Transitioning from coal storage to the eco-friendly processing of plastics
In the heart of Germany, Beckum Kunststoff Recycling GmbH stands tall as a pioneer in sustainability. After taking over a former cement plant site in 2014, a sorting facility for plastic packaging was established. Ten years later, in 2024, another facility rose from the ashes of coal storage, this time in conjuction with Otto Graf GmbH. Now, instead of producing CO2, it churns out high-quality sustainable plastic recyclates, embodying the transformation of historical industrial sites towards the circular economy.
From Waste to Gold
The state-of-the-art facility processes a multitude of plastic fractions from mixed light packaging (LVP). Roughly two-thirds of its input consists of polypropylene (PP) film, with the remaining third being polyethylene (PE) or a combination of polyolefins (PO), primarily presorted material from LVP plants across Europe, from Austria to Norway.
Innovative Tech Rules the Day
The beating heart of the new facility are two cutting-edge STEINERT UniSort Film EVO 5.0 machines. These machines work in harmony with a specialized air flow system that perfectly syncs with the belt speed for stable handling of even the lightest and most flexible films. Klaus Kuhlenbeck, technical manager of the facility, expresses his admiration for the directed and stabilized air flow, which ensures films remain steady on the acceleration belt, and extends to the discharge hood, minimizing disturbance after removal. According to Kuhlenbeck, the current UniSort Film is the most advanced solution on the market, due to its precise material handling capabilities.
This refined handling enables a belt speed of 4.5 m/s, crucial for high throughputs and economic sorting, especially for 2D materials. This prevents films from overlapping or twisting, allowing the sensor fusion of near-infrared (NIR) sensor and color camera to reach its full potential. Exact data capture is crucial for achieving the targeted product purity of 98%.
From Sorted Plastic Films to Secondary Raw Material
Once sorted, the films undergo further processing steps, and are ultimately agglomerated and the hard plastics crushed into flakes. These intermediate products are then cleaned further using the STEINERT MOH magnetic combination separator with EddyC FINES to remove even the tiniest iron and non-ferrous metal particles. The majority of the products then head to the production plants of the GRAF company, where they are used to manufacture durable products for rainwater harvesting. In doing so, customers receive products that aren't just sustainable, but meet the quality of new products, and don't compromise.
Adapting to Future Challenges
Klaus Kuhlenbeck stressed the importance of investing in future-proof technology. The facility was intentionally designed to accommodate changing requirements. "We know that packaging materials and customer expectations are constantly evolving," explains Kuhlenbeck, "that's why we've prepared for future developments by integrating sensor combinations of NIR and color." Kuhlenbeck underlines that a facility is never truly completed, as new challenges crop up, such as composite materials or aluminum-coated films that, if not detected, can affect the final product. Recycling, he emphasizes, requires collaboration along the value chain, as "decades of working independently has now given way to collaboration, which drives the circular economy forward."
Reliability through Testing - Sustainability as the Foundation
The partnership with STEINERT began in the in-house test center at the main site near Cologne, where the groundwork for the successful project was laid as early as 2023. "The machines from STEINERT have delivered precisely what was promised from the start," summarizes Kuhlenbeck, "I've seldom seen such reliability. That's the kind of reliability we need for our vision of sustainable plastic recycling." With the new plant in Beckum, the site of a former carbon emitter is stepping into the future as a beacon of sustainability, with every kilogram of plastic returned to the cycle contributing to climate protection, saving CO2, and preserving natural resources.
- Science plays a significant role in the transformation of Beckum Kunststoff Recycling GmbH, a pioneer in sustainability, as they employ environmental-science and cutting-edge technology, such as the STEINERT UniSort Film EVO 5.0 machines, in their manufacturing process.
- The recycling facility, initially established to process plastic packaging waste, now focuses on climate-change mitigation by churning out high-quality sustainable plastic recyclates instead of contributing to CO2 emissions, a testament to the shift towards the circular economy in the industry.
- As the facility adapts to future challenges like composite materials and aluminum-coated films, finance plays a crucial role in investing in future-proof technology and collaboration along the value chain, ensuring the continuous evolution and success of sustainable plastic recycling.
