1. What quality do the reprocessors expect?
Andy Doran
National Manager, Novelis Recycling

2. Printing and Lithography
Our markets
Novelis is the world leader in aluminum rolling and can recycling
Spun off from Alcan Inc in January 2005
Became subsidiary of Hindalco Industries Ltd in May 2007
We are the only company of our size and scope focused on aluminum rolled products markets,
including:
Building and Construction
Flexible and Semi-rigid Packaging
Printing and Lithography
Cans and Closures
Automotive and Transportation

3. World leading UBC Recycler
North America
480 kt
Europe
220 kt
Asia
30 kt
United States
Latchford, UK
Berea, KY
South Korea
Greensboro , GA
Oswego, NY
Ulsan
South America
125 kt
São Paulo, Brazil
Pinda

4. Latchford site
GPP Plant
Comm. 1942
UBC Plant
Comm. 1991

5. Can body ingot Weighs 27 tonnes Measures 9 x 1.8 x 0.5 metres
Contains 1.5 million recycled drink cans
Is transported to Germany to the rolling mill

6. Why quality matters in aluminium recycling and how to deliver it……

7. Novelis – Latchford used beverage can recycling plant
Hot Metal Transfer
from GPP
Sow Drier
Capacity 16MT
Scraps charged
direct to furnace
Hygiene Extraction System
Cold Extraction System
Belt
Conveyor
Shredder
Dross
Bay
Argon dross coolers
AJS
Automatic
Salt Feeders
Melter 2
Melter 1
Capacity
90MT
Sidewell  
GSSDs
Surge
Hopper
12MT
Off-site
Aluminium
Recovery
Class Scrap
and UBCs
Hot (Furnace)
Extraction System
Decoater
Extraction System
Scrap Receiving and Shredding Area
Decoating and Melting Area
Holding and
Casting Area
Sawing and
Despatch Area
Cold Fines
Screen
Hot Fines
Screen
Decoater
Metal Transfer
Launders
Tilting Holder
Furnace
Capacity 90MT
RGI
Off-site
Al Recovery
Magnetic
Separator
Incoming
Al Scrap
DC Casting
Centre
3 ingots per cast
Two point Grab
32MT Max. Load
Band Saw
21-26MT Slab, 8300mm long
GSSD - Sidewell Stirrer
AJS - Jet Stirrer
ACD
ABF
RGI - Rotary Gas Injector
ACD - Degasser
DC - Direct Chill
ABF - Bed Filter
to Alunorf
Sheet ingot

8. Series of line trips + reducing feedrate
Impact of plastics
24 hrs
Series of line trips + reducing feedrate
13 tph
8 tph
Typical impact of 50tpd
15kt additional shred feed capacity if plastics can be removed

9. Quality checks OUR AGGREGATION CENTRES: AT THE RECYCLING PLANT:
Visual before off loading
Visual after off loading
Moisture test
Magnet
AT THE RECYCLING PLANT:
Visual before off loading
Visual after off loading
Moisture test - all deliveries
Breaking open of pallets / bales

10. Plastic Fire hazard and health and safety risk
Every outage results in 10 minutes lost feed
At 10 t/hr, this equates to 1.67 t lost feed
Excessive melt loss

