Abstract:
Recyclable plastic film is efficiently collected for recycling at stores or other locations by compacting the plastic film as layers in plastic/cardboard bales. The plastic/cardboard bales can be formed using existing cardboard balers that stores typically already have for baling recyclable cardboard. In one embodiment, the plastic/cardboard bales are preferably formed with a bottom layer of cardboard, a middle layer of the recyclable plastic film, and a top layer of cardboard. The layered structure can be modified to omit one of the cardboard layers or to add additional plastic film and cardboard layers.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a divisional of U.S. Utility application Ser. No. 11/299,442, entitled METHOD AND PROCESS OF COLLECTING AND PROCESSING RECYCLABLE WASTE, filed on Dec. 12, 2005; which is a continuation of U.S. Utility application Ser. No. 11/166,516, entitled: “METHOD AND PROCESS OF COLLECTING AND PROCESSING RECYCLABLE WASTE,” filed on Jun. 24, 2005, which is incorporated herein by reference. This application also claims the benefit of U.S. Provisional Application No. 60/617,971, filed Oct. 11, 2004. All of these applications are incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. The Field of the Invention 
         [0003]    The present invention relates to the field of recycling. More particularly, the present invention relates to methods of collecting and processing recyclable plastic film waste through the formation of bales including both plastic and cardboard. 
         [0004]    2. The Relevant Technology 
         [0005]    The field of plastic recycling is increasingly important as the use of plastic wrap and plastic film bags permeate more and more aspects of retail sales as well as the shipping and packaging industry. For example, plastic shopping bags are well known to the general public as they are the predominant method for consumers to carry groceries and other purchased goods from a store. An even greater volume of plastic film, however, is generated for product packaging and distribution. For example, pallets of goods are frequently wrapped with large sheets of shrink wrap plastic to keep the content of the pallet from shifting or falling during transit. Another example is clothing distribution, wherein each garment is typically transported wrapped in its own plastic sleeve. Some estimates are that plastic bags on apparel account for over 60% of plastic waste at retail department stores. 
         [0006]    With this proliferation of plastic wrap and plastic bags into the shipping and packaging industry, there is a need to recover this material out of the waste stream in an efficient and effective manner. Stores that aggressively collect and recycle waste plastic wrap and plastic bags separate from other garbage frequently save hundreds of dollars per month in the cost of trash hauling. Still, the storage, baling, shipping, and processing of the plastic is extremely inefficient under current methods. 
         [0007]    At stores and distribution centers, for example, one conventional method of collecting plastic waste film for recycling is to stuff plastic into other large plastic bags and toss them somewhere in the facility in a haphazard fashion, for example on top of other bales or bins. For transportation, the bags are thrown into the back of a truck for transportation. Both of these methods are extremely inefficient uses of space. 
         [0008]    Because of these challenges, the majority of plastic wrap and plastic bags are disposed of as waste. Not only does this add to pollution and more quickly fill landfills, but the plastic film fills on-site trash receptacles very quickly. Because waste is typically paid for by volume, i.e. the number of waste containers hauled off, the large volume of plastic film that is disposed of in on-site trash receptacles represent a significant cost. In addition, waste plastic film has a recycling value that is unrealized when the plastic film is disposed of in garbage. 
         [0009]    Despite the challenges in collecting recyclable plastic film, uses for recyclable plastic are quickly expanding. For example, recycled plastic is now used in plastic garbage can liners, landfill liners, agricultural film, and composite lumber products for picnic tables, park benches, porches, and walkways where rot-resistant wood-like products are desired. Shipping containers, carpet materials, and hard plastic containers are also more and more frequently made with recycled plastic film. This increased demand for products made from recycled plastic is fueling an increased demand for the collection of recyclable plastic. 
         [0010]    In addition, recent increases in the cost of raw petroleum have led to a dramatic increase in the cost of plastics for plastic products. As a result, the per pound value of collected recyclable plastic has also increased dramatically. This adds to the demand for the collection of recyclable plastic. 
