DESIGN OF
NSU/VIER ©NMINERS
FOR
  REUSE OR DISPOSX1L


-------
    With the exception of the title page and a few minor changes in the preliminary pages,
this report is reproduced as received from the Battelle Memorial Institute.

    The views expressed in these proceedings do not necessarily reflect those  of the  U.S.
Environmental Protection Agency nor does mention of commercial products constitute en-
dorsement or recommendation for use by the Federal Government.

-------
                          SW3P



Proceedings of the Solid Waste

 Resources  Conference on

      DESIGN OF

   CNSU/MER CNMINERS

      FOR

         REUSE OR DISPOSAL

         May 12 and 13,1971

      This publication (SW-3p) reporting on papers
 presented at the seminar co-sponsored by
        Battelle Memorial Institute  -
             Columbus Laboratories
       and the U.S. Environmental Protection Agency
     was compiled by George F. Sachsel.
    U.S. ENVIRONMENTAL PROTECTION AGENCY
                1972

-------
     An environmental protection publication in the solid waste management series (SW-3p)
published jointly by two components of the U.S. Environmental Protection  Agency — the
Office of Solid Waste Management Programs (Washington) and the National Environmental
Research Center  (Cincinnati).
           For sale by the Supeiintendent of Documents, U.S. Government Printing Office
                            Washington, D.C. 20402 - Price $1.75

-------
                            FOREWORD





       One of the characteristics of an affluent society is the




exploitation of natural resources to produce and distribute to




most of its citizens an overwhelming diversity of products, most




of which eventually end up as solid waste.  Because of a variety




of factors—most of them related to population growth, urbaniza-




tion, and affluence—the mere disposal of this solid waste, be it




by sanitary landfill or a combination of incineration and sani-




tary landfill, is becoming more costly.




       The increasing diversity and complexity of the many com-




ponents of solid waste has posed problems not only in disposal




but in reclamation as well.  This Solid Waste Resources Conference




attempted to address itself to the disposal and reclamation of a




segment of solid waste that has been growing more rapidly than




the rest—consumer containers, or packaging.  Among the many




possible responses that might alleviate the impact of this seg-




ment is design of consumer containers to facilitate their reuse




or disposal.  Several of the speakers at the conference addressed




themselves to this specific topic, ranging from the package de-




signer's viewpoint to research reports on "self-disposing" con-




tainers.  Some questioned the concept from standpoints of




marketing demands or particular resources considered renewable.




All of the speakers addressed themselves to one or more aspects




of the reuse or disposal of packaging materials.  The conference




was also characterized by a wide representation, both among the




speakers and the audience.  Dialogue among members of industry







                               iii

-------
and commerce, academic institutions, Federal and local govern-

ment, private-citizen groups, and communications media yielded

some potential solutions and identified a number of problems.

       The main achievements of the conference may well have

been that we developed an appreciation of the complexity of the

problems and of the need for a multidisciplinary attack in the

broadest sense—an attack calling for the efforts not only of

scientists and technologists but of members of almost all seg-

ments of society.  It is the intent of the cosponsors to hold

similar solid waste resources conferences on selected topics

at approximately 2-year intervals in the belief that the inter-

action of many segments of society may be the best approach

for turning problems into opportunities.
                              —GEORGE F. SACHSEL
                                Technical Program Coordinator
                                Solid Waste Resources Conference
                                IV

-------
                                   PREFACE

     This volume is based on a symposium held May 12 and 13, 1971, in Columbus, Ohio.
Each  of the  four parts  of these  proceedings,  corresponding to  the  sessions  of the
symposium,  brings  together  current knowledge   and  thinking in  the  disposal  and
reclamation of consumer containers.

     The symposium  was sponsored  by the division of research and development of the
solid  waste  management  program,  U.S. Environmental Protection  Agency, and  the
Battelle-Memorial  Institute's Columbus Laboratories. The research function of the solid
waste program has since been assigned to EPA's National  Environmental Research Center
in Cincinnati.

     The concept  of national environmental  research centers  brings  to  the total
environmental problem the combined  technological expertise of laboratories that formerly
focused only on one particular aspect of the environment. The Center in Cincinnati, one of
three  in the  country, is  presently organized into  four major areas for research—air
pollution, water pollution, radiation, and solid waste.

     There were many who contributed to the success of the symposium. To all of them
we are grateful and express our thanks.


                                     Andrew W. Breidenbach
                                     Co-Chairman, Solid Waste Resources Conference
December 1971

-------
                         SYMPOSIUM COMMITTEE
A. W. Breidenbach, Director, Division of Research and     Co-Chairman
  Development, Solid Waste Management Office,
  U. S. Environmental Protection Agency

C. A. demons, Chief, Reclamation Branch, Division of
  Research and Development, Solid Waste Management
  Office, U. S. Environmental Protection Agency

L. W. Lefke, Deputy Director, Division of Research
  and Development, Solid Waste Management Office,
  U. S. Environmental Protection Agency

C. J. Lyons, Manager, Department of Biology,            Co-Chairman
  Environment, and Chemistry, Battelle's
  Columbus Laboratories

D. L. Morrison, Manager,  Environmental Systems and
  Processes Section, Department of Biology,  Environ-
  ment, and Chemistry, Battelle's Columbus
  Laboratories

G. F. Sachsel, Director of Solid Waste Programs,
  Environmental Systems  and Processes Section,
  Department of Biology, Environment, and
  Chemistry, Battelle's Columbus Laboratories
                              SESSION CHAIRMEN
SESSION I - OVERVIEW
  A. W. Breidenbach, Environmental Protection Agency

SESSION II - PLASTICS, COMPOSITES AND PAPER
  J. H. Lindholm, Battelle's Columbus Laboratories

SESSION III - GLASS CONTAINERS
  C. A. demons, Environmental Protection Agency

SESSION IV - METALLIC CONTAINERS
  G. R. Smithson, Battelle's Columbus Laboratories

-------
                         TABLE OF CONTENTS

                                                                 Page No.

SESSION I - OVERVIEW

    Packaging and Solid Waste Management	      1
         Hugh H. Connolly
    Recycling — Status and Opportunities	     16
         M. J. Mighdoll
    Packaging and Environmental Protection	     30
         Joseph M. Murtha
    Packaging for Food Systems of the Future	     49
         Norman  A. Vanasse

SESSION II - PLASTICS, COMPOSITES AND PAPER

    Incentives for the Recycling and  Reuse of Plastics	     69
         Jack Milgrom
    Thermoplastics in Waste Recycling	     94
         K.  L. Burgess
    Polytrip®, the Returnable Plastic Milk  Bottle System	    109
         Karl H. Emich
    Reclamation of Plastic-Paper Composites	    121
         Safford W.  McMyler
    Paper Industry Plans	    135
         Judd H.  Alexander

BANQUET

    Keynote Address:  Incentives for Reuse and Disposability  ....    155
         R.  L. Lesher, National Center for Resource Recovery, Inc.

SESSION III - GLASS CONTAINERS

    Design Trends in Glass Containers	    171
         Richard L.  Cheney
    Re-Using Scrap Glass	    185
         Ward R.  Malisch, Delbert E. Day, and Bobby G. Wixson
    Techniques for Self-Disposal	    210
         Samuel F. Hulbert
    Composite Bottle  Design and Disposal	    231
         Philip Williams
    Separation of Glass From Municipal Refuse	    244
         J. H. Abrahams, Jr., and R.  J. Ryder

-------
                        TABLE OF CONTENTS
                             (Continued)

                                                             Page No.

SESSION IV - METALLIC CONTAINERS

    Ferrous Scrap Recycling and Steel Technology	   263
        William S. Story
    Metallurgical Aspects of Reclaiming Container Scrap	   271
        H. V. Makar and H. S. Caldwell, Jr.
    Recovery and Utilization of Aluminum From Solid Waste  ....   295
        R. F. Testin, G. F. Bourcier, and K. H. Dale

AUTHOR INDEX	   317

LIST OF ATTENDEES	   321

-------
 SESSION I

OVERVIEW
             Chairman:

             A. W. Breidenbach, Director
             Division of Research
             Office of Solid Waste Management
             U. S. Environmental Protection Agency

-------

-------
            PACKAGING AND SOLID WASTE MANAGEMENT
                        Hugh H. Connolly
               Office of Solid Waste Management Programs
                   Environmental Protection Agency
         The growth of packaging in the United States has been

a phenomenal one.  It began during the period of the industrial

revolution with the development of such items as the metal

can, the collapsible tube, and the folding carton.  During

the period between 1900 and 1930, flexible packaging was

born through the introduction of such items of kraft paper,

cellophane, and aluminum foil.  During the ensuing  search

for development of new packaging materials, there began a

flood of packaged products that has never stopped growing in

volume or variety.

         Along with this growth has come a great deal of

inventiveness, well documented by such achievements as the

flip-top box, the pull-ring can, the push-button aerosol,

the spray-on bandage, etc.  There is no doubt that  this is

truly the era of "convenience packaging."  However, these

accomplishments in growth and inventiveness are also accompan-

ied by a sizeable growth in contribution to the solid waste

load.

         For example, in 1966, 52 million tons of packaging

materials were produced and sold  in the United States.  Of

this massive tonnage—made up of many billions of individual

units, most of them weighing much less than a pound each—

about 90% entered the stream of solid wastes that had to be

disposed.  This figure was well above the 1958 packaging

materials consumption of 35 million tons, and well  below the

                               1

-------
expected 1976 consumption of 74 million tons.




         Packaging is increasing in quantity much more rapidly




than population.  Per capita consumption of packaging materials




was 404 pounds in 1958, 525 pounds in 1966, and is expected




to be 661 pounds by 1976.  Many factors underlie this dramatic




increase, but chief among them is the continuing rise of self-




service merchandising, creating a growing need for packages




that sell the product without the help of a sales clerk.




This accounts for much of the quantitative increase.  Qualita-




tive changes will be brought about by the need for improved




product differentiation by packaging methods, the rise of




many new food products which call for unique packaging, and




the vastly expanded choice in materials provided the package




designer by the advent of plastics and other relatively new




packaging materials.




         These packaging materials are made  principally




of paper, glass, metal, wood, and plastics, with the last-named




being the most recent contestant in the field and the fastest




growing.  It is anticipated that by 1976, paper and board




will continue to dominate the packaging field with 57% of the




total on a tonnage basis.  It is further estimated that glass




will have 18% of the total, metals 13%, wood 7%, and plastics




5%.




         It is significant to note that, of  the 360 million




tons of  residential, commercial, and  industrial solid wastes

-------
generated today, approximately 13% is discarded packaging




material.  In a typical year, Americans throw away 48 billion




bottles, 4 million tons of plastics, and 30 million tons of




paper.  The very strong relationship between packaging waste




and the peculiarly difficult problem of roadside littering




has been well established by several surveys.




         Nearly all the States in our country have enacted




anti-litter laws which provide for both fines and imprison-




ment for the violator.  However, these laws are very ineffec-




tive, for the violator is seldom apprehended.  The ultimate




solution to the litter problem will come only with successful




educational programs designed to enlist public cooperation




and citizen pride.




         Of packaging materials being consumed today, approx-




imately 50 million tons are being discarded as waste;  only




about 10% are being returned for reuse or reprocessing into




new products.  Collection and disposal of this tonnage is




costing the nation in excess of $450 million.  Assuming no




increase in the unit costs of collection and disposal, which




is highly unlikely, expenditures toward this end for packag-




ing materials is  expected to stand at nearly $600 million




in 1976.




         It has become perfectly clear that steps must be




taken to mitigate the problems created by packaging materials




in waste management.  Where it is feasible to do so, we must




                               3

-------
reduce the destruction of valuable natural resources from




which packages are made.  In all cases, we must reduce the




technical difficulties involved in processing packaging wastes.




          In a report* prepared for our Office by the Midwest




Research Institute, five potential mechanisms were discussed




as possible avenues to the mitigation of these problems.




These mechanisms are:   (1) regulation, (2) taxes, (3) incen-




tive and subsidy programs, (4) educational efforts, and (5)




research and development.  I would like to look briefly at




each of these in turn.




          Regulation, as herein used, means any legislative




measure enforced by the executive arm of the government which




imposes some action on package materials producers, packagers




and/or users.  Midwest Research Institute concluded that




regulation of packaging would be the most effective mechanism




to accomplish the objectives, though it may be a difficult




one to justify.  Given the tremendously complex nature of




packaging, regulation,  to be effective, would tend to embrace




all activities directly and indirectly concerned with packaging.




The costs of such a program appear to be potentially greater




than the benefits that may be expected.




          Let's look  at plastics, for example, which, in ad-




dition to their rapid growth, are permeating the entire pack-




aging field.  Why not legislate against the use of plastics in
 *  The Role of Packaging  in  Solid Waste Management—1966-1976.

-------
any form of packaging materials?  How would this affect us in




our daily lives?  We could go back to buying milk in glass




bottles which would be returned to the store or be picked




up by the dairy which delivers to our doors, rather than have




the convenience of the plastic-impregnated paper cartons.  We




could get along without the plastic bottles and tubes contain-




ing shampoos, hair dressings, toothpaste, cosmetic items,




medicinals, etc. that we use so many of, and go back  to the




glass and metal containers that were previously used for this




purpose.  It might be less convenient, and perhaps more costly,




but we could do it.  We could dispense with plastic-impregnat-




ed paper for frozen goods, too, and either buy all such food




products in cans or, in the cases of fruits and vegetables, in




their fresh form when they are in season.  There may be times




of the year when we couldn't eat the things we like, and we




may have to sacrifice a little taste quality here and there,




but we could make out.  Meat packaging may have to go down




the drain, and the old-fashioned butcher may well be back in




style, but we could live with that.  Many children's toys




would have to be done away with, or be made of more expensive




materials, but kids have too many toys anyway and could get




along with much less.




     Everything I have suggested here says "go back"—go back




to the old ways of doing things.  It means giving up those




many conveniences that have become so much a part of our way




of life—those things that have been made possible by the





                              5

-------
great advances in the technology of plastics production.  Is




this what we want to do—to return to the technology of the




1930's?  Is this the only alternative we have available?  I




say emphatically no!  The technology that produced these




conveniences can, I feel certain, likewise solve the environ-




mental problems caused by them.  I believe we can, in this




case, "have our cake and eat it."




          Under the heading of taxes, two types are discussed




—a use tax, imposed on all packages, and a deterrent type




tax selectively imposed on specific materials.  A packaging




use tax would not directly result in reduction of package




material use, reduction of processing difficulty, or in




elimination of destruction of natural resources.  It would,




however, create the economic wherewithal for the processing




of these wastes.  Justification of a use tax would be easier




than justification of a deterrent tax.  For maximum effective-




ness, however, a packaging use tax would call for extensive




administrative machinery.




          Take, for example, the packaging tax recently pro-




posed by New York City's Environmental Protection Administra-




tion to be collected at the wholesale level on all types of




packaging materials.  This would be a graduated tax based on




an evaluation of the difficulty of disposal of each major type




of material.  Whereas glass bottles would be taxed at 1.3C per




unit, plastic bottles would be taxed at 2.0c per unit.  Steel




cans and aluminum cans would be taxed at 0.5o per unit  and





                               6

-------
0.250 per unit respectively.  Other packaging materials made




of paper would be taxed at 2.3C per pound, and plastic packa-




ging would be taxed at 3.8c per pound.  To me, this sounds




like an administrative nightmare.




          A deterrent type tax would be limited in effective-




ness.  Such a tax would of necessity be discriminatory since




it would be imposed selectively.  A deterrent tax serves, in




effect, as a form of indirect regulation.  Direct regulation




is probably more desirable.




          Various forms of incentives have been used by the




Federal government for decades to achieve desired objectives.




Incentives, as herein used, would be any expenditures of tax




receipts made by the government, or use of the government's




purchasing power, to bring about changes in packaging mater-




ials use or reuse.  Expenditures could be either direct (sub-




sidies, grants, price supports) or indirect (tax credits).




For example, the Federal Government, as one of the largest




purchasers and users of packaging materials, could formulate




regulations banning purchase of non-returnable beverage con-




tainers.  Tariffs on certain imported materials might be




increased thus encouraging a switch to other materials.  De-




pletion allowances for certain mineral resources might be




reduced, thus encouraging heavier reuse of these resources.




Any such potential incentives should be subjected to close




study and scrutiny before being put into effect.  Blind action




could do more harm than good.






                              7

-------
          Two contracts were recently awarded by our Office to




carryout some of the essential economic studies recommended.




The first is for a "Study of the Incentives for Plastic Re-




cycling and Reuse".  Its objectives are to: (1) develop a




number of complete strategies to be applied to the total




system to improve recycling and reuse;  (2) evaluate each




strategy from a systems approach, taking into consideration




the probability of success, administrative problems, legal




constraints, and economics; and (3) select the best strategy.




          The second is for a "Study of the Incentives for




Tire Recycling and Reuse".  Its objectives are basically the




same as those for the plastics contract.  It is anticipated




that similar studies will be carried out relating to paper,




glass, metals, organics, etc., or studies might be more




specifically aimed at such items as junk automobiles, beverage




containers, etc.  Having a detailed picture of the economic




situation before us, it will be much easier to make rational




recommendations regarding use of incentives and/or disincen-




tives.




          Educational programs discussed by Midwest Research




Institute are directed at three groups—industry programs,




consumer education, and intra-government information programs.




Basic to all of these is the assumption that one of the con-




straints to action on the part of those involved is unfamil-




iarity with the problems created by packaging.  Once the




problems are fully understood, voluntary action to mitigate

-------
them may be forthcoming.  This assumption is certainly opti-




mistic but, to a degree, sound.




          Educational programs aimed at both industry and con-




sumer groups ai.e being carried out by such organizations as




Keep America Beautiful, Glass Container Manufacturers Insti-




tute, National Educational Television Network, and others.




Our office is supporting educational efforts both through




extensive publication of its work and film documentation of




its more successful projects.  We hope to expand these efforts




in the near future.




          The research and development mechanism is certainly




a key factor in the reduction of difficulty in processing




waste packaging and in promoting reuse and recycle of packag-




ing materials.  Three types of research and development are




possible:  (1) research on materials and containers; (2)




research devoted to improving salvage and reuse; and (3) efforts




aimed at improving disposal technology.




          Midwest Research Institute concluded that materials




research does not offer foreseeable near-term success, but if




sufficient resources are devoted to this area, perhaps the




picture can be changed.  A few projects of this nature have,




hopefully, set the tone for future endeavors.  We are all




aware of the two new plastic materials for beverage containers




known as  "Lopac" and "Barex 210" which are being test-marketed




by Coca Cola Company and Pepsi-Cola Company, respectively, as




substitutes for polyvinyl chlorides.  These, along with a third





                              9

-------
such material—XT polymer—offer similar characteristics with




regard to gas permeation resistance, transparency,  inertness,




and rigidity for which acrylic plastics are noted,  and suita-




ble for the same general uses.




          Most of you are sware, too, of the work going on at




the University of Toronto in Canada and the University of




Ashton in Birmingham, England, with regard to development of




a biodegradable plastic.  These efforts involve the use of




"sensitizer groups" in the polymer chain which have the prop-




erty of absorbing the ultraviolet light of the sun and using




this energy to break the polymer chain, thus causing brittle-




ness and susceptibility to attack by microorganisms.  Though




these efforts may not yet be considered major break-throughs




in materials research, they are indications that progress is




being made.




          In this same area of materials research, a Solid




Waste Management Office grant to Clemson University, South




Carolina, is supporting research to develop a one-way contain-




er made basically of a water-soluble glass that may be dis-




solved after the container is emptied.  The Project Director,




Dr. Samuel Hulburt, will be discussing the details of this




project later in the conference.




          The Solid Waste Management Office supports a number




of projects devoted to improving both salvage and reuse and




disposal technology.  For instance, Stanford Research Insti-




tute was engaged to determine the technical feasibility of an






                              10

-------
air classification process to separate non-homogeneous dry




solid waste materials.  A pilot air classifier has been con-




structed for separating five such materials.  This unit




operates on the principle that a sufficient velocity of air




passing upward through the mixed wastes will achieve separation




as a function of particle size, configuration, and specific




gravity.




          A wet pulverization system designed to reclaim fibre




from municipal refuse has been developed and is now under




demonstration on a pilot-scale system.  In this system, the




incoming solid waste is dumped into a storage hopper from




which it is fed continuously into the hydrapulper where, through




a pulping action, it is forced through 1/2 inch holes.  Heavy




inorganic materials are removed by a bucket elevator.  The




pulped material passes through a liquid cyclone to separate




heavy materials such as dirt, glass, and small bits of metal.




The remaining organic material passes to a series of screens




which progressively concentrate the paper fibre.  It is es-




timated that 200 tons of paper fibre, 80 tons of ferrous




metals, and 80 tons of glass cullet would be reclaimed from




each 1000 tons of solid wastes.




          At Louisiana State University, a pilot plant has




been designed which is successfully turning cellulose  (bagesse)




into single-cell protein.  The development of the pilot plant




followed the discovery of LSU scientists of a microorganism




that breaks down waste cellulose into protein.  Additional





                             11

-------
work is being conducted to refine processing techniques and




analyze the protein products for digestibility and nutritional




value.




          It has been demonstrated that waste glass can be




used as an aggregate in bituminous mixtures for street mainte-




nance and paving.  Glassphalt, the name given this mixture,




has the potential of solving urban glass waste disposal




problems.  The Project Director, Dr. Ward Malisch, will be




discussing the details of this project later in the conference.




          Where do we go from here?  It is quite obvious to




me that the role of packaging, which has had such a meteoric




rise, is not about to decline.  We are all fully aware of the




part played by packaging as both a marketing tool and a major




contributor to profitability.  It is practically assured that




packaging is destined to play even a bigger and more impor-




tant role in the years ahead.  There is fair evidence, for




instance, that automated supermarkets will become a reality




of the 1970's, with pallett loading stocking of shelves and




automated checkout.  Packaging techniques will play a key role




in these developments if they are to succeed.  Another area




likely for development is portion-packaging for single servings




in countless products, food and non-food, as more individuals




in the family lead their own busy lives and want no-fuss meals




on the run.




          In view of this, then, what action must the Federal




Government take during the 1970's to eliminate future problems





                              12

-------
caused by packaging wastes/  There are many paths open to it,




some of which have been suggested in the form of legislation




introduced for consideration.  It could restrict production




of certain packaging materials, ban no-return beverage contain-




ers, impose severe disposal taxes on all packaging materials,




etc.  Or it could lead the way in assuring new developments




in packaging which will allow our continued use of these




materials at the desired levels without future injury to the




environment.




          The recently enacted "Resource Recovery Act of 1970"




gives a good indication of the route the Federal Government




will take.  This Act provides funds for extensive research




toward:  uses and outlets for recovered wastes;  modification




of product characteristics to enhance recycling;  improved




collection, separation, and containerization;  use of Federal




procurement to develop market demand for recovered resources;




incentives and disincentives to accelerate reclamation of




resources;   effects of existing public policies upon the




recycling of materials; and the necessity of imposing disposal




charges on packaging, vehicles, and other manufactured goods.




The Act also provides funds for demonstrating resource




recovery systems, improvements in such systems, and related




technology.  It is clear that the Federal Government expects




to find solutions to the problems by routes other than restric-




tive legislation against the source materials if at all pos-




sible.






                              13

-------
          However, though we feel the Federal funding related




to problems of packaging waste may well yield beneficial




results, it is not enough.  The industries that produce pack-




ages and packaging materials must shoulder part of the respon-




sibility for financing research to devise packages that are




compatible with recovery and disposal processes.  We can no




longer tolerate the attitude taken by some that industry's




responsibility is solely that of providing consumer items to




the American public which are aesthetically pleasing, efficient,




durable, and at lowest possible cost, and that disposal of




these items after use is solely the responsibility of the user.




When new packaging products are developed, the developing in-




dustry must consider waste management problems in addition to




the items of durability, consumer appeal, and economy.  For




products that are on the market today, methods for recovery,




reuse, and/or ready disposability must be devised.




          We believe that it will not be necessary to make a




drastic change in our mode of living away from the trend of




convenience packaging and "throw-Away" habit.  However, we




will have to look closely at packaging of various types to




determine if the materials used have sufficient present or




potential value as candidates for recycling processes.  As




the earth's available resources dwindle, the acceptability of




convenience packaging may be governed  by a different set of




priorities.  Certainly, we must find the appropriate recycling




or disposal mechanism for each material.




                              14

-------
          Hopefully, this conference will provide some of the




answers necessary to moving us along the correct path toward




our eventual  goal.
                              15

-------
           RECYCLING - STATUS AND OPPORTUNITIES
                        M. J. Mighdoll
          National Association of Secondary Material Industries
          Recycling—a word not even  to be  found  in many

dictionaries and encyclopedias—has suddenly become a house-

hold term.  Recycling—an age-old science of utilizing waste

materials—suddenly is "discovered".  Recycling in just a

period of months, has been embraced by environmentalist and

industrialist, by politician  and educator.