11. Lower quality equals lower value
                                                    
Over a 1 year period, this supplier ‘lost out’ on more than £60,000 of revenue!
The Solution
Simple technology, good housekeeping and training will increase the quality of your deliveries.
Staff training
Your staff are the key to successfully cutting contamination.
Experience tells us that employees are usually willing to make the effort to produce a quality product.
Contamination can be prevented by staff being more aware of the potential problems, and understanding the need to be vigilant. Use this website to help inform and educate staff about the importance of eliminating contaminants, by explaining the impact of contaminants on the recycling process and, ultimately, your business.
Novelis Recycling's business development executives are happy to help with staff training. We can usually supply supporting materials to reinforce the key messages as part of an ongoing training and awareness programme.
Key areas for staff training:
Materials handling
An enclosed receiving area will minimise the risk of moisture and dirt contamination.
UBCs should be stored indoors before, during and after processing - preferably on a concrete floor or hard-standing.
Baled or densified material should be stacked in such a way as to prevent contact from surface water - including snow and ice.
Processing material
Tipping loose cans into wire baskets helps to filter out smaller contaminants, e.g. glass, and can make visual inspection easier.
Control the rate of flow along conveyors with chains.
Fit grilles in holding hoppers.
Set conveyors at a high angle so that heavy objects fall back.
Check the positioning of skips. Use marks on the floor to ensure they are always replaced correctly after emptying.
Can processing equipment
Overband magnets are more effective than roller magnets for removing steel cans.
Eddy current separators provide a positive sort for aluminium UBCs after steel has been removed by an overband magnet.
It is extremely difficult to sort in a hopper. Where hand picking and sorting takes place try to use a flat conveyor if possible.
New sorting equipment technology is constantly being introduced. For information and technical advice about machinery and processing contact Novelis Recycling.
Housekeeping
Maintain your scales
The measurement capability of your scales will help determine bale densities of delivered-in material, and help you to detect the presence of heavy non-UBC material.
Check and clean your machinery regularly
Remove loose cans from under conveyors and balers to prevent the risk of damage to the machinery and / or a build up of dirt or other contaminants.
Check magnetic separators regularly to ensure magnetic head is fully magnetised, and replace if necessary.
Ensure balers are cleaned to remove traces of other materials (e.g. paper, plastic) before baling of UBCs starts.
Check the settings on eddy current separators regularly; for example is the splitter plate set to give the maximum sort?
General cleanliness
We cannot stress enough the importance of keeping all operational areas and equipment clean.
Pay regular attention to the cleaning of floors, skips etc. This not only reduces the opportunity for contamination to occur, it is also an important aid to maintaining health and safety in the work environment and improving staff motivation.
Pay particular attention to keeping floors free of liquid.
Ensure electrical checks on equipment are carried out regularly.
Your suppliers
Practice what you preach!
Encourage and educate your suppliers to understand the importance of quality and the need to cut contamination.
Explain the problems caused by contamination.
Encourage them to visit this website to find out more!
Reject material if necessary - penalise for poor quality.
Grade your suppliers.
Carry out spot checks on loads.

12. What makes for good quality aluminium?

13. Use good machinery and use it well
Simple technology and materials handling:
Avoid over compacting cans or cans and plastic fractions during collection
Tipping loose cans into wire baskets helps to filter out smaller contaminants, e.g. glass, and can make visual inspection easier
Controlling the rate of flow along conveyors with chains
Fit grilles in holding hoppers
Set conveyors at a high angle so that heavy objects fall back
Ensure eddy currents are well positioned and sufficient for the volumes handled
Check the positioning of skips. Use marks on the floor to ensure they are always replaced correctly after emptying

14. Use good people and treat them well
Housekeeping:
Ensure balers are cleaned to remove traces of other materials (e.g. paper, plastic) before baling of UBCs starts
Check the settings on eddy current separators regularly; for example is the splitter plate set to give the maximum sort?
Pay regular attention to the cleaning of floors, skips etc. This not only reduces the opportunity for contamination to occur, it is also an important aid to maintaining health and safety in the work environment and improving staff motivation.
Staff training:
Your staff are the key to successfully cutting contamination
Contamination can be prevented by staff being more aware of the potential problems, and understanding the need to be vigilant

15. Open loop ‘multi-material’ collection and sorting schemes
In general it is difficult (and costly) to separate the small aluminium fraction from multi-material schemes. Therefore it is recommended to separate it early in the sorting process which in combination with improved separation techniques will result in higher yields, better quality and more value. There is the additional advantage of higher consumer involvement .
Glass
household waste, including paper + ‘light fraction’ = plastic bottles (PET), metal containers (beverage cans, etc.) and beverage cartons (if necessary)
Glass
Paper + Light fraction
Glass
Paper fraction
Light fraction

16. Thank you for your interest. andy. doran@novelis
Thank you for your interest! Tel: Mob:

17. Thank you for your interest!
Tel:
Mob: