Abstract:
A system for sorting and processing recyclable materials includes a sorting station including a loading conveyor and a data collection area. Containers received from various distribution centers are loaded onto the load conveyor and moved to the data collection area. The contents of the container are recorded with corresponding weight and origin information. The information recorded regarding the contents of the container is used to credit distribution centers for reimbursement. The recyclable material is unloaded from the container and directed to the proper processing station and prepared for shipment to an end user of the recyclable material.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     This invention relates to a recycling process, and more specifically to a recycling process for sorting, counting and preparing recyclable materials for reuse.  
         [0002]     Many states have instituted recycling laws that charge a deposit fee with each purchase of a beverage container. The deposit fee is returned to the purchaser upon return of the container. The deposit fee encourages consumers to return empty containers instead of throwing them away. Typically, purchasers return the containers to distribution centers such as shopping centers. Those shopping centers sort the containers and send the sorted material to processing centers.  
         [0003]     The processing centers receive, count and prepare the containers for reuse. Preparation for reuse includes the sorting of containers by material type. For example, green glass, brown glass, clear glass, cans, and plastic bottles. The glass is sorted by color and crushed. The cans and plastic bottles are sorted and baled into easily handled bundles for further processing.  
         [0004]     Typically, only a few process centers service many distribution and shopping centers. Each process center receives large quantities of recyclable containers for sorting and processing. Sorting and counting the large quantities of recyclable material received from distribution centers can be costly and time-consuming. In addition, an accurate accounting of recyclable material is required to credit the distribution centers and collect from the container manufactures.  
         [0005]     Accordingly, it is desirable to develop a method and process for efficiently, and economically sorting and preparing recyclable material for reuse.  
       SUMMARY OF THE INVENTION  
       [0006]     The present invention is a method and system for sorting, counting and preparing recyclable material for reuse.  
         [0007]     The system of this invention includes a cell with a loading conveyor and a sorting and data collection station. Containers filled with recyclable material received from various distribution centers are loaded onto the load conveyor and moved to the sorting and data collection station. The container includes a label with container origin information, which is read and recorded in a database. The category and weight of the recyclable material within each container is also recorded in the database along with corresponding weight and origin information. The category of recyclable material includes glass, cans or plastic bottles. The recyclable material is unloaded from the container and moved to the proper processing station. At the processing stations, each category of recyclable material is prepared for shipment to an end user.  
         [0008]     Accordingly, the system and process of this invention increases the efficiency of sorting, counting and processing recyclable materials received from various distribution centers and prepares that material for reuse. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]     The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:  
         [0010]      FIG. 1  is a schematic illustration of a recyclable material sorting and processing system according to this invention;  
         [0011]      FIG. 2  is a schematic illustration of another recyclable material sorting and processing system according to this invention;  
         [0012]      FIG. 3  is a schematic illustration of a sorting station;  
         [0013]      FIG. 4  is a schematic illustration of a container;  
         [0014]      FIG. 5  is a schematic illustration of a control box;  
         [0015]      FIG. 6  is a schematic illustration of a can and plastic bottle conveyor and processing stations according to this invention; and  
         [0016]      FIG. 7  is a schematic illustration of a glass conveyor and processing station according to this invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0017]     Referring to  FIG. 1 , a recyclable material sorting and processing system  10  is disclosed. The system  10  processes recyclable material  11  received from various distribution centers and prepares the recyclable material  11  for processing and reuse by manufacturers. The recyclable material  11  is received within containers  16 . Preferably, each individual container  16  includes only one category of recyclable material  11 , such as cans, plastic bottles or glass. The glass is preferably sorted by color such as brown, green and clear. The system  10  includes a sorting station  12 , a glass bottle processing station  13  and a can and bottle processing station  17 .  
         [0018]     The glass bottle processing station  13 , and can bottle processing station  17  receive recyclable material  11  from the sorting station  12  by way of conveyors  34 ,  36 . The conveyor  36  includes an intermediate portion  36 ′ that dumps material onto the main conveyor  36 . The conveyors  34 ,  36  continuously run during operation to move recyclable material  11  to the proper processing station. Each of the processing stations  13 ,  17  include item specific devices for processing the specific category of recyclable material  11 . The glass bottle processing station  13  includes crushers  54  for crushing glass bottles and bins  48 ,  50 ,  52  for storing crushed glass by color. The can and plastic bottle station  17  includes a can crusher/baler  42 , and a plastic bottle crusher/baler  44 . The baled cans and plastic bottles provide for easier shipping and handling.  