          And well this might be the  case.  .  . for recycling

is the most constructive response we  have yet developed to

answer the challenge of environmental management... to cope

with the mounting piles of solid waste building in direct

proportion to our population  growth and industrial produc-

tivity.

          Today, I have been  asked  to speak on the present

status of recycling and its future  opportunities  .  .  . and

to specifically  relate the present  and  the  potential  to

containers.  Interestingly enough,  the  challenge  of  this

effort is not in describing the  present  status  of recycling

or in projecting future opportunities for  it.  The  challenge

lies in  defining and undertaking the  actions that will be

needed to close  the gap between  recycling  concept and recycl-

ing reality.

          I am  sure that  there  are  few  in  this  room that  need

to be  reminded  of  the  horrors of solid  waste.   There  have been

enough doomsday pictures  and  literature,  enough  statistical

evidence that solid waste is  indeed as  fearsome  a pollution

                              16

-------
menace as that related to air and water.




          And if we accept the seriousness of the solid waste




problem—if we have studied that problem at all—we know that




containers—packaging of all types—represent one of the most




serious sources of solid waste.  The soap box, the milk




carton, the shipping case, the soda bottle, the beer can,




the plastic bubble—we've seen them all in the pollution




pictures and analyzed in the statistical surveys of solid




waste.  Yes, America, the discarded container is there . . .




it is solid waste enemy No. 1 ... it is a victim of our




own modern society ... it must be captured and controlled .




. . but how?




          Are there many among us who would seriously suggest




we ban the can?  That we abolish the container?  That we




legislate the package into extinction?




          No, if we are to be realistic—and if we desire to




deal effectively with the solid waste problem today and in




terms of the affluence and sophistication of our society, then




we must certainly accept a few critical facts.




          We must accept the fact that solid waste, however




much we minimize its quantitative growth through organized




effort, cannot be planned out of existence.  Solid waste will




always be produced as a corollary of industrial production




and life itself.  It can, however, be qualitatively control-




led.  Recyclability can be introduced as a public mandate;




industrial production need not be conditioned solely on





                             17

-------
marketability.




          Secondly, we must accept the fact that solid waste




materials must be thought of in affirmative and constructive




terms, not negative ones.  We must acknowledge that burning




and burying waste comes after efforts are made to utilize




it, not before.  We must, in short, establish our priorities




correctly—and that would certainly seem to dictate a much




greater orientation to recycling, not disposal, activities




and incentives.




          Thirdly, we must accept the fact that recycling




is not an act of magic.  It holds no miraculous power that




transcends the laws of economics.  We must, therefore, agree




that recycling, the utilization of solid waste, requires and




is entitled to the strongest and most comprehensive economic




support we can give it.  In oversimplified terms, every ton of




solid waste that can be recycled is a ton of new raw material




recovered with a profit factor, not a ton of waste to be




disposed of at a substantial cost and with a resulting loss




of natural resource conservation.




          Therefore, if we will accept these hard facts of




life, we can only come to one conclusion:  that recycling as




a positive and primary response to the solid waste problem




must be given  a new set of conditions.  Recycling must be




encouraged through every economic, technological, legislative,




and psychological means at our command.
                             18

-------
          This alone represents a reversal of priorities.  Our




history unfortunately has been one that either ignored the




role of recycling or—even worse—permitted the construction




of economic roadblocks and disincentives to waste utilization.




          Thus—as we take a look at the status of recycling,




we are truly looking at an amazing industrial phenomenon . .  .




One that occurred on the dark side of this planet, such was




the lack of public or governmental concern, except for a few




wartime years .  . .  one that occurred purely as a result of




economic need, for there was no ecological urgency, no




national concern with dwindling natural resources throughout




the past decades.




          Truly an amazing phenomenon . .   . here is the




recycling industry today:  supplying more  copper and lead




each year than is mined from our country's soil . . .  provid-




ing a third of the nation's aluminum, a fourth of its zinc,




a fifth of its paper.




          For a number of decades, the secondary materials




industries in this country have been recycling metals, paper,




textiles, rubber, glass—hundreds of recoverable materials.




It all began with a scattering of small businesses, which




have since grown up in this century.  They matured, develop-




ing highly complex techniques and sophisticated processes.




They invested in new technology and volume-oriented equipment,




expanded research facilities, found new market outlets.  They




built a major industry, one which today operates at an $8





                             19

-------
billion level annually.




          The recycling industry was there ... in those




"dark" years, when its contributions to the economy were




cloaked in anonymity . .  .  when it was not commercially




advisable to say "rag content" paper—so we had "cotton




fiber content" . . .  when it was more discreet to say "wood




pulp substitute", not "waste paper".




          The recycling industry was there ... in the un-




fortunate wartime years,  when it led great national efforts




to reutilize materials in short supply. . . when it taught




new lessons in economics and technology to those who said




"it can't be done".




          And here it is in 1971 .  . . having not only




survived the hot-and-cold attitudes of an illusive public,




the cyclical now we need you-now we don't policies of




manufacturing industries, and the less than consistent policy-




making of Government.




          Yes, here it is—alive and well in 1971—but now




challenged to perform a role of mountainous proportions, as




big as that very solid waste mountain we've had so dramati-




cally pictured for us.




          But this present status of the recycling industry




—and the present conditions under which it operates—cannot




be expected to single-handedly win  the new war on solid




waste.  The "discovery" of recycling is one thing;  under-




standing and effectively applying it to the whole solid waste





                             20

-------
spectrum is something else.




          "Recycling" is such a simple word.  But how com-




plex it is in terms of the economic-technological inter-




relationships it involves.  How complex it is in terms of




consumer purchasing habits, in terms of the kind of legisla-




tive turn-arounds that are needed.  If only one thing has




become obvious to those recently initiated into the world of




recycling, it is that "recycling" is not synonymous with




"collecting".  They soon learned that recycling is directly




linked to our ability to utilize increased quantities of




recycled material in existing markets and a broader range of




products—and that this recycling expansion is itself linked




to a new set of conditions .  . . some "new rules" in economics,




new technological developments, new thinking in government




circles, new attitudes on the part of the consuming and




waste-generating public.




          There are no short cuts, no curative or preventive




pills.  The answer to transcending from present status to




future opportunities lies in change . . . the kind of change




that will promote recycled materials use, not more virgin




supplies . . . that will favor use and reuse, not use and




discard . . . that will encourage a constructive public




response and thus initiate purchasing habits that will




trigger industrial action in the form of new raw materials




use policies.

-------
          Since paper constitutes the largest single element
in solid waste, it represents a revealing case in point.
Let's look at waste paper—the tens of millions of tons of
it that are discarded each year—a large percentage of which,
perhaps half, comes from packaging .  . . containers of all
types and sizes.
          What has happened in this paper container field is
astounding—and it represents the best evidence for the
change that is essential to successful recycling of this solid
waste.
          In the decade of the Sixties, the use of paper by
every one of us grew at an unprecedented rate.  Led by  the
packaging field, paper use by 1970 hit a peak of 500 pounds
per person a year.  We thus reached a new peak in production
and a new low in recycling .  . . because while we Americans
used 58 million tons of paper—the largest amount ever—we
recycled less than 20% of it  ... in fact, almost down to
half the percentage rate for recycling during the 1940's,
when there was  a much lower total volume of paper produced.
In short, we have been guilty of double jeopardy  ... we
use at the highest rate in the world, and recycled at
proportionately the lowest.
          What  is even more revealing is the  raw materials
use policies of the paper  industry.   In those same ten  years
of the Sixties, the rate of virgin pulp use outpaced  that of
waste  paper  at  a  3 to 1 ratio.   Where waste paper had
                              22

-------
supplied 26% of the total raw material furnish of the paper




and paperboard industry in 1960, it was down below 20% by 1970.




          Look at the paperboard industry, where containers




are manufactured.  This segment of the paper industry has




traditionally represented the largest single market for waste




paper, and especially the bulk grades found in municipal




waste.  In I960, about 42% of all containerboard was made




from "combination board"—that made largely with recycled




fibers.  By 1970, this important market had decreased to a




28% level.  In other words, in the short space of ten years,




the largest single outlet for waste paper had shrunk by one-




third.




          More production, greater use, larger waste generat-




ion—but less recycling.  Certainly not a desirable situation;




certainly a recycling status in need of change.




          Look at other fields involving containers.  Look at




aluminum, where the production of aluminum cans increases




annually, with little regard for economically viable or




technically feasible recycling.  Metallic containers—with




all the convenience of a design engineer's imagination can




create and a production line can produce.  Marketability,




not recyclability, is the motivation—and so we have bimetal-




lic containers which defy effective reuse.




          On and on could go the examples indicative of a




lack of concern with the recyclability of containers or the




use of their recycled elements in new products.






                             23

-------
          And yet containers can be recycled.   They can be a




new material resource, not a solid waste or litter problem.




Let's go back to our paperboard container example.  Corrugated




containers and other paperboard cartons can be recycled




directly into new containers and packaging products.  In




fact, a large percentage of municipal waste consists of such




containers.  And, on the other hand, a large market exists




for new containers.  The obvious question then is:  why isn't




a larger percentage of these recyclable materials used as




new raw material furnished by the paperboard industry?




          And that question, gentlemen, brings us to that




gap I spoke about at the beginning of this presentation.




That gap—the difference between the status of recycling




today and the potential it can have—must be the focus of




our attention.  The ultimate success of recycling in




responding effectively to the solid waste problem is depen-




dent on the steps that are taken—not talked about—to permit




the recycling opportunities that are possible.




          These opportunities we envisage can only become




reality with the changes to which I refer.  We need changes—




some basic, and perhaps radical, changes in our thinking.  We




need changes in psychological attitudes among consumers about




the value of products made with recycled materials  .  .  .




changes in Government policies relating to purchasing speci-




fications that discriminate against recycled materials  .  .  .




changes in industry attitudes regarding responsibilities  in




                             24

-------
balancing recycled and primary materials usage .  .  .  changes




in attitudes by well-intentioned citizens, who see in the




act of collection of waste materials the cure-all solution to




the solid waste problem .  .  .  changes in tax laws that favor




primary resources industries and thus serve to impede the




economics for recycling.




          Some of these positions are so ingrained that it




will take a concentrated effort to revise them.  But  we must—




for change is imperative if  we are to translate our success




in utilizing industrially generated waste to successful




recycling of packaging products on a public level.




          The urgency of removing biases and prejudices and




installing incentives is critical to successful recycling.




Isn't it surprising that the Federal Government—the  largest




single generator and seller of waste materials—still pro-




hibits or limits the use of recycled materials in many of




the products it purchases?  Doesn't it amaze you that we




demand solid waste collection and more recycling in our




cities—and then construct municipal regulations that remove




the companies equipped to do this from the urban community?




la it not incongruous that we consumers discard a box, a




package, a container—and yet do not direct our new purchase




power toward products that use these materials again?




          For too long we have lived with a philosophy based




on limitless natural resources.  Now we know better.   New




concern—concern with both our environment and the limitations




                             25

-------
of land and trees—has bred some new thinking.  We are now




experiencing the first positive steps to close that recycling




opportunity gap.  The needed turn-around is now underway—




and it is already visible in the declared actions of Govern-




ment, the public, and industry.




          It is visible in New York—where back in February




Mayor John V. Lindsay declared: "the deck is stacked against




the recycling industry.  We must end it now.  We intend to




redesign our entire purchasing system to include a preference




for recycled products".  And in these last weeks, New York




City became the first to actually buy some of its products




with a required recycled materials content in their




specifications.




          It is visible in Washington, where the General




Services Administration and other Federal procurement agencies




are responding  to President Nixon's directive—a directive




that called for a "reversal of the trend".




          It is visible in industry—where company after




company, sensing the will of the public—is orienting purchas-




ing policies to recycled materials.




          It is this kind of action that will broaden the




markets for recycled materials and create the favorable




economic conditions that will  in turn broaden the recycling




horizon for containers.  It will also expand technological




development, because it is only with a favorable economic






                              26

-------
atmosphere that technical study and research effort will be




undertaken.  And it is important that such research be initia-




ted;  it will lead to greater adaptability of recycled raw




materials to a larger range of industrial products ... it




will bring about truths, instead of myths, relative to the




performance standards of products made with recycled materials.




         Ahead are studies of this country's tax structure,




which presently encourages the harvesting of trees—at the




direct economic disadvantage of waste paper . .  .  which




presently makes it more profitable to use virgin wood pulp




rather than recycled containers.




