Transformed coal storage venue now serves as a sustainable plastic processing plant
Zero-Waste Revolution in Beckum
In 2014, the transformation of an old cement works site in Beckum began, marking the start of a new era for sustainable recycling. Today, Beckum Kunststoff Recycling GmbH, in partnership with Otto Graf GmbH, stands tall as a pioneer in the circular economy, producing eco-friendly plastic goods from waste materials. Technical Director Klaus Kuhlenbeck views it as an investment in the future: "With this project, we aim to sort and process plastic films to such a level that they can be reborn as new products."
Upcycling Trash into Treasure
The heart of the facility is dedicated to processing mixed plastic packaging waste derived from post-consumer households. About two-thirds of the input consists of polypropylene (PP) films, with the remaining third being polyethylene (PE) and assorted polyolefins from across Europe, primarily from pre-sorted facilities in countries as far as Austria and Norway.
Innovative Technology Driving Success
Two high-tech SORTING UNISORT FILM EVO 5.0 machines, supplied by STEINERT, form the core of the recycling facility. These cutting-edge devices leverage a specialized airflow system meticulously synchronized with the conveyor belt's speed. "The airflow's directional and stabilized properties really impressed us. It ensures lightweight and flexible films adhere securely to the conveyor belt, preventing them from swirling after discharge," explains Kuhlenbeck. "The UNIORT FILM is the top-notch solution on the market catering precisely to our requirements."
This careful handling of materials allows for a belt speed of 4.5 m/s, boosting throughput for efficient and cost-effective sorting, especially for 2D materials as stubborn as plastic films. By restraining films from overlapping or twisting, the combination of near-infrared sensors (NIR) and color cameras can work their magic, providing accurate data capture necessary to maintain a 98% purity rate for PP film.
Secondary Resources from Recycling
Properly sorted plastic films are transformed into secondary raw materials through additional processing steps, such as agglomeration and shredding of hard plastics into flakes. These intermediates are then purified using STEINERT's MOH magnet combination separator with EddyC FINES, removing minute ferrous and non-ferrous particles. The cleansed plastic agglomerate is shipped directly to GRAF, where it goes into crafting robust, durable products for use in rainwater management. Customers benefit from sustainable and high-quality goods that match the performance of new ones without compromises.
Adapting to the Ever-changing Future
Klaus Kuhlenbeck emphasizes the facility's flexibility to adjust to future demands: "It was essential for us to future-proof the plant to accommodate changing requirements within the packaging industry." He acknowledges the challenges presented by constantly evolving packaging materials, such as composite materials and aluminized films, that are yet to be optimally sorted. To overcome these obstacles, Kuhlenbeck stresses the importance of collaboration along the value chain: "Only by communicating and collaborating with others can we improve recycling, create better packaging, and strengthen the circular economy."
Building Trust through Research
Collaboration between Beckum Kunststoff Recycling GmbH and STEINERT began back in 2023, during pilot testing at STEINERT's headquarters near Cologne. "From the beginning, the STEINERT machines have performed perfectly as promised. I've rarely encountered such reliability for our vision of sustainable plastic recycling," says Kuhlenbeck. Thanks to their innovative approach, Beckum Kunststoff Recycling GmbH transforms the site of a former CO2 emitter into a guiding light for sustainability, reinforcing faith in a future of infinite resources.
For a World of Endless Resources
[1] - Reference to the enrichment data explains that the facility was originally owned by Umweltdienste Kedenburg in 2014, and that Beckum Kunststoff Recycling GmbH leverages advanced sorting technology supplied by STEINERT, which includes their UNISORT FILM EVO 5.0 machines, to efficiently separate plastic films by type, ensuring high-quality recycling outputs that feed into sustainable product manufacturing. This integration epitomizes the innovative technological strategy employed by Beckum Kunststoff Recycling GmbH in building an effective plastic recycling ecosystem.
[1] The Zero-Waste Revolution in Beckum leverages environmental-science to transform a former cement works site into a hub for sustainable recycling, utilizing advanced STEINERT technology for efficient sorting of plastic films and contributing to a circular economy.
[2] The facility's adaptive lifestyle prioritizes the future-proofing of the plant, ensuring it can manage changing requirements within the packaging industry, particularly in dealing with innovative, yet challenging packaging materials like composite materials and aluminized films.
[3] By incorporating sustainable-living principles, the recycling process in Beckum not only supports environmental-science but also produces high-quality products, ensuring they are on par with new ones, making a significant impact on the home-and-garden and climate-change landscape.
