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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:

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.

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.

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 #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:

The 0-100mm material falls through the OCC Screen onto a Debris Roll Screen (DRS). This DRS screen 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 tends to be highly compacted and flattened plastic bottles and tin cans, is conveyed directly to a second DRS screen. Here paper is removed by additional aspiration and any remaining glass is removed by further screening. The remaining plastic bottles and cans enter the Container Sorting section of the system, which is explained in more detail later on.

The 100mm+ material, mostly newspapers and magazines, smaller papers and the un-compacted plastic bottles and cans, flows through the OCC Screen and is conveyed to our NewSorter Screens. These screens separate the newspapers and magazines from the rest of the mixed material. The newspapers and magazines are then conveyed to our De-inking Screen, which removes any rigid paper (light card packaging). The newspapers and magazines are transported to a Quality Inspection Cabin, where material quality is checked and any remaining plastic film (plastic film tends to travel with all material streams and needs careful monitoring throughout the process) is removed. Film is transported by pneumatic extraction to dedicated processing bays. The finished newspapers and magazines are conveyed directly to a storage bunker ready for collection by reprocessors.

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 3 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 #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:

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 #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 #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.