing small facilities(under 100 tons per day capacity).

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With aluminum cans representirig 25 per-cent of aluminum sheet shipments, usedcans dominate the available scrap supply.

process is expected to improve therecovery of metal from dross withoutthe need for environmentally trouble-some fluxes. It is also speculated thatthis process can be extended into themelting of UBC and other scrap. Ifthis proves to be the case, this proc-ess then has the potential to circum-vent the delacquering process andimprove metal recovery.Utilize a variable ratio air/oxygen/fuelburner system to increase the meltrate of well-type melters used for themelting of delacquered UBC shreds.

RR

For more information, contact Harry Phipps at(919) 597-2370, or fax (919) 597-8633.

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The big operators get bigger. With Build it and they will come. Hal Consider both volume and weight.e typical MRF being bid, built and McGaughey of CRlnc., one of the lead- Kevin Murray is a top consultant with

sted in less than 18 months at a cost ing MRF system vendors, notes that Camp Dresser & McKee. He feels a

xceeding $4 million, small private firms new MRFs tend to hit design capacity clear understanding of the volume ofnd it difficult to compete against bigger very soon after opening. Citizens will materials is needed when designing a

RF operators. At present, six firms op- participate, he concludes. MRFs tipping floor and storage area.

rate nearly half of the nations MRFs.hese firms are Browning-Ferris Indus-es, CRlnc., Laidlaw Waste Systems,esource Recovery Systems, Resourceecycling Technologies and Wasteanagement. Of these, only RRS has

rivately held stock.Governmental Advisory Associates

as collected more extensive data onRFs and waste sorting plants. Thisew York City firm recently issued its

econd guidebook (see the Informationources department in this issue). Weill be presenting additional MRF datand findings from this report in our Maysue.

ome rules of thumb

nough MRFs have now been built orre under construction that some gen-ral rules can be identified. The expertsffer this advice.

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McGaughey concurs: The lack of a suf- Focus on container lines. Murray ences in the container mix among com-ficiently sized tip floor is the biggest believes paper sorting lines will remain munities.problem Ive seen [in this industry], he fairly typical, while the design of sorting Store thy processed materials. Withsays. Murray recommends at least two lines for commingled containers will vary tighter markets and weaker prices for re-days storage capacity on the tip floor. more from MRF to MRF, due to differ- cyclables in recent years, some experts

Strong views of the futureA number of the analysts offer addi- ture MRFs as a way to reduce labor At the same time, the relationshiptional comments about the future de- requirements. between equipment manufacturer and

velopment and operation of MRFs. Lack of uniformity. Rather than buyer is changing. CalRecoverysHere is a sample. moving toward a similarity of facilities, Savage contends that performanceAutomatic glass sorting. Auto- the MRF industry of the mid-90s will guarantees will become more com-

mated glass sorting [by color] is just incorporate numerous different tech- mon for MRF equipment purchases.too slow, says Hal McGaughey of nologies and ideas, s ay s M c- Interest by OSHA in MRF opera-CRfnc. Such a system wont be intro- Gaughey. This isnt a cookie cutter tions. Wayne Pferdehirt of the Uni-duced in the U.S. at least until 1993, concept, he says. versity of Wisconsin sees the federalhe predicts. New equipment and equipment Occupational Safety and Health Ad-

Shipping of processed materials. standards. With the MRF industry ministration becoming more in-Kevin Murray of Camp Dresser & growing, equipment needs and stan- terested in MRF operations. Accord-McKee sees more MRF operators sit- dards are changing. For instance, ing to Pferdehirt, the types of con-ing facilities along railroad lines to several speakers at the symposium terns will focus on worker access totake advantage of improved rail ship- noted that reliable plastic bag open- sorting platforms, the length of timeping services and rates. ing equipment is needed if bagged re- an employee is required to sort mate-

Use of air systems. George Sav- cyclables collection is to become rials and the use of lock-outs or tie-

age of CalRecovery, Inc., the consuit- more common. CRlnc.s McGaughey downs on processing equipment.ing firm, contends that you will see says, We havent found. a good bagmore air classification systems in fu- opener yet.

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ecommend having additional storageapacity for processed materials. Murrayeels up to 30 days capacity for proc-ssed recyclables is required. Mc-

Gaughey recommends consideringpare trailers to store processed mate-als, particularly if a MRF has little us-ble storage space and off-site trailerpotting is available, although he doesote that MRFs arent really large

nough to be able to play the com-modities game.Add those docks. McGaughey feels

you can never have enough loadingocks.Flip thy paper. The experts all agree

hat newspaper conveyor lines mustmechanically flip over the paper so sort-rs can remove more contaminants.Carefully consider the role of the

mechanic. Murray suggests that highlymechanized MRF systems require theperator to carefully select and trains mechanics and equipment repairersonnel.

Several predictions regarding MRFends are offered as a sidebar.

he realities of ownershipeveral analysts now view MRF owner-hip more as a political question than anconomic issue. CDMs Murray con-

ends that the primary reason a localovernment may desire public owner-hip of a MRF is one of control. Ronundberg, a financial consultant with

R.W. Beck and Associates, concurs.The MRF ownership issue is typicallyot an economic decision, he notes.

afety, safety, safetyhe top analysts are uniform in their

hinking about one issue, and they singom the same choir book. Murray ofDM: Pay attention to the worker safety

ssue. McGaughey of CRlnc.: Workerafety and comfort is becoming much

more an issue.Pam Harris, the director of loss control

ervices for Browning-Ferris Industries,as carefully assessed the workplace is-ues of MRF operations. From her per-pective, attention to workplace con-erns is not motivated by a desire to

void federal Occupational Safety andealth Administration citations, but it isbout productivity and morale, she con-udes. The concern for injury and acci-ent prevention can generate improved

morale, which is important when consid-ring the cost of replacing trained, ex-erienced workers.She separates these workplace issuesto four categories:

INTRODUCING

Whats all the Plus about?

Circle 22 on RR service card

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Safety. Safety hazards can occur inany areas of a MRF, including those

ssociated with work surfaces, walkingurfaces, equipment and overhead haz-rds, and potential injuries created byoor lighting, excessive noise and ex-eme temperatures.Harris feels the key safety concern isat there are always problems withutting people in the air. BFls experi- I

and to watch for cumulative trauma.Such advice has been heeded by manyMRF operators. For instance, CRlncsstandard sorting rate is 30 pieces perminute, but the firm tries to rotate work-ers every two hours.

Harris offers a number of safety hints,which are listed in a sidebar. RR

A materials recovery facility in OrangeCounty, Orlando, Florida shows materialsbeing conveyed from the tipping floor toan above-ground sorting platform (1). Con-veyors in a materials recovery facility inDenmark move materials in much thesame way (2).

nce is to carefully design the overhead

alkways used by sorting personnel.Health. The five key sources of health

roblems among MRF workers are va-ors; fumes; exposure to liquids; the ef-ct of dusts, such as from metals,ood, paper, glass, dyes and pigments,nd dirt; and from biological sources, in-uding bacterial, viral, endotoxin, pollen,sect, fungal, mildew, mold, spore and

nimal sources.Hazardous waste. Harris sees aowing problem with the receipt atRFs of small amounts of hazardousaterials from residents and small

uantity commercial generators.Ergonomic and biomechanical.any MRF vendors are becoming morecused on the effect of sorting tasks one muscular and skeletal system. Har-s research shows that the most com-on injuries are ergonomic in natured involve shoulders, back and knees.particular, she urges the elimination of

ctivities that require twisting motions