Recycling Horticultural Films: Handling and Marketing Lois Levitan Recycling Agricultural Plastics Program (RAPP) Dept Communication Cornell University Ithaca NY MID-ATLANTIC FRUIT & VEGETABLE CONVENTION, SMALL FRUITS – JANUARY 29, 2015

LEVITAN, CORNELL UNIVERSITY My Objectives Convey that recycling horticultural film won’t all be smooth sailing, but is do-able By end of talk, have a roomful of well informed recycling enthusiasts 2

LEVITAN, CORNELL UNIVERSITY Topics What is recycling? Challenges to recycling horticultural plastics. Overcoming the challenges. Products made with recycled horticultural plastics. By whom? What I hope to learn from growers. 3

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PLASTICS RECYCLING CONFERENCE 2014 – LEVITAN, CORNELL UNIVERSITY 5 Plastics-to-Oil HEAT + PRESSSURE ( + catalyst)  oil or wax + inorganic residue (e.g., carbon black)

LEVITAN, CORNELL UNIVERSITY 6 Waste-to-Energy ≠ RECYCLING ENERGY RECOVERY BY INCINERATION (COMBUSTION AT HIGH HEAT) Graphic: SICK Sensor Intelligence. United States: 67 large Municipal Solid Waste incinerators + several hundred industrial, medical and hazardous waste incinerators of all sizes (Source: Waste Incineration. Unites States Response to UNEP Questionnaire for Paragraph 29 Study, Enclosure 4a, Rev. May 2010) Organic waste  inorganic ash, flue gas + heat

LEVITAN, CORNELL UNIVERSITY 7 Fuel Pellets PLASTIC PELLETS or 10% PLASTIC + BIOMASS  burns hotter, flows better

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PP bulk bags LEVITAN, CORNELL UNIVERSITY Horticultural Plastics Many different film and rigid products. Many colors, multi-colored. Different resins, & mixes of resins, with additives. Mostly low density PE, but also HDPE, PP, PS. PVC used historically; some still used, particularly in imported products. 9 Greenhouse & tunnel covers Mulch film Plant pots, flats, trays: PE, PP, PS

LEVITAN, CORNELL UNIVERSITY 10 Horticultural Plastics Challenges to recycling characteristics inherent to these plastic products characteristics of the products after use in fields & nurseries cost and logistics of collection and transport from fields (or nurseries) to recycling markets Photo: Delta Planstics

Challenges to recycling: characteristics inherent to complex, technical products Thin films with multiple extrusion layers, each with additives and colorants for specific agronomic or horticultural purposes: Block UV Repel insects Absorb or reflect heat EVOH O2 barrier Hold moisture Reinforce structure Prevent backwash Stretchability Stickiness Tensile strength Flexibility Rigidity Longevity Degradability LEVITAN, CORNELL UNIVERSITY 11 John Deere Max-Flat PE irrigation drip tape Jphn Deere Pro-Flat PVC drip tape

Plant pots, flats, seedling trays HDPE, PS, PP, blown, molded, thermo-formed Photo: Lois Levitan, RAPP LEVITAN, CORNELL UNIVERSITY

Maple syrup tubing Mostly LDPE tubing (some old PVC tubing) with fittings, connectors, and ball valves of nylon, polycarbonate, rubber Photoa: Lois Levitan, RAPP LEVITAN, CORNELL UNIVERSITY 13

Photo: Lois Levitan, RAPP Used & stored outdoors, in mud, rain & snow Often with residues of soil, plant debris, moisture, stones & grit Possible or perceived pesticide residues & soil pathogens Bulky LEVITAN, CORNELL UNIVERSITY 14 Photos: Lois Levitan, RAPP Challenges to recycling: characteristics of products after use (post-consumer)

LEVITAN, CORNELL UNIVERSITY 15 Photo: Delta Plastics Delta Plastics (L)LDPE irrigation polytube, Challenges to recycling: characteristics of the products after use (post-consumer) Photo: Lois Levitan, RAPP Baled mulch film Mulch film: strips of LDPE, typically ≤ 1 mil thick (  high surface:volume ratio). Lays on soil, gets very dirty. White, black, silver, occasionally clear or other colors. Sometimes 2+ color layers. Some with nylon or EVOH O 2 barrier layer. Photo: Sky Plastics

Pesticide containers, chemical drums. HDPE. Example of Extended Producer Responsibility (EPR): Ag Container Recycling Council (ACRC) financed by pesticide manufacturers and distributors. ACRC protocols require triple rinsing, special handling & approved end-uses that minimize exposure. ACRC oversees a national network of collectors, processors, end-product manufacturers. 10 million lb collected 2014; 150 million lb since began in early 1990s. Photo: Lois Levitan, RAPP LEVITAN, CORNELL UNIVERSITY 17 Photo: Nate Leonard, RAPP

Horticultural Mulch Film: Before & After Washing BEFORE WASHING1 MINUTE LATER LEVITAN, CORNELL UNIVERSITY 18 Paul Vanderpool: “Recyclers have learned how to recycle better” Photo: Lois Levitan, RAPP New technologies & advances in processing equipment creating new recycling options

F. Paul Vanderpool American Cierra Corporation 491 Grant Ave. Auburn, NY office m “Recyclers have learned how to recycle better” 19 Photo: Lois Levitan, RAPP