         [0011]    Nevertheless, the volume of plastic that is collected for recycling remains considerably lower than is feasible. One key imitation on the use of recyclable plastic is that plastic film is difficult and costly to collect. For example, consumers using small plastic bags rarely return them to a source whereby they can be recycled. In addition, shrink wrapped plastic and garment bags at department stores are often discarded rather than collected. In particular, garment bags and shrink wrapped plastic at department stores and warehouse stores are often discarded because the volume of space required to store all the plastic accumulated within the store becomes too expensive to dedicate to that purpose. Although there are feasible methods for collecting plastic film, such as dedicated plastic compactors and balers, these devices are too expensive and the volume of space that must be dedicated to storing pre-compacted plastic is usually impractical for most businesses. 
         [0012]    By analogy, efforts at recycling cardboard have been much more successful. Cardboard recycling is performed at retailers, for example, by using large cardboard balers to compact waste cardboard and form the waste cardboard into bales for storage and transportation to cardboard recycling facilities. Cardboard balers are generally not used for plastic recycling, however, because they are much too large for the volume of plastic that is dealt with. Cardboard balers are typically designed to form forty-eight inch tall bales. The amount of loose plastic it would take to form a forty-eight inch tall bale simply cannot be stored by most, if not all, retailers. As a result, unlike cardboard, for which there is an efficient recycling infrastructure, there is currently no effective method for collecting large volumes of recyclable plastic. 
         [0013]    In addition, plastic and cardboard cannot be mixed for recycling. This is because they are completely different materials that are recycled by very different processes. There are also no efficient methods to separate plastic and cardboard since the value of either material does not justify the labor. For this reason, it is well known that the presence of plastic film in a cardboard bale leads to rejection of the entire bale such that it is discarded rather than recycled. 
         [0014]    Accordingly, it would represent an advance in the art to provide systems and methods to more efficiently and less expensively collect and process recyclable plastic for use in downstream recycling processes. 
       BRIEF SUMMARY OF THE INVENTION 
       [0015]    The present invention relates to the collection of recyclable plastic film in bulk form. As noted above, the disposal or collection of plastic film from large retail stores, discount warehouses, and distribution centers has heretofore presented a significant cost to companies that made it inefficient or impractical. This difficulty in recovering recyclable plastic film results in the waste of a significant amount of otherwise recyclable plastic and reduces profits for those that do collect and recycle the plastic film. 
         [0016]    These problems are overcome by the herein disclosed methods for the collection of plastic film within plastic/cardboard bales formed through novel methods of using balers such as conventional cardboard balers. In general, a plastic/cardboard bale is formed of layers of cardboard encompassing one or more layers of plastic. Thus, an amount of plastic insufficient to form a bale by itself is combined with one or more cardboard layers and compacted in a plastic/cardboard bale. As a result of these improved methods, a locale can use a cardboard baler not only to form cardboard bales, but also to form plastic/cardboard bales. 
         [0017]    Accordingly, a first example embodiment of the invention is a method for collecting recyclable plastic. The method generally includes: providing a cardboard baler; placing a first layer of cardboard in the baler; placing a layer of recyclable plastic film in the baler on top of the first layer of cardboard, wherein the layer of recyclable plastic film has a thickness of at least about three inches; and operating the cardboard baler to form a bale formed of plastic and cardboard. 
         [0018]    Another example embodiment of the invention is also a method for collecting recyclable plastic. This method generally includes: providing a cardboard baler; compacting a first layer of cardboard in the baler; compacting a layer of recyclable plastic film in the baler on top of the first layer of cardboard, wherein the layer of recyclable plastic film comprises a plurality of used plastic bags and/or plastic sheets and has a thickness of at least about three inches to about thirty-six inches; and compacting a second layer of cardboard over the plastic layer, whereby a bale is formed of plastic and cardboard, wherein the bale has a thickness of from about twenty-four inches to about sixty inches. 