         [0019]     Referring to  FIG. 2 , the system  10  is shown with two sorting stations  12 . As appreciated, multiple sorting stations  12  speed the sorting of recyclable material  11  and provide for adaptation to differing volumes of recyclable material  11 . Each of the sorting stations  12  sort, and gather data relating to the incoming recyclable material  11 . It is within the contemplation of this invention to include multiple sorting stations  12  to provide increased sorting capability. The recyclable material  11  is dumped onto conveyors  34 ,  36 . However, multiple processing stations  13 , and  17  can be provided for increasing the volume of recyclable material that can be processed.  
         [0020]     Referring to  FIG. 3 , the sorting station  12  sorts and collects data to track the amount and type of recyclable material  11  received from each distribution center. The containers  16  loaded on the load conveyor  14  move toward a data collection area  15  manned by at least one operator  28 . Multiple containers  16  are loaded onto the load conveyor  14 . Sensors  18  disposed on the load conveyor  14  and at the data collection area  15  control movement of the containers  16  toward the data collection area  15 . Preferably, the sensors  18  are optic sensors as known in the art. However, a worker knowledgeable in the art with the benefit of this description would understand that any sensor for detecting the presence or absence of a container could be used in this invention to control movement of the containers  16 .  
         [0021]     Preferably each container  16  includes a computer readable label  24  ( FIG. 3 ). The computer readable label  24  includes information pertaining to the origin of each container  16 . Preferably, the computer readable label  24  is a bar code that is readably by a scanner  22  mounted within the data collection area  15 . Although, a bar code and scanner are described, it is within the contemplation of this invention to use any type of computer readable identification label to allow automatic collection of data relevant to each container  16 .  
         [0022]     Referring to  FIG. 4 , preferably, the container  16  is a box structure defining a specified volume. A lid  31  covers the open top of the box to allow stacking of several containers  16  and to prevent contaminants and trash from entering the container  16 . Further, the container  16  can include features such as openings to aid movement of the container during loading and unloading.  
         [0023]     Referring back to  FIG. 3 , upon reaching the data collection area  15 , the contents and origin of each container  16  are determined. The scanner  22  reads the computer readable label  24  and stores the information within a data acquisition system  23 . The label  24  preferably at least includes information concerning the origin of the container  16 , however, additional information may also be provided such as, date and time of shipping, tracking numbers, along with any other pertinent information useful in accounting and tracking recyclable material within the container  16 .  
         [0024]     The operator  28  attending the data collection area  15  removes the lid  31  of the container  16  and examines the contents. Preferably, each container  16  includes only one category of recyclable material  11 . Preferably, the distribution center that shipped the material has presorted the recyclable material  11 . The data collection station  15  includes a weigh conveyor  20 . The container  16  is weighed and the weight of recyclable material within the container  16  is recorded in the data acquisition system  23  and matched to the origin information read from the computer readable label  24 . The data acquisition system  23  stores data on the type and amount of recyclable material  11  received from each distribution center.  
         [0025]     The operator  28  examines the contents of the container  16  and presses a corresponding switch on a control panel  25 . Referring to  FIG. 4 , the control panel  25  includes switches  27 ,  29 ,  33 ,  35 , and  37  that correspond to specific categories of recyclable material. Preferably, the categories of recyclable material include cans, plastic bottles, and glass bottles. The glass bottles are further defined by color such as brown, green and clear. The operator  28  presses the corresponding switch on the control panel  25  to record the type of recyclable material  11  within the container and match that data with information already recorded on the origin and weight of the recyclable material.  
         [0026]     The system performs a check upon engagement of one of the switches  27 ,  29 ,  33 ,  35 , and  37  to assure proper selection of recyclable material  11  category. The category of recyclable material  11  selected by one of the switches  27 ,  29 ,  33 ,  35 , and  37  is compared to the weight of the container  16  and contents. If the material selected does not correspond with the weight, an error is signaled to the operator  28 , prompting actuation of the correct switch  27 , 29 , 33 , 35 , and  37 . As appreciated, a container  16  full of plastic bottles will weigh much less than a container filled with glass bottles. Therefore a detected weight differential beyond a given range is brought to the attention of the operator  28  for correction.  