         Ahead are more comprehensive policies linking what




municipalities generate as solid waste and that which they




purchase as new  raw materials and products . . .  linking what




industries manufacture as products and that which can be




recycled . . . linking this country's future raw materials




policies with environmental and conservation realities.




         Ahead is a new wave of public concern ... a public




response that will represent a demand factor as great as any




consumer reaction we have known.  The public has been in an




informational vacuum:  it has had a poor understanding of the




dimensions of the solid waste problem or the options open




to the public sector through recycling.  My Association has




taken a leadership role—and I am pleased that we are now




being joined by Government, environmental, and other industry




                              27

-------
groups—to inform the public.   In view of the social cost of




present solid waste management, and the added burden the




future portends,  can there be any doubt that the public




deserves the facts? . .  .  and the opportunity to respond




through a recycling purchasing orientation?




         Ahead lies stronger municipal and state action . .  .




and here we must hope the logic, not hysteria, is in command.




We must exert efforts to evolve the kind of regulations which




will advance solid waste utilization, not impede it.  Premature




packaging taxes or other so-called control devices must not




be hastily instituted as a guise for dealing with the solid




waste problem.  Overnight solutions will not be found to




resolve the solid waste problem, and the penalty approach




cannot serve as the alternative to what is really required:




a program that establishes the economic and technical opportun-




ities for expanded recycling and assures the most effective




use of all the raw materials this nation possesses.




         Yes, there are recycling opportunities.  I believe




what we are witnessing now is but a scratching of the surface




for recycling's future.  What we are experiencing now is an




awakening to the problem and a recognition of the needs.




         We have found that the nation does care enough  to




put action where before we had only rhetoric.  With positive




action, such as I have described, recycling represents  a great




potential and real promise.  Today's discarded box  can  be




                               28

-------
tomorrow's container:  recycling—economically and technically




sound recycling—will make it so.
                              29

-------
         PACKAGING AND ENVIRONMENTAL PROTECTION*
                     Joseph M. Martha
                 Sandgren, Murtha, Lubliner Inc.
      Some men like golf and fishing, but I find that my

hobby has become attending environmental conferences.   I

became active in the field about a year ago when I went to

one that lasted three days and three nights,  and when I

realized that you couldn't scratch the surface after three

days and three nights I started to go to shorter sessions. But

I have attended them from Paris to Portland,  and  I am afraid

that in attempting to solve our solid waste problem we may

be creating a  larger one, for we have to add to it the com-

panion concerns of land,  sea, natural resources,  and cer-

tainly the tremendous  problem of verbal pollution  about

pollution.

      In fact,  if we  could only harness the vocal energy that

has been spent on this subject, we may be able to  clean up the

problem of solid waste over night.  As Will Rogers  said,

"all I know is what I read in the papers, " and from them I've
*Note: Instead of a formal speech,  Mr. Murtha's subject was
       treated as a slide presentation,  and his remarks at
       our conference and throughout this  text were related
       to a variety of visual materials which could not be
       reproduced herein.
                              30

-------
been soaking up information like a sponge.   I bring you no




technical expertise this morning.  However,  I have con-




fidence that industry and the government will, in time,  re-




solve many of the problems that we're discussing.  I would




just like to share with you some impressions that I have




gained, both as a consultant to consumer product companies




on packaging and from attending all these conferences.




       Frankly,  I am appalled at some of the irresponsible




remarks that are made by representatives of various groups




interested in the subject of solid waste disposal.  I am a little




concerned that we are starting to see—for a subject as vital




as this to our National interests and our individual lives--




vested interests, pressure groups,  and marketing competition




for attention which is creating a rather sad misconception with




the consumer.   Certainly the packaging industry has been




buffeted  on all  sides by consumerism,  which is against




packaging puffery, and by  conservationists,  who are against




packaging pollution and the irresponsible use of our raw




material supplies.




       In addition, of course,  all levels of the industry have




some economic concerns and well they might. Can you imagine,




for example, what might happen if a major food manufacturer
                             31

-------
insisted that a given percentage of the packaging supplies




they send on to the  consumer would have to be reclaimed




and recycled9  It could create chaos over night.




       Consumer companies are concerned about  other




things, too.  What is the effect on brand loyalty as con-




sumers start to measure some of their own ecological




criteria for the package that they buy every day?  We've




been reading in the press quite a bit about that subject. One




of our major clients had a bunch of young tigers, mostly




product managers,  form a consumer protection committee




on their own with no authority, but to make recommendations.




They also requested top management to allow them to con-




stitute a package planning committee which would  set




standards, ecological  standards, for every package that




that huge  corporation distributes through retail stores. So




there are reasons for  concern,  business reasons, and




economic reasons,  as  well as our own social reasons.




       The dialogue is increasing in volume and intensity.




Industry and government are talking to each other, and they




also are doing a lot.  It takes a great deal of time, as we




know.  My first impression is that we are, however,

-------
ignoring the consumer.  We're talking down to them quite a




bit.




       If you analyze the packaging industry's advertising




over the past six months, and then if you attended a lot of




conferences, you might be astounded by the fact that there




isn't much consistency in what they are trying to tell the




consumer.  This is also true about what their business




concerns are, as they look towards further government




activity at the Federal, State and local levels.




       There has been virtually no research that I know of




done on the level of consumer concern.  We did a great  deal




of this in the '60's, when we were first promoting composite




packaging and convenience packaging. We tested the con-




sumer from every possible angle to find out where his levels




of concern for convenience and cost were, and where the




two axes would meet on the charts to indicate that he would




be willing to pay 40% more for a package if he got convenience.




But we don't know what the consumer is  willing to do today




in terms of conservation concerns as they relate to packaging.




And that,  basically,  is what I  would like to  chat with you




briefly about.
                             33

-------
          SYNPOSIS OF COMMENTS RE SLIDES




       I am going to rely on some slides, from this point




on, because my business really is visual and I feel much




more comfortable in this medium rather than in the verbal




aspects of communication.  The title assigned to me origi-




nally was 'Designing from Beginning to End1, but I am going




to change that.  Actually what we're talking about  this




morning is packaging and environmental protection and you




have here today a very knowledgeable group of specialists




who can give you all kinds of statistics and programs.




       However, we are wondering will industry sell re-




cycling.  We're also wondering how we're going to handle




the recycling if our cities are in extremely critical situations




with respect to finances, and how they can handle  and dis-




tribute wastes.  We are concerned in many ways about the




makeup of packaging.




       I mentioned composite packaging a moment ago, and




how in our business and in packaging development and  design




it became almost an expression of virtuosity in the 1960's




to be able to use 7 laminates and  different types of material




in a package,  because we were getting such tremendous
                             34

-------
technological breakthroughs in the packaging industry.




Nevertheless, we still had the  consumer out there --




looking,  watching,  confused, hearing a great deal, seeing




a little, and he wanted in on the subject.  So I want to talk




about communications planning to the consumer, which I




consider the missing link in environmental programs as




well as the subject  of packaging pollution.




       We are concerned with  the areas of communications




planning as a company, just as we are with package design,




with marketing and research, and this is  not a commercial.




I just wanted you to know that all of these tools have to  be




put to work somewhere along the line, if we're going to find




out how much activism we can  expect from the consumer




with respect to packaging.




       Now,  we all are potential victims  of the ecology,




even those who act  as  designers and planners of aesthetic




environments.  In fact, I'm reminded that you have a very




fine designer here in Columbus called Eugene Smith who,




five years ago, put together a film on "Ugly America".  At




the same time we were working on another version of this




subject, and took it on tour around the country.
                             35

-------
       At that time, we were thinking only about people,




and we didn't worry so much about soiid wastes.  We were




primarily concerned about visual environment, the aesthetics,




the honky-tonk streets that we were creating in our munici-




palities, and our question was then, "Is business responsible




for bad designs?"  Is it the businessman who says, "Don't




talk about aesthetics,I've got my eye on the bottom line,  and




profitability is all I am concerned with".




       Today,  our corporations  are much more interested




in their responsibilities with respect to ecological programs




and, specifically, they're concerned with their communi-




cations posture with all of their publics on the subject, and




we think we're going to see a great deal within the next year




of consumer product companies trying to reach the consumer




in their home with their concern about packaging and ecology.




I will have a little more to say on that specifically as we look




at more visuals,  for package design and development cer-




tainly can contribute substantially to the challenge of solid




waste disposal.




        If we had  a packaging "explosion" in the '60's when




convenience packaging and composite packaging became the
                             36

-------
by-word,  then maybe we should now be looking for a packaging




"implosion" where we go back and use our talents to simplify




our packaging and to simplify the materials that we use in




developing them.  We are concerned with a great many




brands and these brands are being measured by the consumer,




and also being measured by research.  Here, for example,




is a report by our research affiliate, the firm of Opatow




Associates, and I'll read it for you.. .. "complaints about how




packaging is raising prices have increased steadily in the




past  three years".  This is a report of  this year.  "Complaints




about storage  and convenience seem to  have decreased some-




what, or perhaps we're testing smaller packages.  The




voluntary comments about the problems of disposal,  either




in terms of bulk or in terms of environmental effects, have




increased to the point where specific questions must now be




included in many questionnaires to  measure opinions related




to these subjects. "




       Opatow Associates has been doing quite a bit of




research for major consumer brands and this is their




comment, and they specialize in packaging research,  after




looking over six months of research reports.  The report
                             37

-------
goes on to say. . . "There are already evidences of growing




consumer concern.  At the same time, experts within the




packaging industry and in government at all levels are in




serious disagreement with respect to the methods for




attacking packaging pollution.  This tends to confuse and




frustrate the consumer who wants to make a contribution.




In the final analysis,  if it continues,  it will probably




fractionate and dissipate programs which are already pro-




liferating from many sources and at many levels. "




       You all know that consumer campaigns are increasing




very rapidly in which industries within the total packaging




industry are trying to express their concern about ecology




and, of course, they  use it to further their marketing efforts.




In the '60's,  raw material suppliers and packaging suppliers




were in fierce competition for the convenience package.  We're




distressed if, in the final analysis,  advertising will be used




to set up the same competition on so serious a subject as




ecology and packaging pollution.  We are even starting to see,




and I counted six of them the past month,  ecology symbols




and identification devices being used by individual industries,




and if these are proliferated it can only result in  confusing




and frustrating the consumer.
                             38

-------
       I have been challenged at a half dozen conferences




about quotations or facts I've cited from public sources on




paper fiber and the savings of trees, and I know  that it is a




very complex subject.  But when it suits  some companies,




and I am not  picking on St.  Regis, believe me, because this




same type  of advertising is used quite a bit in the paper in-




dustry now, they go all out to tell consumers about the savings




made possible by recycling. Yet, in conferences such as




this one, there is little agreement,  particularly  in terms of




the paper industry, that this accomplishes much with our




present reforestation methods.




       The Resource Recovery Act  of 1970 includes  seven




major areas  of activity, and I am sure most of you are familiar




with them.   The Environmental Protection Agency in its  Solid




Wastes  Office is sponsoring a wide variety of long and short-




term studies to evaluate the most promising approaches  to




these problems.  These were spelled out at considerable




length at the  National Packaging Show in Chicago last week.




But as far  as we know,  there is no research being done with




the consumer to develop effective communications programs,




so they can understand  the problem  better, and so they can




choose from  their options in contributing towards cleaning
                             39

-------
up the solid wastes problem.




       For example, what is the level of consumer concern




with respect to packaging pollution?  How does it affect




brand loyalty? What kind of programs might channel these




concerns into constructive action? What kind of communi-




cations approach will best meet these concerns ?




       We know that newspapers are  (this slide happens to




be only for New York City,  incidentally) the biggest problem




in our waste disposal systems,  but we don't see anybody




doing anything to help the consumer get rid of them easily.




Even handling them is often terribly difficult,  and we wonder




why self-liquidated premiums aren't offered so that people




can somehow  just physically handle or segregate ten issues




of the New York Times.  It's quite a job,  if you've ever




tried it.




       We think that a lot more will have to be done to make




it easier for the housewife and easier for her family to




segregate and start the recycling process. For if segregation




doesn't begin  in the home, or maybe even in the retail dis-




tribution channels, local government agencies are left with




the massive problem of disposing of these materials and,
                             40

-------
from everything that I have heard, to build the kind of in-




cineration plants that we might need will probably take ten




years -- and perhaps more tax money than we have available.




       It doesn't require an expert to  go into any super-




market, any drugstore, and quickly go down the line and see




places where packaging material can be saved, and see places




where the problem of ultimate recycling by reclamation could




be simplified.  But no matter what starting point you pick you




hurt somebody.