         [0019]    Yet another example embodiment of the invention is a bale formed of cardboard and recyclable plastic. The bale generally includes: a layer of recyclable plastic film, the layer of recyclable plastic film comprising first and second opposing surfaces, wherein the layer of recyclable plastic film comprises a plurality of used plastic bags and plastic sheets and has a thickness of at least about three inches; and a first layer of cardboard in contact with the first surface of the layer of recyclable plastic film, wherein the layer of recyclable plastic film and the first layer of cardboard are compactly bound together to facilitate transportation and storage. A second layer of cardboard can formed on and in contact with the second surface of the recyclable plastic film layer. Other cardboard and plastic film layers can also optionally be included in the bale. 
         [0020]    These and other objects and features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which: 
           [0022]      FIG. 1  illustrates a cardboard bale according to the prior art; 
           [0023]      FIG. 2  illustrates a plastic/cardboard bale according to one embodiment of the invention; 
           [0024]      FIG. 3  illustrates a plastic/cardboard bale according to another embodiment of the invention; 
           [0025]      FIG. 4  illustrates the insertion of recyclable plastic film into a cardboard baler for forming a plastic/cardboard bale according to embodiments of the invention; 
           [0026]      FIG. 5  illustrates a plastic/cardboard bale formed in a cardboard baler according to embodiments of the invention; 
           [0027]      FIG. 6  illustrates a series of plastic/cardboard bale stacked for storage according to another embodiment of the invention; 
           [0028]      FIG. 7  illustrates a bin for storing recyclable plastic prior to its compacting in a plastic/cardboard bale according to another embodiment of the invention; and 
           [0029]      FIG. 8  illustrates another bin for storing recyclable plastic prior to its compacting in a plastic/cardboard bale according to another embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0030]    Reference will now be made to the figures wherein like structures will be provided with like reference designations. It is understood that the drawings are diagrammatic and schematic representations of presently preferred embodiments of the invention, and are not limiting of the present invention nor are they necessarily drawn to scale. 
         [0031]    In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to one skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known aspects of cardboard balers and recyclable plastics have not been described in particular detail in order to avoid unnecessarily obscuring the present invention. 
         [0032]    Referring now to  FIG. 1 , a conventionally formed cardboard bale  100  includes a compacted single layer  102  of cardboard. As depicted, the compacted cardboard bale  100  is bound together by bands  104  to keep the cardboard bale  100  in a compacted state. Cardboard bale  100  can be formed by a cardboard baler as generally depicted in  FIG. 4  or any other suitable baler or device used to compact cardboard. Typically, the majority of the individual pieces of cardboard that form cardboard bale  100  come from the same product distribution activities that generate most recyclable plastic film. 
         [0033]    As previously noted, it has been conventionally held that cardboard cannot be mixed with plastic film in collecting materials for recycling. More particularly, the chemical and mechanical processes for recycling cardboard and plastic film cannot work if both are present. It has therefore been axiomatic that cardboard bales, such as bale  100 , cannot contain any plastic film or the whole bale must be discarded. This is because not only can the materials not be mixed in recycling processes, but the cost of separating plastic film from cardboard is too high for cost-effective recycling. As a result, mixed cardboard and plastic bales have heretofore been discarded as waste. 
         [0034]    Contrary to this conventional thinking, however, it has been surprisingly found that plastic film can be effectively combined with cardboard in forming a combined cardboard and plastic film bale. As generally depicted in  FIG. 2 , one embodiment of such a combined cardboard and plastic film bale  200  incorporates a first layer  204  of cardboard, a layer  202  of plastic film, and a second layer  206  of cardboard. The plastic film layer  202  is in effect sandwiched between the two cardboard layers  204 ,  206 . The compacted plastic/cardboard bale is bound together by bands  208 . 
         [0035]    It can be readily seen in  FIG. 2  how a significant amount of plastic film has been compacted to a very small space in the plastic/cardboard bale. In addition, it is also apparent that a significantly less amount of plastic is used in this plastic/cardboard bale than if the entire bale were formed of only plastic film. Thus, because a smaller amount of plastic film can be compacted in a single bale, the plastic can be disposed of in a timely fashion from a single location. In contrast, if the plastic were required to fill the entire bale, it would require many days, weeks, or even months to fill a single bale, requiring great expense to store a significant amount of uncompacted plastic. 
         [0036]    Although it is preferred to have cardboard layers both above and below the plastic film layer, other embodiments of the invention may use only a single cardboard layer on one side of a plastic film layer. Alternatively, a plastic/cardboard bale may have numerous layers. For example,  FIG. 3  illustrates several plastic film layers  256 ,  260 ,  264  sandwiched between several cardboard layers  254 ,  258 ,  262 ,  266  to form a plastic/cardboard bale having a thickness  252 . Of course, one skilled in the art, in view of the disclosure herein, could configure a plastic/cardboard bale with any number of layers of plastic and cardboard. The limiting factor is that the thickness of each plastic layer and the number of such plastic layers must be cost effective. This use of numerous plastic film layers may be preferable in locations where there is little storage space for loose plastic or cardboard and so it is desirable to frequently compact the on hand loose plastic and cardboard in multiple layers. 
         [0037]    With reference now to  FIG. 4 , a conventional cardboard baler  400  is used to form plastic/cardboard bales according to embodiments of the invention. Using conventional cardboard balers greatly reduces the cost to retailers and distributors that already have the balers on-site in that they do not have to acquire another machine nor do they have to store two machines, one for cardboard and one for plastic. The construction and operation of conventional cardboard balers, such as for example cardboard baler  400 , is well known in the art and will not be described in great detail herein. Most conventional balers are designed to form 48 inch, 60 inch, or 72 inch bales. 
         [0038]    Generally, it can be seen that cardboard and plastic can each be inserted through a top opening  402  while a gate  404  is in the open position. In the illustration, a series of bags  302  containing plastic film have been inserted into the baler. Although not visible in the illustration, a layer of compacted cardboard of preferably twelve to eighteen inches is already formed below the uncompacted plastic bags  302 . After the gate  404  is closed, the baler  400  can then be operated to compact the plastic bags  302  into a compacted plastic film layer over the previously compacted cardboard layer. It is preferably to load and compact several cycles of plastic bags, for example eight to twelve, to form an ideally sized plastic film layer. For example, a preferred plastic film layer will be from about nine inches to about eighteen inches in thickness. 
         [0039]    After the plastic film layer is formed, an operator preferably inserts a cycle of cardboard and then operates baler  400  to compress a layer of cardboard over the plastic film layer. This top layer may be formed over several load cycles and preferably has a thickness of twelve to eighteen inches. Finally, the finished bale is bound, preferably with wire in contrast to conventional plastic bands, to keep it compacted and then ejected from the baler  400 . Preferably the bales have two wires at each end to further bind the bales.  FIG. 5  illustrates a completed and bound bale  200  seated within the bottom portion of baler  400 . Alternatively, as illustrated in  FIG. 3  and previously discussed, multiple layers of plastic film can be formed within a single bale and top or bottom cardboard bales can be omitted. These embodiments are less preferred, however. 
         [0040]    Referring now to  FIG. 6 , forming stacks of plastic/cardboard bales  200 A-C is important in the recycling industry because it allows for economy of storage and transport efficiency. Completed plastic/cardboard bales  200 A-C are typically stored for a time at distribution and recycling centers, as seen in  FIG. 6 , stacked on top of one another to conserve space. During transport to these locations, bales are typically stacked on top of one another on a flat-bed trailer. As the trailers travel, turn corners, bounce, etc., the need for increased stability is important as bales shift and tend to lose their structural integrity. The weight of these bales is often over one thousand pounds, accentuating the tendency of the bales to shift and lose structural integrity. 