Mobile film reclamation system Cleans film ON-SITE, allowing flexibility in scheduling Bales film for shipment ON-SITE Self-contained, small footprint Meets all California power plant restrictions Cleans film with proprietary non– water processes High volume capacity Contact: Lloyd Gleaves, CEO , Mobile cleaning, baling, grinding equipment LEVITAN, CORNELL UNIVERSITY 20 Photo: Romall Ind

Best Management Practices (BMPs) What not to do! Keep plastic clean and dry as possible Shake out pebbles & clumps of soil Roll or fold into pillow-sized bundles Store off ground, out of mud, grit, gravel Separate plastic by color and type 21 LEVITAN, CORNELL UNIVERSITY 21 Photo: Jim Zecca. Madison Co

Greenhouse, hoophouse, high tunnel covers Clear or white sheets of (L)LDPE. Excellent quality for recycling. Challenge: Keep clean & remove efficiently, meeting needs of growers & recyclers Photo: Lois Levitan, RAPP LEVITAN, CORNELL UNIVERSITY

Without prep for baling: 23 LEVITAN, CORNELL UNIVERSITY 23 Photo: Jim Zecca. Madison Co 4 hrs to finish bale, vs. ½ hr with plastic prepped in stacked bundles

LEVITAN, CORNELL UNIVERSITY 24 Efficient compaction:

Challenges to recycling: Cost & logistics of collection and transport from fields or nurseries, etc. to recycling markets In most of the U.S., agricultural plastics are dispersed acrosss the rural landscape  high costs of collection LEVITAN, CORNELL UNIVERSITY 25 Difficult to amass full 40,000 lb truckloads

LEVITAN, CORNELL UNIVERSITY Why should society & recyclers care about this particular set of plastics? Less than 2% of plastic discarded in US, but possibly 10% of film* Very visible 2-10% When left in the fields catches in bushes, ditches, ravines Alternatives to recycling not pretty: burning, burying in fields bad for air & water quality Landfilling costly to society Societal value of recycling >> economic value: All society benefits from conservation of resources & energy. 26 Plastic discarded in US Agr film *based on VT data calculated by Annie Macmillan, VT Agency of Agriculture.

LEVITAN, CORNELL UNIVERSITY Agricultural Plastic Recycling Markets: Processors (Reclaimers) & Manufacturers 27 Domestic markets can & do process used horticultural plastic. Location. Location. Location. More options, less costly to recycle where farms (& plastic use) are concentrated: FL, CA. Smaller, regional recycling markets important for co-mingled supply from less concentrated areas. Some recycling markets vertically integrate to guarantee supply & increase efficiency. Some pick up & some require drop-off. Only a few pay for material. Some take-back products after use & give credit on purchases. Recycling markets typically put < value on difficult-to-recycle plastic than it costs to collect & transport.

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LEVITAN, CORNELL UNIVERSITY Capacity to recycle 200 million lb/yr, with potential to double. Only (L)LDPE

LEVITAN, CORNELL UNIVERSITY 30 Recycling arm of Command Packaging. Opened late million lb/yr capacity (CA uses 150 mm lb/), Convert mulch film to 125x reusable smarterbags™. $3 million CA grant Nov’14. Recycling arm of Command Packaging. Opened late million lb/yr capacity (CA uses 150 mm lb/), Convert mulch film to 125x reusable smarterbags™. $3 million CA grant Nov’14.

LEVITAN, CORNELL UNIVERSITY 31 Opened Collect mulch film & drip tape from large Florida farms. Shred, clean, dry film. Sell to pelletizers worldwide. 40 million lb/yr at current site.

LEVITAN, CORNELL UNIVERSITY 32 California collection area only. Pay based on dry weight polyethylene tubing, 8¢/lb towards new orders, 4¢/lb cash.

LEVITAN, CORNELL UNIVERSITY 33 bridon cordage

LEVITAN, CORNELL UNIVERSITY 34 The Blackmore Company Call (800) about recycling polystyrene trays. The Blackmore Company Call (800) about recycling polystyrene trays.

LEVITAN, CORNELL UNIVERSITY 35 com/recycling-program Manufacture & recycle plant containers: HDPE, PP, PS. 10 million lb/yr recycling capacity

NBF Plastics: plywood substitute, PIMS technology, anticipate 1-2 million lbs/yr TERREWALKS® sidewalk pavers from agricultural bale wrap, thermokinetic processing Top skin: blue boat wrap Top skin: black & white silage bag film Top skin: maple tubing & fittings Core: Irrigation drip tape LEVITAN, CORNELL UNIVERSITY 36 TERRECON Dishashish Plastic Manufacturers LLC: garbage bags, ~ 20% recycled b/w silage bags (1 million lb/yr).

37 Photo: Lois Levitan, RAPP LEVITAN, CORNELL UNIVERSITY 37 Lois Levitan, PhD Recycling Agricultural Plastics Program Dept Communication, Cornell University Ithaca NY QUESTIONS from YOUR EXPERIENCE: Efficient methods/equipment that minimize dirt/debris in removing cover plastic & mulch? Rollers, balers or other equipment that compact plastics tightly for transport? Please contact me!