       Consider,  just for a moment, gift packaging of  liquor.




How many of us  would be willing to buy the bottle as it  stands




on the shelf?  40% of the liquor  sold in the U.S. is sold during




the holiday season, and we have contributed by developing




quite a few designs for holiday liquor packaging.   And every




year it becomes more of a challenge to use more composite




materials,  to use more aluminum, to  use more ribbons,




even to put plastic symbols attached to the outside carton.




Just in this area alone there  could be a tremendous savings




in packaging materials and a saving in solid wastes.




       For ten years I've been kidded  by the steel industry




because we once made a recommendation for rounded,  square




cans rather than round cans.  It would slow down the manu-
                            41

-------
facturing process slightly and require some mandrels,  but




other than that,  consider the fantastic saving in materials. . .




about 20% in the ends alone,  because you don't cut away so




much waste as you do in a  circle. . .about 18% less in corru-




gated cartons  to contain the cans. . .about 12% saving in linear




shelf space in the supermarket which the retailer would like.




I am only using these figures as examples of all the areas




that a non-expert could look  at in order to save materials,




because if you save package  materials you reduce solid




wastes.




       Five years ago I judged a packaging competition,  and




we gave the grand award of the show to a Kroger orange




juice container in a poly-pouch.  Since the orange concentrate




is a  solid in a frozen form, it doesn't need the protection that




some of the other packages afforded.  It was interesting to me




that  this  package,  while apparently it was functional, econo-




mical, and everything else,  was totally rejected by the




consumer in test markets.   Think of the saving if we went




to concentrated  syrups, or added our own water or soda in




the home;  or to collapsible  boxes, with all kinds  of ways to




crease them and design them so that they can be more




easily compacted.
                            42

-------
       We have found that in some of the research we've




been doing that one of the real problems is the sheer bulk




of packaging and the difficulty the consumer or the housewife




has in compacting them in order to cut down the  bulk of the




solid waste that has to be carried out in trash.  We have so




many packages today that are really  multi-packs of indi-




vidual packages.  Look at some of your soap packaging where




the soap is wrapped in aluminum foil, then put in a carton,




the carton is put together with 9 other cartons, then it is




wrapped in poly, and marketed as a deal in a multiple package.




The same is true of cereals.  There  are great opportunities




in these areas to cut down.




       Some years ago in working in the flour and sugar




field,  we found out that in flour over  80% of the housewives




put the flour in their own storage  container in the home.  Yet




we still have expensive flour containers, composites of




plastic, foil, and fiber, and the same thing very often in the




area of condiments and spices and herbs.  These could also




be put into very inexpensive pouches  which then could be




placed in the container in the home.




       Do you remember the packages  that the astronauts




used in their weightless trips? Actually, ten years ago the
                             43

-------
Quartermaster Corps in Chicago proved the feasibility of re-




torting process fruits and vegetables in plastic pouches rather




than in cans, so it is a long way from that to getting them into




the supermarket and understanding how to handle them. But




this  is just an idea for babyfoods, because if the babyfoods




could be  retorted in  a mylar pouch then it also would cut down




tremendously on material's waste and cost, and it might also




make it much easier to dispense.




       I  said one of  my major concerns  is this question of




communicating to the consumer,  and before that is the concern




about what will the consumer do if they get such a program''




Suppose that the consumer were shown how they could contrib-




ute to solid waste disposal in packaging.  How much will they




actually do? I think that those are two of the  most important




questions in a lot of  the technical and very specific discussions




that  we go through in this type of conference.




       For example, suppose that we were able to flag a




product and identify  the type of packaging material to the con-




sumer at the point of purchase.  Then the consumer would




have the  option of purchasing packages which  would contribute




to the ecology.  Suppose that we use, and this is very hypo-




thetical and quite schematic,  a blue square for metal packaging
                             44

-------
and a green circle for glass and a red triangle for paperboard




containers,  folding cartons, and  so forth.  And suppose that




standards were established so that the manufacturer would




be entitled to use these symbols if they met very minimum




standards such as a minimum amount of recycled materials




in the packaging,  etc.  Then the consumer could  go to the




supermarket shelf and start to make  up his or her mind about




how important the whole question of packaging and solid waste




is to them.  They would have the option at  that point to do




something about it.




       Now suppose we went a step further and,  of course,




the  supermarket would have signs in the store indicating that




packages with these symbols on them did meet minimum




standards for recycling and reclamation, and here was the




program and this is what we would do about it. Then, instead




of one huge  shopping bag, whether you buy 3 packs of gum or




20 packages of cereal, you are given  three different sized




bags designed to deal with the volume of metal containers,




glass containers, and  dry groceries,  and each one of them  is




coded so that at  the checkout counter, as you came around,




the  segregation process was already  started.
                             45

-------
       All this is a way of motivating and educating and




bringing this process up to a level of consciousness and




awareness where the consumer starts to carry out the cycle




himself, which would mean that, right here in the supermarket,




your metals would be separated from your glass and your dry




groceries and folding cartons would also be separated.  Hope-




fully, this process would  continue on into the home, which




might mean new designs for our trash containers, etc., but




we would  segregate as the products  were used and the packages




were discarded.




       And then we would have to help in various other areas.




For  example, why not offer as a self-liquidating premium a




can compressor, or compactor, at $1.98.   I am not trying to




put Whirlpool out of business, but we would design the cans




with prestressed lines so that they would compact easily, and




a child could do it.   This  only calls  for the same torque that




you  might remember on the old-fashioned orange juice  squeezers.




       Suppose that instead of deposits on bottles we put a  de-




posit on well-built, returnable,  plastic carrying cases,




because one of the problems in  getting the glass back is how




to carry it.  After you would return the  containers that you buy




the product in, the  glass  would  be disposed of in suitable bins








                            46

-------
at the supermarket parking lot.




       We also believe that, whether or not any communi-




cations system is set up, the companies who are marketing




the brands will have enough concern about the consumer's




reaction to the ecology that they will cooperate.   And so at




the supermarket parking lot there would be disposal bins,




and this  could be dramatized through signs on the road




signalling where disposal sites  are  set up.   Maybe we could




even keep our beaches clean by having a similar  system of




disposal bins providing for three different types of materials




at the food service areas and other  key locations.




       Well, some will  say that any program regardless of




source builds an awareness of pollution problems and stimu-




lates consumer education activity.   We hear this a lot,  but




we think it's  wrong.  We think that a Tower-of-Babel approach




to such a serious subject makes an  ultimate unified effort on




a national scale difficult if not impossible.   The dangers are




that this kind of confusion and frustration can lead to arbitrary




legislation.   It may also stimulate commercial exploitation of




environmental activities and this is  already in evidence. And




it may delay worthwhile solutions coining out of  competition




among elements of the packaging industry,  which now tends
                             47

-------
to put the blame elsewhere and thus operate against the co-




ordinated national program.




       In concluding, I have just these few points to leave




with you.  First, that consumer research is necessary to




determine the levels of concern.  Secondly, that a communi-




cations program industry-wide by the packaging industry




should be undertaken to educate and motivate the consumer.




Third, centralize  and coordinate the consumer communi-




cations program nationally which might be done in EPA.




Fourth, an effective visual and verbal identification program




starts with basic principles and policies.  Establish liaison




for the communications program with manufacturing and




distribution levels of the packaging industry to provide




leadership and encourage cooperation.  Fifth, feed the




results of technical studies into the national communications




program to ensure most meaningful activities at the local




level.  Sixth,  and my last point,  design and develop a program




based on consumer research to simplify and standardize




packaging using marketing criteria.




       I am sorry that I ran to the full length of my time,




Mr. Chairman, thank you very much.







                         # # #





                            48

-------
        PACKAGING FOR FOOD SYSTEMS OF THE FUTURE
                    Norman A. Vanasse
                 General Foods Corporation

          Good morning  ladies  and  gentlemen.

          It's a pleasure to be here  today.   I

appreciate this opportunity to speak  and the  chance

to participate in  the Solid Waste  Conference  pro-

gram.

          So far,  we have heard from  some distin-

guished representatives of industry and government.

In the next day-and-a-half I'm sure we'll hear

many equally stimulating  and informative presenta-

tions .

          This morning, I would like  to talk  about

the demands of Food Systems of the Future on  Pack-

aging and their relation  to effective solid waste

management.

          We'll look at these  packaging demands

from three points of view  — that of the consumer,

the distributor and the ecologist.  Following this,

I would like to review  current thinking on interim

and long-range solution of the solid  waste problem.

          To begin, then, let's take  a broad-brush

look at tomorrow's  food consumer and  her world.

          The consumer  of the  1970's  and 1980's
                         49

-------
will by-and-large be the youngest, best educated




and most affluent in history.




          By 1975 it is estimated that more than




17 million Americans will be college graduates.




And also by that year,  more than half the popula-




tion 25 years and over will have high school




diplomas.




          The time is soon approaching when more




than half the nation will be 30 years of age or




less.  And this trend toward a more youthful soci-




ety is expected to continue.




          Nearly half the women in the United




States between 18 and 65 are gainfully employed —




daily supplementing their household income.




          The next two decades will see more con-




sumer discretionary income than ever before —




resulting both from growing affluence and increased




entry by the housewife into the job market.




          Younger, richer and better educated —




tomorrow's food buyer will present a whole new ball




game for the food industry and the food packaging.




          A major way in which these changes will







                         50

-------
          Individuality will be still another




characteristic of tomorrow's food buyer.  Put




another way, the housewife of the future will feel




an increasing need to accentuate herself as dis-




tinguished from others — to be an individual.




          This individuality is expected to express




itself through increased consumer style and color




consciousness — leading to an acceptance and




demand for decorative, stylized packaging.




          Both the products and packages she buys




will be expected to contribute to her sense of




individuality and self-actualization.




          The meals and snacks tomorrow's housewife




serves the family and friends will be expected to




enhance her self image of individualism and




creativity.




          Interacting with these consumer attitudes




will be what sociologists call a lower frustration




tolerance.




          Put more simply, tomorrow's food buyer




will be much less patient with circumstances and




situations which frustrate her intentions.
                         53

-------
          Convenience in terms of easy product




availability and variety will become increasingly




important to the consumer.  Equally vital will be




product convenience in terms of easy preparation




and storage.




          Tomorrow's wife and mother simply won't




have the time or inclination to engage in difficult




or time-consuming meal preparation.




          And I think with productivity per man-




hour increasing everywhere else, the housewife is




correct in demanding equal freedom from drudgery.




          So this is a brief look at tomorrow's




convenience food consumer.




          Educated and affluent, she reflects the




permissiveness of a youth-oriented society.




Venturesome and individualistic, her attentions




have turned to the new and the different in order




to accomplish self-actualization.




          And of primary concern to the food




industry and food packaging, she demands all these




gratifications through less effort and inconven-




ience than ever before.
                        54

-------
          For us in the food industry, meeting the




demands and expectations of this future food buyer




will call for a number of shifts in emphasis.




          As the tastes of both her and her family




grow more sophisticated, the demand for more




single-portion packaging will certainly arise.




Father may demand French-cut string beans with his




pot roast while brother and sister see southern-




style cream corn as the only acceptable companion.




          One family member may have a pressing




social engagement at the dinner hour — demanding




an individual hot snack in place of the programmed




evening fare.




          In fact, we see a definite trend away




from the traditional three square family meals and




toward more odd-hour snacks and eating on-the-run.




          Our consumer and her family won't confine




their venturesomeness and other new attitudes to




eating.  The whole life style will be one of




individualism.




          This world of the future will also demand




much in the way of package aesthetics and product








                        55

-------
information.




          Already,  the need for attractive pack-




aging is making itself felt throughout the industry.




In the future, packaging aesthetics will play an




even greater role.




          Of equal importance will be the informa-




tion provided on the package.  Already, federal




state and local laws require detailed information




in many areas.  Still further information — for




example, caloric and nutritional values — are




voluntarily provided.




          In the future, the demand for package




information can only rise.  Tomorrow's sophisticat-




ed consumer will want to know as much as possible




about her intended purchase.




          What is it? — How will it look? — How




do I make it? — and is it good for us? — these




will all be prime buyer considerations, facts the




consumer will expect the package to supply.




          To keep pace with the consumer's lowering




frustration tolerance, future packaging will have




to lend itself to more and more convenience.
                         56

-------
          Easy open; easy close; easy storage;




easy disposal — all these factors will be prime




considerations in package design.