         [0027]     The selection of one of the switches  27 , 29 , 33 , 35 , and  37  also initiates movement of the container  16  from the data collection area  15 . The container  16  moves further down the weigh conveyor  20  to a crane  32 . The crane  32  lifts and moves the container  16  to one of the two conveyors  34 , 36 . The contents of the container  16  are dumped onto the one of the conveyors  34 ,  36  and moved toward one of the processing stations  13 , 17 . The container  16  is moved to a washing station  38 . At the washing station  38  the container  16  is washed, dried and disassembled. The disassembled containers  16  are stacked and shipped back to various distribution centers for reuse.  
         [0028]     Referring to  FIG. 6 , the can and bottle processing station  17  is schematically shown and includes the conveyor  34  and a diverter arm  40 . The cans and plastic bottles unloaded on the conveyor  34  move toward the first or second processing station  42 ,  44 . The cans move to the first processing station  42 . The first processing station  42  crushes, compacts and bales the cans. Plastic bottles are routed to the second processing station  44  that compacts, bales the plastic bottles. The output from each of the first and second processing stations  42 ,  44  provides for easy transportation to the end user of the recyclable material.  
         [0029]     The diverter arm  40  moves to direct incoming recyclable material  11  to the proper processing station  42 ,  44 . The switch actuated by the operator  28  initiates action by the diverter  40 . Movement of the diverter  40  is coordinated with the speed of the conveyor  34  such that the proper category of recyclable material  11  is routed to the proper processing station  42 ,  44 . The sequence of unloading the recyclable material from each container creates gaps of a predetermined duration between loads moving down the conveyor  34 . The diverter  40  moves to direct the next oncoming load of recyclable material into one of the designated processing stations  44 , 42 .  
         [0030]     Referring to  FIG. 7 , the glass bottle processing station  13  is schematically illustrated and includes the conveyor  36 . Glass bottles moving down the conveyor from the sorting station  12  are separated according to color. The bottles are separated into brown, green and clear glass. Each load of glass bottles is already separated and moves down the conveyor  36  toward segregated bins  48 , 50 , 52 . Diverter arms  40  direct the glass bottles through a crusher  54  and into one of the bins  48 ,  50 ,  52  that correspond to the color of the glass. The color of the glass bottle is identified on the control panel  25  at the data collection station  15 . The specific load of recyclable material  11  dumped from the specific container  16  is tracked from the unload point on the conveyor  36  to each bin  48 , 50 ,  52 . The diverter arms  40  are opened or closed according to the selection made at the sorting station  12 . The glass is dumped into the crusher  54  suspended over each of the bin  48 ,  50 ,  52 . The output-crushed glass fills the segregated bins in preparation for reuse by glass manufactures or other manufactures reusing the crushed glass product.  
         [0031]     Referring to  FIG. 1 , in operation, containers  16  of recyclable material  11  are loaded onto the load conveyor  14  at the sorting station  12 . Sensors  18  regulate movement of each container  16  toward the data collection area  15 . At the data collection area  15 , the computer readable label  24  on the container  16  is read by the scanner  22 . Information contained on the label  24  is stored in the data acquisition system  23 . The operator  28  removes the lid  31  and examines the contents of the container  16 . The operator  28  actuates one of the switches  27 , 29 , 33 , 35 ,and  37  corresponding to the category of recyclable material  11  within the container  16 . The container  16  and contents are weighted by a weigh conveyor  20 . The category type and weight information of recyclable material  11  contained within the container  16  is matched with the origin information read from the label are recorded within the data acquisition system  23 . Actuation of one of the switches  27 , 29 , 33 , 35 , and  37  initiates the gantry crane  32  to lift and move the container  16  to one of the conveyors  34 , 36 . The crane  32  dumps the contents of the container onto the proper conveyor  34 ,  36  and unloads the container  16  at the washing station  38 . The recyclable material  11  moves to one of the processing stations  13 ,  17 . The specific load of recyclable material  11  is tracked from the sorting station  12  and diverted according to category to the desired processing station  13 ,  17 .  
         [0032]     The foregoing description is exemplary and not just a material specification. The invention has been described in an illustrative manner, and should be understood that the terminology used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, one of ordinary skill in the art would recognize that certain modifications are within the scope of this invention. It is understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention.