A Polymer Engineering Company Encore Background Command Packaging - PowerPoint PPT Presentation

A Polymer Engineering Company

Encore Background  Command Packaging recognized that the movement to sustainable packaging was here to stay  Only way to survive long term is to embrace the new world  Corporate initiative to make film products from PCR  Supply of film grade PCR comes from “Recyclers”…

The “Recycler” Model Trash Hauler / Scrap Broker Recycler!

The “Recycler” Model  Primarily in the trash/scrap business  PE is PE…most of the time  Opportunistic buyers = inconsistent sourcing over time  No consideration of physical properties (MFI, Density, Dart, Tensile, etc)  Can only be used as filler

The “Recycler” Model The Encore Model

The Encore Model NOT JUST A RECYCLER – A POLYMER COMAPNY Homogenous Consistent Encore Clean Specialized

Homogeneity SOLUTION CHALLENGE  Sortation?  Hundreds of different  Not feasible for film types of PE  High labor costs  Find source stream that is  Most manufacturers have homogenous and consistent very specific raw  Ag film! material formulations  One grower will typically use one type of plastic for entire  Slightest variances can ranch (sometimes 1000+ acres) cause low output,  When removed, all film has downtime, or product same polymer structure, same additive packages, same sun failure exposure, etc

The Encore Model NOT JUST A RECYCLER – A POLYMER COMAPNY Homogenous Consistent Encore Clean Specialized

Consistency CHALLENGE SOLUTION  Even when a “Recycler”  Find sourcing that is abundant and solidify long can provide a resin that term contracts works once, they can  Estimated 100-150 million rarely reproduce the lbs of ag film discarded same month after month every year in CA alone!  Inconsistent and  Encore factory in the opportunistic sourcing = epicenter of ag film usage inconsistent resin  Long term contracts with many of the largest growers

The Encore Model NOT JUST A RECYCLER – A POLYMER COMAPNY Homogenous Consistent Encore Clean Specialized

Cleanliness CHALLENGE SOLUTION  Ag film is one of the dirtiest sources of scrap in the world  Up to 80% contamination by weight  Compare to other sources of scrap with <10% contamination  Resin must have less than .1% contamination to be suitable for high end applications (i.e. blown film)

Extra Credit If Encore processes 10 truckloads of plastic, and there Plastic recycling is always measured in NET POUNDS . is 10% contamination, how many trucks of contamination have been removed? In order to generate 10 NET TRUCKLOADS of plastic, Encore must recycle 50 truckloads of incoming scrap. 1 Truckload 50 Truckloads Incoming Scrap x 80% = ….. … At 80% contamination? 40 Truckloads!!!! 8 Truckloads

Cleanliness SOLUTION CHALLENGE  Years of R&D  Ag film is one of the dirtiest sources of scrap in the world  Working with world’s best engineers and machinery  Up to 80% contamination by weight  Machinery fine-tuning (and course tuning)  Compare to other sources of  Advanced water treatment scrap with <10% contamination  Proprietary melt filtration  Resin must have less than  Stringent QC policy .1% contamination to be  All resin must pass blown suitable for high end film test at 1 mil using applications (i.e. blown film) 100% PCR

The Encore Model NOT JUST A RECYCLER – A POLYMER COMAPNY Homogenous Consistent Encore Clean Specialized

Specialization SOLUTION CHALLENGE  Hire specialized staff including  Most Recyclers sell PhD in Polymer Engineering “polymer soup”  Understand customer process and needs!  As a manufacturer, if you  Catalogue each input source don’t know what it is then by its properties (MFI, Density, Strength, Color, etc) you can only use it as  Create custom blends of source filler materials to arrive at engineered polymer for  You cannot truly replace specific application important parts of  Compound additives if necessary (i.e. Antioxidant) formulation

Specialization SOLUTION CHALLENGE  Testing. Lots of testing!  Even once sources are catalogued and formulations  Encore implemented a full are developed, variables QC lab that is staffed change 24/7 with technician  QC testing for moisture  Example: Drip irrigation content, MFI, density, and scrap typically made from contamination every 2 MDPE hours  ….but depending on  Even minor deviation from manufacturer and ‘major’ target properties can be supplier, density can be adjusted for with different anywhere from .935 to .950. combinations at front end.

Encore Today  Paradigm needs to ANYTHING THAT RUNS shift 15% Color 3% Octene  PCR does not have to A/B LLDPE 1% 20% be filler Slip 1%  Cheaper, not cheapest  Still, PCR is not virgin  Color  Odor  Gels? HDPE 60%

Contact Information Aviv Halimi 831.296.0080 Aviv@Encore-Recycling.com