         [0041]    The structure of the inventive bales is particularly beneficial in that having cardboard layers  204 A-C,  206 A-C sandwich plastic layers  202 A-C forms structural bookends that allow the bales to maintain form and be transported safely and effectively. In other words, whereas the plastic layers are not strong enough to effectively stack perpendicularly on their own, the cardboard end layers provide excellent structural integrity so the bales can be stacked perpendicular to gravity without collapsing. The top and bottom cardboard layers  204 A-C,  206 A-C therefore preferably each have a thickness of at least about twelve inches to provide good support, but as few as six inches or even three inches may also be used in some embodiments. 
         [0042]    In addition, the cardboard ends of the plastic/cardboard bales allow the bales to be tightly secured by straps tightened by a winch on a flat-bed trailer without the force of the straps breaking the bales part. 
         [0043]    Accordingly, one embodiment of the invention is a method of transporting or storing plastic/cardboard bales by stacking two or more plastic/cardboard bales, wherein each of the bales has a cardboard layer, perpendicular to the stack, on each end of each bale such that the bales do not lose structural integrity and do not collapse. Such cardboard layers preferably have a thickness of least about three inches, more preferable at least about six inches, still more preferably at least about twelve inches. 
         [0044]    In addition to providing structural support, the top and bottom cardboard layers  204 A-C,  206 A-C also help contain loss of debris when the bales  200 A-C are transported on an open flat-bed trailer. Cardboard is less likely to pull loose in the wind than plastic and so having cardboard at the end pieces reduces the likelihood of plastic being pulled loose. The cardboard layers are also beneficial when the bales are stored on the ground in that the cardboard absorbs water, reducing the amount of water entering the plastic. 
         [0045]    One example process of implementing the invention involves first gathering recyclable plastic film to a single location. Such plastic may include plastic generated on-site, for example plastic shrink wrap or plastic garment bags removed from clothing prior to sale. Plastic may also be gathered from other locations. For example, a collection location may have a plastic bag collection program wherein consumers can return their small plastic grocery or shopping bags for recycling. In addition, plastic bags can be collected throughout a community, such as at local schools, to promote recycling and thereby provide the double effect of providing a revenue stream for the store (sales of recyclable plastic) and by generating community goodwill. 
         [0046]    The gathered plastic film must then be stored for a brief period of time. Storing recyclable plastic according to one embodiment of the invention includes providing a specially designed collection area. As seen in  FIGS. 7 and 8 , such a collection area may be for example a tall narrow ball bin  280 ,  300  similar to those currently used to store large rubber balls and the like. Within a ball bin  280 ,  300  a plurality of single plastic bags  302 , such as a garbage bags, are filled with shrink wrap and other accumulated plastic. The plastic bags  302  are preferably themselves recyclable plastic film bags having other recyclable plastic film therein. 
         [0047]    A ball bin  280 ,  300  can be conveniently located near a cardboard baler so that bags  302  of plastic film can be stored vertically to minimize occupied floor space. The ball bins can also be formed or placed on a pallet  288  or wheeled dolly so it can be moved as desired. In the embodiment of  FIG. 7 , the ball bin  280  can have a lightweight frame  282 , for example formed of PVC. The depicted ball bin has a funneled top opening  290  and plurality of bungee cords or ropes  286  that keep bags  302  from falling out. For storage, the plastic bags can be either tossed in through the funneled top opening or pushed between the movable bungee retainer cords  286 . The bags can then be removed for compacting by pulling them through the movable bungee retainer cords  286 . In the depicted embodiment of  FIG. 8 , in another example the ball bin also be a metal cage having top and bottom openings where the plastic bags  302  can be tossed in and removed. 
         [0048]    The bags of plastic are preferably stored in a ball bin until it is completely full. That volume of plastic is then loaded into the baler over a series of compacting cycles to make a plastic/cardboard bale. It has been determined that one bin of approximately 4 feet in width, 4 feet in depth, and ten feet in height can hold the plastic generated over two to three days by a typical large retail store or discount warehouse. 