          In some cases, the package will come to




play an even greater role in actual food consump-




tion than today.  Eating utensils, for example,




may be an integral part of the package or even the




product itself.  We will also see more packages




serving as the actual eating cup, bowl or plate.




          This, then, is a look at the future




consumer and the packaging that will serve her.




          Now, let's look at the food distribution




systems of the future and their impact on packaging.




          A prime consideration in examining future




distribution trends are some rather dramatic pro-




jections for transportation costs.




          Trucking costs are expected to rise




40 percent above the inflation index by 1981.  Rail




costs, on the other hand, have a forecast increase




of 30 percent during the same time period.




          To put it short and sweet, it's going to




cost a lot more to move anything anywhere in
                         57

-------
tomorrow's world.




          What does this mean for the packager?




          One trend will certainly be toward more




compact and lighter packages — even if a possible




rate base change from weight to volume should




occur.




          How individual packages fit together into




cases and on pallets will also be a prime consider-




ation.  Wasted space can only mean wasted money,




and more money than ever before.




          Compact, light-weight and damage-free




packaging will be required as the competition for




store shelf space becomes more intense.




          Today, the average grocery store carries




approximately 8,000 separate items.  In the next




10 years, however, we estimate a 57 percent in-




crease in the number of dry grocery products alone.




With frozen foods and the like, we look for a 125




percent increase in individual products.




          Excess bulk and difficult handling simply




will not be possible in this highly competitive




market situation.  And packaging will be called
                         58

-------
upon to play an increasing role in their elimina-




tion.




          One area of conflict between these




distribution trends and ecological concern is the




severe limitations placed on the concept of




returnable containers.  As stores become more




crowded and transportation rates rise, the econom-




ics of returnables will become increasingly




prohibitive.




          Turning to the ecologist and his view of




future packaging, I'm sure he must shudder at the




ramifications of much of what I've said so far.




          Though certain aspects of this consumer




and food distribution world I've outlined lend




themselves to ecological concerns, many others




combine to paint an initially bleak picture in




terms of environmental protection.




          By 1976, for example, it is estimated




that more than 73 million tons of packaging




materials will be used annually in the United




States — that's more than 661 pounds for each




man, woman and child.
                         59

-------
          Going further, one expert has predicted




that this annual per capita level could reach 900




pounds by the dawn of the 21st Century.




          Though we've all heard similar projec-




tions a hundred times, I never cease to be awed by




the magnitude of such figures.




          From a purely ecological point of view,




it could be said that all packaging should be




reduced to a bare minimum.  A purist in this field




could easily demand a return to the most basic in




packaging technique — promising doomsday as the




only alternative.




          But to assume that housewives should buy




cereal in 20 pound bags or their beef by the side




is as absurd as to say that ecological considera-




tions should be totally ignored.




          And I don't feel that sensible ecologists




see a return to a world devoid of convenience as




the answer, anyway.  I think they see the solution




much as most of us do — as a balanced approach




combining the stronger points of each position.




          Speaking for society, the ecologist








                        60

-------
makes it perfectly clear that a concentrated




environmental protection effort in all areas is the




mandate of the future.




          He recognizes consumer demands in pack~




aging and other areas but warns that these very




buyers could be buried in the results of their own




quest for convenience.




          A statement of the varying conflicts




among the future demands of the food consumer,




distributor and the ecologist is not a new theme




by any means.




          It does, however, merit periodic




examination since it is fundamental to the dilemma




facing the food packaging industry and society as




a whole.




          It is a realistic assumption that modern




food packaging helps allow many women the free time




to leave home and participate in environmental




protection activities.




          The farm wife of 100 years ago felt




fortunate if able to attend even a monthly social




event.  And even these were often devoted to food
                        61

-------
preparation — for example, corn husking.




          But today's woman usually has a social




agenda rivaling a movie star — and often with a




family and a job to boot.  And packaging — food




and otherwise — has made a major contribution to




this emancipation.




          However, the very same housewife that




demands the ultimate in packaging convenience is —




either directly or as part of society -- demanding




effective and total solid waste control.




          So the obvious question arises — can




society have all the convenience and other pack-




aging attributes demanded by its future course




while still progressing toward total environmental




protection?




          Put another way — can the consumer and




society have their cake and eat it too?




          To me, the answer is a definite YES.




          I feel that the same technology that




produced our present and potential states of the




art in packaging can — through a systems approach




provide effective solid waste management.
                         62

-------
          Through innovation, cooperation and




plain hard work, society can and will have all




that it desires in each area.




          The dynamics of a free economy dictate




that the food industry strive to meet all consumer




demands — packaging and otherwise.  Failure to do




so — regardless of how noble the reason — would




prove economic suicide.




          Certainly, government could regulate




packaging to an extent where all consumer desires




and convenience went by the way side.  But such




dangerous overreaction could cripple our free




market system beyond the point of no return.




          We recognize that sensible legislators




and administrators seek to work within the param-




eters of the free enterprise system in order to




reach solutions.




          Functioning in a free economy, we at




General Foods see our ultimate mission as that of




providing the consumer of tomorrow with all the




convenience, freshness, aesthetics and other




attributes she desires.
                         63

-------
          With us — as I'm sure with most




companies — this is the name of the game.




          But we also feel that this can and must




be accomplished hand-in-hand with a definite con-




tribution to the systems approach to solid waste




management I mentioned earlier.




          No one point along the road from a




package's inception to its ultimate disposal can




be singled out as totally responsible for the solid




waste problem.  Any workable solution must come




from an integrated effort at all points — each




engineered to facilitate the other.




          This conference, incidentally, is typical




of the ways in which this solution will be found.




Only through meaningful communication and coopera-




tion can a systematized effort be formulated and




effected.




          Effective communication to the public at




large is also vital.  And today, public awareness




of the packaging industry's environmental concern




has never been greater.




          Paramount in creating this increased







                         64

-------
public understanding have been several dramatic




reclamation efforts — each combining economic and




social incentives for container collection.




          But I'm sure I speak for the entire




packaging industry in saying that in the long view,




such measures are at best a stop gap.




          The ultimate solution — all authorities




agree — lies in mass recycling.  For maximum




effectiveness, the only answer can be total




municipal recycling plants — plants able to sort




mixed garbage and retrieve useful materials and




energy without a pollution problem.




          Time does not permit a discussion of the




economics and methods involved in such plants.




But the experts insist that such systems can be




operated — and operated at a profit.




          All of us, I'm sure, recognize that this




network of recycling plants supported by a totally




sympathetic packaging technology won't spring out




of the blue tomorrow, next month or even next year.




          Therefore, all of us — government and




industry — must also seek interim solutions in








                         65

-------
addition to long range ones.




          To do otherwise would be like building




vertical takeoff airports while neglecting fixed




wing airports because someday jets might be




obsolete.




          The food industry and its packaging




elements must act now to ease the load on current




incineration, landfill and other solid waste




disposal operations.




          At present, this is being accomplished




in several ways — primarily through the reduction




of bulk, weight, and overall packaging excesses.




We are also constantly looking at new packaging




materials — materials which lend themselves to




compaction and pollution-free burning.




          And, interestingly enough, we are finding




that many of these changes actually add to —




rather than detract from — consumer product




acceptance.




          This development poses an interesting




question — one which we could all keep in mind as




this conference moves from the overview to the
                        66

-------
specifics of technological exchange.




          The question is — where are the best




ways to mutually serve the best interests of the




consumer and the environment?  Where, through




technology and innovation, can we give society the




best from all possible worlds.




          In closing, let me again emphasize the




need for an integrated systems approach to effec-




tive solid waste management.  The only solutions




will be those that account for all the variables —




consumer demand, distribution economics, techno-




logical capabilities and ecological necessity.




          I hope my sketch of tomorrow's packaging




for tomorrow's foods has given you a further in-




sight into some of these variables.




          I also hope I have shown how consumer




demand interacts in many varied ways with the




viewpoints of the distributor and the ecologist




toward packaging.




          I feel the food industry is highly aware




of the need for corrective action on the solid




waste problem — both in the interim and over the
                        67

-------
long haul.




          And not only are they aware of the




problem but have and will continue to make sig-




nificant contributions to its solution.




          Thank you for your kind attention.




Again, let me say it has been both a pleasure and




an honor to speak here today.




          Thank you.
                        68

-------
            SESSION II

PLASTICS, COMPOSITES AND PAPER
                                   Chairman:

                                   J. H. Lindholm, Chief
                                   Paper, Packaging and
                                    Graphic Arts Economics
                                   Columbus Laboratories
                                   Battelle Memorial Institute

-------

-------
        INCENTIVES FOR THE RECYCLING AND REUSE OF PLASTICS
                           Jack Milgrom
                        Arthur D. Little Inc.
          We have just completed a study for the U.S. Environ-

mental Protection Agency to explore incentives for the recycl-

ing and/or reuse of plastics.  This is the first of  the so-

called incentive studies that include not only the gathering

of information, but an attempt to find solutions.

          But why select plastics for this study?  Plastics

represents less than 2%, on the average, of the solid waste

stream.  However, in addition to being very much in  the

public's eye today, plastics belong to that category of mat-

erials whose physical properties are often degraded  during

recycling, and essentially none is being recycled from the

consumer.  On the other hand, materials such as metals, glass,

and paper are being recycled today, and the recycling of

these materials will no doubt increase;  therefore,  the con-

centration of plastics in solid wastes could become more sig-

nificant.

          There were two aspects to this study:  (1) to develop

a descriptive model of the plastics cycle, and during the

study we interviewed all segments of the plastic cycle from

resin producer to supermarket;  and (2) to develop complete

strategies for promoting the recycling and reuse of  plastics.

At present, we will present some of the information  that we

gathered, but will withhold information related to overall

strategies until the government agency has fully reviewed our

recommendations.  However, we have cautioned our client that

                             69

-------
in the development of strategies relating to plastic materials,




significant action cannot be taken unless the strategies in-




clude all competitive materials.




          In carrying out this study, it was important to de-




fine certain terms that are used by the industry and develop




new ones.  The words reuse and recycle, for example, are often




used interchangeably.  Reuse indicates that the package is




used over again in its same form.  The returnable bottle is an




excellent example.  On the other hand, recycling implies that




the packaging material is reprocessed, which in the case of




plastics means remelted and reformed, either into its original




form as in primary recycling, or into another plastic form as




in secondary recycling.  Thus, plastics can be pyrolyzed to




yield non-plastic materials such as oils, waxes, and greases.




Considering economic value, reuse offers the highest return,




and pyrolysis and energy conversion the lowest.




          We have also developed a new term called NP or




nuisance plastics.  These are the plastics of no value, and




they are usually  found in the disposal area.  A corrollary




term, SP or scrap plastics, is plastic that has potential




value.  It is equal to SP  (scrap plastic of value) + NP.  In




other words, if the scrap plastic cannot be used, it becomes NP.




          Because this study was limited to recycling, only




thermoplastics  were considered.  Thermoplastics can be melted




and reformed numerous times in contrast to thermosets that




only can be melted and formed once.  As shown in Table 1,




                             70

-------
thermoplastics represent 80% of all plastics.  Recycling coat-




ings and adhesives (not including extrusion coatings) is vir-




tually impossible.  Thus, excluding these still leaves 75% of




all plastics as potentially recycleable material.   Our study




has only included the "Big 5" thermoplastics, namely, high and




low density polyethylenes, polypropylene, polystyrene, and PVC.




These account for 89% of the potentially recycleable plastics.




          Early in our study, we developed seven objectives or




criteria for assessing alternative strategies.  These also




served to guide us in our information gathering phase.  These




objectives are listed in Table 2.  I would like to comment on




two of them.  The first objective, which is the prime one, re-




fers to environmental damage.  There are two aspects to this




damage—an economic aspect and an aesthetic one.  One example




of economic damage is that caused by burning plastics in




facilities noc specifically designed for this operation.  An-




other example, which is probably more significant, is caused




by the high bulk density of uncrushed rigid plastic containers.




This can cause difficulties in disposal from the garbage can




to the collector and ultimately in the final disposal area.




Assorted plastic packaging that is not compressed occupies as




much as 800 cu ft/ton, in contrast to the approximately 30 cu




ft/ton density of the completely compressed plastic material.




