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Step-by-step through the Casepak MRF #7

Our MRF includes a dedicated and state-of-the art baling press to ensure we present material to reprocessors in the most efficient way possible. Finally, our processing facility includes the most modern and advanced Human/Machine interfaces, ensuring that we have a continuous supply of management information to remain flexible, efficient and are constantly striving to do better.

Step-by-step through the Casepak MRF #6

Any remaining material at this stage of the process will be non-target material and will be conveyed to dedicated residue compactors. The residue line has a dedicated sampling position to ensure we are tracking the MRFs residual waste performance on a continuous basis. Our ambition is to operate at zero waste by maximising material recovery and disposing of residual waste material into energy routes.

Step-by-step through the Casepak MRF #5

The plastics and cans travel on to the Container Sorting section of the system. A further Pre-Sort Cabin ensures that we can remove any remaining residual waste materials and extract additional plastic film. From here material is intensively recovered using automated technology as follows: An overband electro-magnet recovers ferrous (steel) tins and cans An Eddy Current Separator recovers aluminium cans, foil and aerosols An optical sorter recovers clear and light blue PET bottles and trays An optical sorter recovers clear and natural HDPE bottles An optical sorter recovers all other mixed plastics (#1 to #7) Each recovered Container material stream passes through a final quality inspection area to ensure material meets the highest product quality standards. From here material is pneumatically transported into vertical storage bunkers to await baling.

Step-by-step through the Casepak MRF #4

Material falling through the NewSorter Screens is conveyed to our Polishing Screen. The Polishing Screen does the final separation of the remaining mixed papers from three dimensional plastics and cans. The mixed paper from the Polishing Screen joins up with the material from the De-inking Screen and is conveyed to the Quality Inspection Cabin where a combination of manual inspection and optical sorting technology removes and recovers any non-target materials.

Step-by-step through the Casepak MRF #3

From the Pre-Sort Cabin, material flows on to our OCC Screen. Here, rigid cardboard floats over the screen and after final quality checking is conveyed directly to a dedicated storage bunker ready for baling. The first section of the OCC Screen is fitted with hardened metal discs, which assist with breaking of glass bottles and jars and ensure that glass is removed from the mixed material at the earliest possible opportunity. The OCC screen discs are sized to separate material into two different size fractions: 0-100mm 100mm+ The 0-100mm material falls through the OCC Screen onto a Debris Roll Screen (DRS). This DRS is sized to separate material of less than 50mm (principally glass and shredded paper) and once extracted this material is transported to our Glass Clean Up System where the lighter non-glass material is removed and recovered, using magnets and aspiration. The glass produced is transported directly to storage bunkers for collection by reprocessors. The 50-100mm material, which...Read More >

Step-by-step through the Casepak MRF #2

The material from the Metering Bin is conveyed to our Pre-Sort Cabin where fully trained quality inspectors remove any oversized general waste materials and recover target materials such as plastic film.

Step-by-step through the Casepak MRF #1

The first step in maximising recovery through technology is to present the material to the system properly. This is done via our Metering Bin, which ensures a smooth and even flow of material onto the system. The Metering Bin drum is fitted with carbide teeth, ensuring that any bags of material are ripped and opened.

The Casepak MRF Process

Casepak produces the highest quality and quantity of recoverable materials with minimum manual intervention. To achieve this, our highly automated, flexible and efficient Materials Recycling Facility system operates to high benchmark levels and lowest cost per tonne. To meet this, we focus on: Understanding material streams and compositions and how to adapt for them Maximising the recovery and purity of all materials Ensuring high levels of plant reliability and availability Attention and consideration for the highest levels of Health & Safety Our carefully designed and constructed MRF ensures maximum functionality to produce high quality results on a continuous and on-going basis. To illustrate, we would like to take you on a journey through our MRF recycling process to describe how mixed recyclable materials are separated into their individual streams to recover their value.

Account management

Customer service is at the heart of Casepak’s recycling services. All clients have a dedicated account support team led by an account manager who ensures that the recycling service is responsive, timely, professional and personable. At Casepak we understand that waste management and recycling services need to adapt to changing timetables and circumstances. When you’ve got an extra load of recyclable materials to process or need additional storage space, your Casepak account manager will provide a solution.


We rigorously analyse and report on all materials processed at the MRF. Our reporting system exceeds the MRF Code of Practice requirements and includes the monthly analysis of client input materials and the resulting outputs. These reports form the basis of our partnership approach to continuous recycling improvement. Reports are prepared in a standard, easy to read format and can be amended to meet customer requirements. They are available in print and digital formats.

Material destinations

Recyclable material is an extremely valuable resource and a competitive marketplace operates worldwide, with different sectors sourcing and purchasing material for a range of reprocessing options. This results in some materials being exported. The UK has limited capacity for recycling, hence the need to export. However, where possible, Casepak will send materials for recycling within the UK. Should material be exported for recycling, this is in line with the requirements set out by the Waste Shipment Regulation and auditing process of the Environment Agency (EA). Casepak is fully compliant with all legislation and ensures there is a clear audit trail which is used by the EA to provide evidence that material is exported to appropriately licensed facilities, and that agreed material quality standards are met. The EA also carries out random checks at the docks before containers of materials are exported. This is a strict audit trail which allows the EA to track containers at the dock back to the...Read More >

Recycling process

Our process maximises the value of your materials while securing sustainable, fully traceable outlets. To do this, we ensure that our material outputs always conform to reprocessor quality standards, are traded in accordance with all necessary regulations, and prioritise circular solutions over other forms of recycling. We understand the fluctuating market dynamics and foster close partnerships with both suppliers and buyers of resources. This ensures that your material is always used in the optimum way. Wherever possible, we support home markets while ensuring that the price and value is competitive. Click here to read about our process in detail.

Managing your materials

Through our recycling and waste management programmes, we’ll help you to develop recycling collection methods and change behaviour to ensure that your recyclable materials meet reprocessor quality standards. We’ll work with you to avoid contamination and make recommendations on storage. Education is key and this is paramount in all Casepak’s partnerships. The MRF has large pre and post-treatment storage areas. This gives you additional flexibility to manage fluctuating amounts of recyclable materials from kerbside collections. Working together, we’ll minimise waste, optimise collections, and maximise the value of your recyclable materials.

Recyclable materials

The Casepak Materials Recycling Facility processes the following recyclable materials: Paper, including wrapping paper Card, including food packaging, TetraPaks and juice cartons Glass, all colours Steel, food and drink cans Aluminium, food and drink cans, foil, aerosols Plastic, including milk bottles and bleach bottles. Click here to download a guide on how to help householders manage plastic recycling. We have also published a Recycling Guide which provides a definitive list of what can and cannot be recycled at the MRF. Click here to download a copy.

Casepak Materials Recycling Facility

Co-mingled collections can only deliver good quality recycled resources if they are processed at an efficient Materials Recycling Facility (MRF). The Casepak MRF exceeds the UK’s MRF Code of Practice requirements and produces TEEP compliant outputs, making it the ideal sorting and segregation destination for both local authority and commercial dry mixed recyclables. Located in Leicester with quick road links to the M1, the MRF incorporates advanced materials sorting technologies and is backed by our comprehensive quality grading and reporting system. Working in partnership with local authority and commercial organisations nationwide, the MRF recovers at least 95% of material processed, maximising the quality and value of material outputs from dry mixed recycling schemes. Click here to watch our MRF video