         [0049]    It is preferable to make each plastic layer as thick as possible to reduce the number of plastic/cardboard bales. Fewer plastic/cardboard bales is preferable since it reduces the number of bales that need to be specially handled. It is estimated that large retail stores using a ball bin as describe herein to store plastic film will generate approximately one plastic/cardboard bale for every eight or nine cardboard bales. 
         [0050]    Upon formation of a plastic/cardboard bale, such as for example plastic/cardboard bale  200  or plastic/cardboard bale  250 . The plastic/cardboard bale can then be stored on-site until it is shipped to a plastic and cardboard processing center, optionally via other distribution locales such as returns centers. Because, the plastic film has been compacted in the plastic/cardboard bales, it takes up the less space in a trailer or other transportation vehicle as a similar weight of loosely gathered plastic film. 
         [0051]    At the downstream plastic and cardboard processing center the bale is separated into its constituent parts, for example first cardboard layer  204 , plastic layer  202 , and second cardboard layer  206 . Because the plastic film in the plastic/cardboard bale is contiguous, the compact plastic layer can be easily and readily removed and isolated for recycling. Thus, neither the plastic nor the cardboard is contaminated by the other. 
         [0052]    Cardboard balers typically form bales that are about forty-eight inches tall, about sixty to seventy-two inches wide, and about thirty inches deep. A single plastic layer, in turn, may comprise from about three inches to about thirty-six inches or more in height. Alternatively, the layer of plastic film can be described as being at least about 5% of the bale thickness, more preferably from about 10% to about 70% of the bale thickness. While less than about 3 inches, or less than about 5%, can be used in embodiments of the invention, unless the price per pound for recyclable plastic film becomes very high it is significantly less financially feasible to process a bale to collect such a relatively small volume of plastic. In addition, having at least about 30% cardboard in each bale helps ensure sufficient rigidity for bale stability and containment or plastic. 
         [0053]    A lower cardboard layer will preferably be from about 5% to about 95% of the bale thickness, more preferably about 75% of the bale thickness. The optional top cardboard layer is preferably thinner than the bottom cardboard layer such that it can be more easily removed when the bale is disassembled. A top cardboard layer thickness of about three to twelve inches, more preferably about six inches to about nine inches, is therefore preferred. Although not necessary, the use of the top cardboard layer is preferred as it helps keep the bale more compact and intact than it would be if plastic film were on the top of the bale. 
         [0054]    Of course, the denotations of top and bottom are interchangeable and the bales can be formed in an inverse manner to that described hereinabove. 
         [0055]    Various approaches can be used to track the weight of plastic film that is pressed into each plastic/cardboard bale. One efficient manner of keeping track of the volume of plastic that is compacted in each bale is simply to measure the thickness of each plastic layer and multiply that thickness times other known constants such as the dimensions of the bale to determine an approximate plastic volume. This number is particularly helpful for use in determining the value of the plastic that has been recovered. 
         [0056]    For example, it is currently known that every three inches of compacted plastic film in a 60″ by 48″ by 30″ bale weights about 50 pounds. A 72″ by 48″ by 30″ bale, in turn weights about 65 pounds. Thus, upon the formation of the bale the thickness of the plastic film layer can be approximately measured in inches and a weight estimate can be made. 
         [0057]    Alternatively, the thickness of the plastic film layer can be estimated as a fraction of the bale thickness. Regardless, the entire bale can also be weighed so that the correct fractional portion of the load is assigned to the plastic film layer. Past measurements of separated bales as well as the known densities of plastic and cardboard can be used to create tables that indicate any adjustments to these estimates if more precise estimates are desired. 
         [0058]    At the plastic and cardboard processing center, the whole bales can be again weighed. After the bales are broken open and the plastic is separated from cardboard the plastic can once more be weighed to get a final accurate measurement of the recovered plastic film. Of course, not all of these measurements may be necessary depending upon the accuracy and tracking that is desired. 
         [0059]    After sorting the cardboard and plastic, each of the cardboard and plastic can be baled separately and shipped either on truck or rail car to paper and plastic consuming manufacturers throughout the country. 
         [0060]    The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.