          The aesthetic aspect is essentially a subjective




term, and the best example is litter.  For example, consider




the following two plastic packaging items as litter—a piece




                             71

-------
of transparent plastic film and a large, opaque, rigid plastic
container.  The latter is obviously the most visible and,
therefore, most people would consider it aesthetically dis-
pleasing.  However, the same container sitting in one's back-
yard is considered less damaging to the environment than the
container along the roadside, which illustrates the importance
of the degree of exposure.
          I would also like to comment on Objective No. 7.
Plastic packaging can be either mono- or multi-plastic, that
is based on more than one plastic material, and they also can
be composites.  A composite is a product consisting of one or
more plastics together with a non-plastic substrate.  As many
of you know, the technical problems of reprocessing multi-
plastics or composites makes this approach unattractive.  Re-
processing or recycling requires the plastic to be homogeneous:
one plastic type with minimal contamination.
          We mentioned earlier that plastics represent less
than 2% of the solid wastes.  Accordingly, the technical and
economic problems of recovering these materials from the final
disposal site are overwhelming.  This suggests that any attempt
to recover scrap plastic from the consumer of necessity would
have to be done by intercepting it before it reaches the final
disposal area.  Therefore, collectability should be considered.
Again, let us consider plastic film and containers.  Normally
the household consumer considers plastic film in the same way
as paper wrapping and discards it in the trash can.  In con-
                             72

-------
trast, the rigid container is often set aside.  It is easily




segregated from the household refuse, and in the past, contain-




ers were set aside for return to the store.




          Let us now look at the entire plastics cycle shown




in Figure 1.  The resin producer is responsible for determin-




ing the chemistry of the plastic product.  The fabricator




takes the granulated or pelletized resin and transforms it




into a shaped article.  The converter then uses the fabricated




items such as film to make, for example, plastic bags.  Both




of these sectors are responsible for producing the end plastic




item.  The manufacturer/packager segment, and in particular




the packager, is the major decision-maker in the packaging




cycle.  He is the one who decides just what type of plastic




package he wishes to use for his product.




          As one proceeds from resin producer to packager and




on to the consumer, one goes from the very large companies to




the smaller ones.  Geographically, resin producers in the U.S.




are relatively concentrated, particularly along the Gulf Coast;




whereas, the wholesaler/retailer sector and obviously the




consumers are distributed according to population density.




          Note by the dashed line that all segments of the




plastic cycle, including the consumer, generate NP.  Thus,




there are two major sources of NP, that from the industrial




sector and that from the consumer.  Some are not aware that




plastics today are being extensively recycled.  For example,




as an integral part of their operation, fabricators usually




                            73

-------
recycle between 10 and 15% of their production.  This amounts




to more than 1.5 billion Ibs.  In addition, the resin produ-




cers sell SP that they themselves cannot use through the re-




processor segment.  This is a small segment of the industry




today.  Nevertheless, approximately 1 billion Ibs. of scrap




plastic went this route in 1970.  The reprocessor purchases




scrap plastic and converts it to secondary resin.




          We have prepared flow diagrams for each of the seg-




ments of the plastic cycle.  That for the resin producer is




shown in Figure 2.  The decision points are represented by




the triangles and are listed in Table 3.  The pentagonal




symbol represents various categories of NP.  In our report




we have prepared a rather complete catalogue of sources of NP




generated by the various segments in the plastic cycle.  Note




that NP can be generated during every operation.  This diagram




illustrates how scrap plastic can be removed in three different




ways:  0-) by recycling it in ones own facilities;  (2) by sel-




ling it to a reprocessor; or (.3) by removing it as NP.  Anoth-




er important aspect illustrated by this diagram is  the produc-




tion of "offgrade" resin.  If the resin producer does not meet




the specifications designated by his customer, or if he has




to dispose of transitional material produced as he  changes




from grade to grade,  the product is called virgin off-grade




resin, in contrast to virgin prime resin.  Now if market con-




ditions are such  that the resin, producer cannot  sell  all of




his products, he  stores it and  then sells  it to  the highest




                             74

-------
paying customer.  In times of low demand he often sells this




surplus as offgrade material.  This procedure provides the




resin prices.  Incidentally, 1970 was a year where most of




these resins were produced in oversupply, and the resin




producer is currently attempting to use this safety-valve tech-




nique.




          Now let us turn to the consumer's segment.  The con-




sumer really does not consume most products, he merely uses




them for a certain period of time.  This time corresponds to




the service life of a given product.  Thus, a plastic product




in the hands of the consumer only becomes NP when it is of




little value to him.




          A summary of the estimated service lives of differ-




ent plastic products is shown in Table A.  The products listed




in Table 4-A are the most significant ones for this study.




Note that the production losses are included.  The values




listed in Table 4 were used to estimate the volume of differ-




ent plastic products in the disposal area.




          Let us next examine the types of NP in the disposal




area today and as we estimate to 1980 (see Figure 3).  Not




surprisingly the major component is that derived from packag-




ing, corresponding to about 60% of all NP in the disposal area.




Accordingly, the development of strategies focused on these




two types of NP can solve the major problems of plastics in the




solid waste stream.  Notice that housewares, which is the




third category, only represents about 6% of the total NP.





                             75

-------
Most other types of NP are present in small fractions and would




be difficult to recycle because many are present as composites.




          The statistics used to prepare the graph in Figure




3 are shown in Table 5.  Based on the Big 5 thermoplastics,




6.5 billion pounds of NP were estimated to be in the disposable




area in 1970.  By 1980, we expect this to rise to 18.8 billion




pounds.




          Packaging wastes, which are almost 4 billion pounds




today, will rise to approximately 10 billion pounds by 1980.




This represents a decrease in the percent packaging waste as




a percent of all plastics in the disposal area.  Other plastic




items with long service lives, for example wire and cable, will




account for more and more of the NP during the coming decade;




and it is this factor which will reduce the percent packaging




waste.  However, these estimates do not include the potential




increase in NP, if plastic beverage containers become a reality.




We do not believe that this will occur to any large extent be-




fore 1975, but by 1980 the penetration of the market could




yield as much as 2 billion pounds of NP, if recycling and re-




use does not become a viable solution.  Thus, packaging




wastes in 1980 could be 12 billion pounds.




          Table 6 shows the composition of NP according to  the




type of plastics in the disposal area.  Polyolefins which in-




cludes polyethylenes and polypropylenes, are the major type  of




plastic in the disposal area today.  It represents about 70%




of NP  from all sources, but that from packaging accounts for





                             76

-------
82%.  PVC from all sources of NP accounts for about 12%, while




that from packaging is only 6%.




          Many are surprised to discover the large volume of




NP produced by industry, but wastes from each segment are cum-




ulative.  Though the resin producer produces as little as 1%




NP, this is added to the larger waste generated by the fabri-




cating and converting operations.  Table 7 shows the various




sources of industrial NP;  fabrication and converting account




for the major portion, and are approximately 60%.




          The total amount of industrial NP is about 1 billion




pounds.  The major plastics in industrial NP are LDPE and PVC,




as shown in Table 8.  The relatively large concentration of




PVC is more difficult to process and reprocess than the other




major thermoplastics.  We do not forsee any major changes in




the composition of industrial wastes during this decade.




Looking at packaging NP from the consumer sector, according




to form, almost 90 weight percent of all packaging is mono-




plastic (see Table 9).  Thus, most of this packaging is po-




tentially recycleable.  Though the rigid containers account




for approximately 40 weight percent of all plastic packaging




wastes, on a volume basis rigid containers are the major type




of plastic packaging wastes.  Looking ahead to 1980, we do not




see any major changes in the composition of packaging wastes




by form.  Although the production of composite and multi-




plastic film will increase, rigid mono-plastic containers will




still account for the major portion of packaging wastes on a




                             77

-------
volume basis.




          Because plastic bottles are potentially the most




easily collectable and, therefore, recycleable wastes, let us




examine the type of bottles in the disposal area today and




in this decade, as shown in Table 10.  Most plastic bottles to-




day are fabricated from one plastic—high density polyethylene.




They accounted for 84% of all plastic bottles in the disposal




area in 1970 and this percentage could rise to 88% by 1980.




Fortunately, only two major grades of high-density polyethy-




lene are used for bottles today.  Thus, if one could collect




bottles such as those used for milk, bleach, and detergents,




collection and separation could go hand in hand.  The plastic




bottle, therefore, which can be considered the most damaging




to the environment, as explained earlier, is fortunately the




most collectable and potentially the most recycleable.




          In conclusion, let us examine the major impediments




to recycling plastics.  The key one is economics.  Secondary




resins compete with off-grade virgin resins. Ten years ago, in




1961, the difference in price between these two for a typical




film application was 3c/lb.  Today it is virtually zero, or




certainly no more than 1C.  Thus, instead of narrowing the




gap, our strategies have been aimed at widening the gap between




these competitive materials.




          Another important impediment is the political one.




As all of you know, governments often work at cross purposes.




For example, many government specifications insist upon the




                             78

-------
use of virgin material, instead of developing specifications




based on performance.  To give another interesting example, we




have noted that the U.  S. State Department in their AID pro-




gram has removed secondary plastics from their approved list.




Thus, foreign manufacturers are unable to receive favorable




financing from the US on purchase of these secondary materials.




Incidentally, these items were only removed during 1970.




          Another impediment is the psychological one.  The




general usage of the terms virgin and secondary material sug-




gest to the consumer that the secondary product is inferior.




This a common impediment whether the product is a plastic or a




textile.




          Finally, and certainly not last, is the technical




impediments.   As mentioned earlier, plastics must be homogen-




eously one material, free of foreign contamination.  Otherwise,




they are not  easily recycled.




          Looking at plastic wastes as a resource, we believe




that some plastic containers are reuseable, for a number are




being reused  in the packaging of milk today.  Others are




potentially recycleable, and we believe that schemes can be




developed to  promote their easy collection.
                             79

-------
           TABLE 1.   PLASTICS PRODUCTION—1969

Type
All plastics
Thermoplastics
Thermosets
Thermoplastic coatings
Pounds
(Billion)
18.7
14.9
3.7
0.8
% of
Total
Plastics
100
80
20
4
Big 5 thermoplastics  , ^
  (excluding coatings)           12.5                  67

Thermoplastics
  (excluding coatings)           14.1                  75
(a) Source:  U. S. Tariff Commission

(b) HDPE, LDPE, Polypropylene, Polystyrene, PVC.  Extrusion
    coatings are included in this category.
                             80

-------
              TABLE 2.
1.  Minimize environmental damage.

2.  Maximize pound-volume of troublesome
    nuisance plastics (HP) recycled and/
    or reused as a percentage of total
    plastic production.

3.  Minimize pound-volume yield of trou-
    blesome nuisance plastics as a
    percentage of total plastics pro-
    duction.

4.  Minimize the sum cost of achieving
    Objectives No. 1, 2, and 3.

5.  Minimize economic disruption.

6.  Minimize disposal costs consistent
    with the objective of minimizing
    environmental damage.

7.  Maximize the recycleability of
    plastics with regard to their
    ease of collection and their ease
    or reprocessing.
                  81

-------
           TABLE 3.  DECISIONS
1.  Additives Required?

