New Recycling Facility Redefines ‘State of the Art’

What Goes Around…

 

Frank Antonacci says he’s lost track of how many tours he’s led of the All American Material Recovery Facility (MRF) in Berlin, Conn., which handles material from across the Nutmeg State and Western Mass.

“Suffice it to say, it’s a big number,” said Antonacci, a principal with Murphy Road Recycling, an operator of several recycling facilities, which, in partnership with Van Dyk Recycling Solutions, suppliers of the system’s equipment, opened the state-of-the-art facility in early 2022.

Since then, in addition to overseeing this intriguing operation, which processes more than 50 tons of recyclable material an hour, Antonacci and Jonathan Murray, director of Operations for Murphy Road Recycling, have been leading individuals and groups through the massive facility to show them what goes on there and why this operation is among the most advanced of its kind in the country — and the world, for that matter.

And there have been many different constituencies donning the bright orange vests, hardhats, and audio systems needed to hear and be heard over the din of countless conveyer belts and sorting machinery. These include elected officials, business leaders, public-works crews, press members (including BusinessWest), and, perhaps most importantly, representatives of the companies that buy the recyclables — and many of them have made the trip to Berlin.

What they take in is a facility that was built with three primary goals in mind: to increase the quantity, quality, and purity of recyclables; to provide an innovative and safe working environment; and to have the flexibility to adapt to ever-evolving consumer habits (more on that later) and recycling market conditions.

And more than a year after it opened to considerable fanfare, this MRF is accomplishing all three, especially with regard to the purity of recyclables, said both Antonacci and Murray, noting that this is something that communities, states, and those buying the recovered products are demanding.

“Today’s curbside material isn’t what it was 10 or 15 years ago. Then, it was heavy on newspaper and relatively clean. Today, everyone reads news online and orders everything from the internet. Today’s stream is full of small cardboard boxes and shipping envelopes and requires that we, as recyclers, innovate and change our thinking around the sorting of recyclables.”

The fully integrated system, replete with artificial intelligence and high-tech scanners, is dedicated to the maximum recovery of all recyclable material, with several second-chance mechanisms in place to make sure valuable material doesn’t slip through the cracks, said Murray, adding that the design includes state-of-the-art equipment to target paper, cardboard, boxboard, glass, and five types of plastic.

Elaborating, he said the system first separates paper from aluminum and other metals and plastic and then digs deeper to identify and sort different types of plastic, such as the PET (polyethylene terephthalate) used to make water and soda bottles, and HDPE (high-density polyethylene) used to make food and beverage containers, shampoo bottles, cleaning-product bottles, and similar products.

“The optical scanners are trained; they’re learning all the time to know what the makeup of a PET bottle is,” Murray explained. “If a scanner’s job is to pick PET bottles, it knows it by reading the makeup of the bottle. Everything else travels on to the next optical scanner, which may be looking for HDPE or milk jugs or laundry detergent bottles; it scans for those and shoots those out.

“The scanners are actually looking for the makeup of what’s in that material,” he went on. “It shoots a blast of air to kick it out or leave it in, and they’re trained at the factory and adjusted, so if we’re seeing a higher level of PET in the mix than HDPE, we can make adjustments so it will recognize that quicker and make sure we’re getting it all out.”

For this issue, BusinessWest toured the massive facility in Berlin and talked with Antonacci and Murphy about this operation, the evolving recycling market, and how the Berlin MRF redefines what would be considered state-of-the-art in this industry.

 

Leaving Little to Waste

Murray calls it the “Amazon effect.”

That’s a term he and others in this industry use to describe the influence of that giant corporation on life in general — and especially the world, and business, of recycling.

“Today’s curbside material isn’t what it was 10 or 15 years ago,” he noted. “Then, it was heavy on newspaper and relatively clean. Today, everyone reads news online and orders everything from the internet. Today’s stream is full of small cardboard boxes and shipping envelopes and requires that we, as recyclers, innovate and change our thinking around the sorting of recyclables.”

And these sentiments effectively and concisely explain what the All American Material Recovery Facility is all about — innovation and changing how people think about recycling and waste-disposal diversion.

“We took a significant amount of risk and leveraged our expertise, as well as a very strong team, to develop what we have here.”

The facility, and the roughly $40 million invested in it, represent another entrepreneurial venture, and gambit, undertaken by the Antonacci family, which was recognized by BusinessWest as its Top Entrepreneurs in 2018 for their creation of an eclectic and highly successful stable of businesses, with ‘stable’ being one of the operative words.

Indeed, this large and impressive portfolio includes a horse farm, Lindy Farm in Somers, which has bred and trained a string of champion trotters; Sonny’s Place in Somers (named after the patriarch of the family, Frank’s grandfather, Guy ‘Sonny’ Antonacci), a huge and continually growing family-entertainment venue; GreatHorse, the high-end, horseracing-themed private golf club created on the site of the former Hampden Country Club; and Murphy Road Recycling.

All of these ventures represented considerable investments and risks, Antonacci said, adding that the MRF in Berlin is no different.

“You’ll see many of the same themes throughout this facility as you would at our other operations,” he explained. “We took a significant amount of risk and leveraged our expertise, as well as a very strong team, to develop what we have here.”

The company looked at a number of recycling facilities starting in 2018 and made the decision to buy the Berlin facility in 2020, at the height of COVID.

“It was a considerable risk and investment at that point,” he went on. “But we knew that there would be life after COVID, and we believed that the region really needed a reliable, scalable solution to handling the growing amount of single-stream material.”

By single-stream, he noted that recyclables from businesses and consumers come with various materials mixed together, often with materials that shouldn’t be placed in recycling bins but are anyway — from batteries to electronic devices.

This venture represents the expansion and modernization of an existing recycling facility, Antonacci said, adding that everything about the facility is state-of-the-art, a phrase he used early and often in this conversation, because it’s certainly warranted.

“We integrated tried-and-true mechanical separation though screens with optical technology,” he noted as he talked about what is really the heart of this operation. “We have machines that are optically looking at the material to polish any contamination or any mixture of different grades of recycling, and that’s done through highly advanced camera systems with artificial intelligence.”

 

Reading Material

The facility handles recyclables from roughly 100 communities in Connecticut and Western Mass., Antonacci explained, noting that materials from many communities in the 413 are aggregated and then brought to Berlin for processing. Overall, it handles upwards of 1,000 tons of material per day, a huge jump from the 350 tons a day handled by the largest facilities in the area prior to the opening of the MRF in Berlin.

Beyond size and scope, this facility stands out for many other reasons.

Indeed, the operation employs a dozen optical scanners that can identify and separate materials based on their chemical composition, and utilizes robotics and AI to perform additional quality control.

“The quality of the material that we’re able to glean from the blue-bin mix is really remarkable,” Antonacci said. “Leveraging our expertise and that of Van Dyk Recycling Solutions, we’ve moved the industry forward a generation with the design of this plant, based not only on the scale, but on the quality of the materials coming out of here.”

As they were developing the Berlin facility, those at Murphy Road toured a number of recycling operations in this region and other parts of the country, Murray said, with an eye toward adopting best practices and technologies. But there are some things being done here that would be considered unique and groundbreaking, he went on.

This includes a dual-feed system set in parallel lines, Antonacci said, adding that this is a different approach to preparing materials for final processing. Other innovations include the picking stations, where employees handle quality control, which are enclosed in dust-controlled, climate-controlled boxes which place a premium on worker comfort and safety.

“We went through a painstaking effort of keeping people away from places that could harm them,” he told BusinessWest. “We invested heavily in automation to further increase the safety and productivity of the facility.”

Beyond these safety features, the facility was designed to effectively handle ongoing evolution in consumer habits and thus the recycling stream. As he talked about this and pointed to the streams of paper moving along conveyer belts, Murray noted that, despite declines in readership, a large amount of newsprint still winds up in recycling bins.

“We took a significant amount of risk and leveraged our expertise, as well as a very strong team, to develop what we have here.”

But these same bins are being increasingly dominated by both cardboard packaging — that aforementioned ‘Amazon effect’ — as well as myriad kinds of plastic, aluminum, and tin cans.

Overall, the bins are cleaner than they were years ago, he went on, adding that the overall quality of the end product — what is ultimately sold to companies to make new products — is a function of how effectively the different materials, especially the many types of plastics, are separated.

And this is where the All American MRF stands out from other facilities.

Elaborating, Antonacci said this facility’s sorting capabilities extend to polypropylene, used to make everything from yogurt containers to margarine tubs; from Dunkin’ Donuts coffee cups to the packaging for to-go food products.

“This is something that has historically been hard to separate,” he explained. “But we have both the optical technology to look for polypropylene number 5, which those containers are made out of, and there’s also a laser on our optical machine that enables us to see those black plastics — the to-go containers — which most facilities can’t.”

 

Bottom Line

There are ever-larger amounts of polypropylene #5 winding up recycling bins, and the ability to separate it from everything else is becoming increasingly important, said Antonacci, adding that this is just one of the reasons why he and Murray are giving so many tours these days.

People want to see what separates this facility from most others — with the emphasis on separates. It not only represents state-of-the-art in this industry, it defines it.