2.  Colorants Required?

3.  Within Specifications?

4.  Sell to Fabricator?

5.  Can Waste Plastic be Recycled in Own
    Facilities?

6.  Can Waste Plastic by Sold to Reprocessor?

7.  Sell to Compounder?
                  82

-------
         TABLE 4.  ELAPSED TIME FOR PLASTIC PRODUCTS
                   TO REACH DISPOSAL AREA
                                                  Estimated
     Product                                     Life  (Years)


                   A.  Elapsed Time 0-5 Years

Production Loss^                                     0
Packaging                                              1
Novelties                                              1
Photographic Film                                      1
Disposables (Dinnerware, hospital goods)               1
Construction Film                                      2
Footware                                               2
Apparel                                                4
Household Goods                                        5
Toys                                                   5
Jewelry                                                5
                 B.  Elapsed Time 6-10 Years

Sporting Goods (Recreation, boats)                     7
Automotive                                            10
Phonograph Records                                    10
Luggage                                               10
Appliances                                            10
Furniture                                             10
Cameras                                               10

                 C.  Elapsed Time 11-30 Years

Wire and Cable                                        15
Business Machines                                     15
Miscellaneous Electrical Equipment                    15
Hardware                                              15
Instruments                                           15
Magnetic Tape                                         15
Construction                                          25
(a) During production, compounding, fabrication, and convert-
    ing the resin and manufacturing the plastic items
                            83

-------
        TABLE 5.  NUISANCE PLASTICS IN THE DISPOSAL

Type of
Product

1970
Million
Ib wt %
1975
Million
Ib wt %
1980
Million
Ib wt %
Packaging
Footwear
Records
C and A Film
(b)
Industrial Wastes
  Toys
  Transportation
  Appliances
  Furniture
Wire and Cable
Novelties,
Disposables
  Others{C>

Housewares
Construction
3925
  90
  95
 130

1000
 310
  90
 100
  60
  40

 100
 120

 425
  50
60.1
1.4
1.4
2.0
15.3
4.7
1.4
1.5
0.9
0.6
1.5
1.8
6.5
0.8
6445
140
140
195
1830
555
250
230
170
95
200
230
885
100
56.2  10,170
 1.2     190
 1.2     205
 1.7     285
                              15.9
                               4.8
                               2.2
                               2.0
                               1.5
                               0.8

                               1.7
                               2.0

                               7.7
                               0.9
       3,050
         945
         470
         440
         355
         480

         400
         430

       1,270
         150
54.0
 1.0
 1.1
 1.5

16.2
 5.0
 2.5
 2.3
 1.9
 2.5

 2.1
 2.3

 6.7
 0.8
TOTAL
                   6535
                     11465
                             18,840
(a) Source:  A. D. Little

(b) Construction and Agriculture

(c) Includes business machines, instruments, luggage,  sporting
    goods, apparel.
                              84

-------
          TABLE 6.   PLASTICS  IN THE DISPOSAL AREA IN
                    1970 ACCORDING TO TYPE OF PLASTICS
(a)

From Packaging From all
Million Million
Type of Plastics Ib wt % Ib
Polyolefins 3240 82.6 4231
Styrene polymers 445 11.3 1006
PVC 240 6.1 775
TOTAL 3925 5992
Sources

wt %
70.6
16.8
12.6


(a)  Source:   A.  D.  Little

(b)  Includes  cups,  refuse and household bags

(c)  Does not  include business machine,  instruments,  luggage,
    sporting  goods, novelties, disposables,  construction
                            85

-------
                           TABLE 7

                  SOURCES OF INDUSTRIAL NP

                          (1970) (a;>

Operation
Polymerization
Compounding/ Reprocess ing
Fabrication
Converting
Other (b)
Million
Ib
200
100
310
260
130
wt %
20.0
10.0
31.0
26.0
13.0
TOTAL                      1000
(a)  Source:  A. D. Little

(b)  Wastes generated in distributing products from
     manufacturer/packager to consumer.
                              86

-------















^^
a

s~*
P-I

c/l
oo pq
W to
i—l  --d" o co r^-
m i— I iH eg



CN o CN r*- co a>
CTN •<]• i — 1 P^- CN] -i
i &j
a.
o  o
K J CM c/^ PL, H






































OJ
tH
4-J
4-1
•H
,-]
Q

<^



a)
o
^4
d
o



a)
87

-------
TABLE 9.  TYPES OF PLASTIC PACKAGING

Type of
Physical
form
Film
Film
Rigid
Rigid
Packaging
Composition
Monoplastic
Polyplastic
Monoplastic
Composite
Consumption
(Billion
pounds)
1.84
.31
1.54

wt %
46.8
7.9
39.2

                           0.24           6.1

-------
      TABLE 10.  PLASTIC BOTTLES IN THE DISPOSAL
  Type of       Million          Million          Million
  Plastic         Ib      wt %     Ib      wt %           wt
HDPE              524     84.0     920     87.0   1409    87.9


LDPE               32      5.1      35      3.2     40     2.5


Polypropylene      10      1.6      12      1.1     15     0.9


PVD                58      9.3      92      8.7    140     8.7



TOTAL             624             1059            1604



(a)  Source:  A. D. Little

-------
                  V)
                 _QJ

                  O
                                 Q)
                                 cc

                            \
                                                c
                                                o
                                  \
O)
l-
3
                  c
                  o
                          X
                             X
                                                in
                                                O
                                                Q.
                 w
                 _I
                 CJ
                 u
                 (—I
                 H
                                                     \
                                                        \
\
                 O
                 M

                 [K
                                                             \
                                 o
                                 C)
                                 .0
                                 o
                                                               \
                                                                 (J
                                                                 o
                                              (U "D
                                             tr p
                            90

-------
©

-------
                Novelties, disposables
                Appliances
                Transportation
                Wire and cable
                Others
Construction
Records
Footwear
Construction and
  Agriculture film
Furniture
                                               Industrial NP
                                               —      —
                                               Packaging
1970
                 1980
     FIGURE 3.   PLASTICS  IN THE DISPOSAL AREA
                  (Source:   A. D.  Little)
                           92

-------
                                        W
                                        H
                                        en
                                         O
                                         <
                                         P-.
jo spunod uoi||ig
    93

-------
            THERMOPLASTICS IN WASTE RECYCLING
                      K. L. Burgess
                 The Dow Chemical Company

          Plastics are a diverse group of mate-

rials, and each product family offers unique

properties that enable it to fulfil certain market

needs.  Essentially all plastics are derived from

petroleum, and are carbonaceous matter.  In recycle

we can consider plastics to be either hydrocarbons,

with energy values, or engineered molecules with

reusable physical  properties.

          A thermoplastic material, by definition,

is one that softens and flows  when heated.  This

means that thermoplastics can be recycled

repeatedly.  The fact that polyethylene, poly-

styrene, and polyvinyl chloride are "reworkable"

has been long understood in the plastics industry.

Plastics fabricators rework their scrap with little

concern that a significant percentage of the poly-

mer is subjected to multiple passes through the

fabrication process.

          Since it is well established that thermo-

plastics are easily reworkable, it is pertinent to

ask the question, "Why do we have a plastics waste

recycle problem?"  The answer is a complex descrip-

tion of technical, distribution, marketing,

emotional  and consumer problems.  One way to look

at these problems is to compare the nature of  the

scrap plastic found in  the fabricators plant to the

                        94

-------
plastic solid waste as generated by the consumer.
          The fabricator has his waste located at
the fabrication site; avoiding costly collection or
freight.  He has a fairly constant supply in terms
of both quality and quantity and since a trip
through the extruder will not significantly change
the prime product, the scrap is easily mixed with
prime material  with no change in process or article
properties.  He has control  of the handling of the
waste to insure that it is clean and that different
plastics are not mixed.  His scrap is the same
specific type,  grade, and color of material as the
prime material  he is using.
          The major key to the fabricator reuse of
scrap is the fact that different polymers are
scrupulously kept separate.   In general, plastics
do not mix with each other to form useful alloys.
For example, polystyrene in  polyethylene or in
polyvinyl  chloride will result in a two phase
system that will  have properties less than the
properties of the individual components.  This is
true of almost  all  mixtures  of the major plastic
materials.  Since any material  will obviously be
sold on the basis of the property balance for a
given market, heterogenous blends of scrap gener-
ally have less  value than the components parts.
                        95

-------
It is also obvious that the final  product must have
properties to fit some application or it will  have
no value at all.
          Thermoplastic property values can be
recovered from the scrap essentially in two ways.
The first requires isolation of a  pure plastic
component.  The second requires finding a "compati-
bilizer" that will improve the properties of an
article made from mixed plastics.
          The Dow Chemical Company has been
involved in reclaimation projects  involving both
isolation and modification.  One utilized pure
polyethylene which went from fabricator to consumer
and back to recycle without dilution with the  other
polymers.  The second project is a research program
to develop a compatibi1izer for plastic mixtures.
Thus, we have some experience in both of the
preferred choices for solution to  the problem.
          In order to isolate a pure plastic
component from collected solid wastes, we would
first have to separate plastics from the other
wastes, then further separate the  collected plastic
into the individual types and grades.  This would
involve very significant costs.  Therefore, if
possible, it is more desirable to  keep the material
from getting into the waste streams in the first
                        96

-------
pi ace.
          The Golden Arrow Dairy experiment in San
Diego has received considerable attention and is an
example of avoiding the solid waste stream.  The
dairy and its Vice-President, Don Calori, deserve a
considerable vote of thanks from the Plastics Indus-
try for engaging in the breakthrough experiment and
sharing their experience with us.  The Dow Chemical
Company has not contributed directly to this
project, but as a resin supplier to the dairy we
have been involved in discussions on equipment,
methods and markets for recycled or reclaimed
plastic.
          Golden Arrow markets milk in disposable
HOPE containers.  They observed the ecology concern
of their customers and decided to do something
about it.  A project was set up to have the used
bottles picked up by the regular delivery man and
returned to the dairy.  A significant volume of a
single  type and grade of plastic was available at
one point with very little cost incurred  in the
collection.  A grinder was installed to reduce the
bottles to a saleable and shippable flake and a
market  was found for the flake.   This sounds very
simple  but no part of the project has really been
that easy.   A relatively large percentage of the
                        97

-------
home delivery bottles are returned but 5% of the
returns are contaminated in such a way that they
cannot be recycled.   This means that  each bottle
has to be inspected  before being ground and the
added labor cost is  significant.  Some contamina-
tion occurs even with this inspection.  Another
restriction is that  the bulk density  of the flake
is not high, so it cannot be shipped  large dis-
tances without added freight cost.  Cartons for  the
flake do not present a problem in this situation
but they could add cost if the grinder did not  have
readily available used containers.
          A market for the ground PE  has proven  to
be the largest obstacle.  It was determined because
of health laws that  recycle could not go back into
milk bottles or other food packages.   The earliest,
and most publicized  market, was a plastic drainage
tile.  Government specifications required virgin
polymer for that use so the outlet was temporarily
lost although the cost and properties were attrac-
tive.  The dairy has found other customers but
their path has not been easy.   This is probably  to
be expected in a real breakthrough project but  I
think we have learned a few things.
          This type  of recycle is a waste manage-
ment problem.  Going from the  consumer to the
                         98

-------
collector without contamination is not easy and



finding uses for the scrap, even though the proper-



ties are good, will  be very dependent on economics.



Virgin plastics are  relatively inexpensive.



Rehandling, container, shipping and marketing costs



can easily put the price of scrap at a level  that



is unattractive relative to virgin material.   These



problems can be solved but since some of them are



local  in nature, it  will take good management and



good marketing on the part of local distributors.



Technical problems,  such as quality control,  are



inversely proportional to the degree of consumer



interest in making such a program work.  The  other



problems such as government regulations and custo-



mer trust can be worked out with time and con-



scientious effort.



          Since pure plastic components are not



readily available, development of compatibilizing



agents is desirable.  Last October at the Society



of Plastics Engineers Regional Technical Conference



in New Jersey, J. N. Schramm of The Dow Chemical



Company, reported on the use of chlorinated poly-



ethylene as a compatibi1izer for mixed plastic



scrap.  This development is unique because, as



stated earlier, plastics do not normally mix  to



give useful products.  The scientific reasons for



                        99

-------
incompatibility of plastics and why an experimental
approach is necessary are worth some explanation.
The mixing of liquids, which is one way of describ-
ing amorphous polymers, has been well  studied for
small  molecules.  Solubility can readily be defined
with the usual  free energy formula:
                   AF = AH-TAS
If the free energy of mixing is favorable, the
materials are soluble.  The same is true of large
molecules but all  of the emperical  rules that we
have built up for small molecule mixing fail  for
polymers.  The  entropy change for small molecules
is small and fairly constant, therefore the
enthalpy (useable heat content) determines the
solubility and  all of our rules are built around
this simplification of the free energy equation.
With large molecules, the entropy change is signi-
ficant and variable, therefore the simplified
solubility rules do not hold.  Like dissolving like,
solubility parameter, and the cliches  of solution
technology are  worthless.  The limited study of the
solubility of large molecular solutes  in large
molecule solvents has proven these facts but has
not systematically demonstrated a set  of entropy
rules similar to the common enthalpy rules.
                        100

-------
          If solid materials are mutually insol-
uble, they can still be combined to give useful
products if they can be made to adhere.   Laminates
and aggregates are well known as heterogenous
materials that are useful  as long as the phases
have some degree of intermolecular bonding; adhe-
sion.  The major polymers, polystyrene,  poly-
ethylene and polyvinyl  chloride do not have
capabilities for hydrogen  bonding and they have
very limited polarity,  therefore very small Van  der
Waal forces.  Because  of these molecular limits,
they demonstrate very  low  adhesion and do not form
useful  laminates without special treatment or
special  compatibilizers.
          Schramm's report at the RETEC  noted that
chlorinated polyethylene (CPE) has the unique
property of mixing with most polymers and the
capability of "gluing"  together a composite made of
the polymers found in  the  normal waste stream.
Table 1  illustrates the properties obtained from
such a  blend.  Note that the tensile impact in-
creases  significantly  even though the tensile
strength does not.  This is exactly what would  be
expected from increasing the interphase  adhesion
of a heterogenous mass.  The scrap used  in these
experiments has the composition noted in Table  2.
                        101

-------
Other data obtained by using mixtures of pure
polymers are shown in Table 3 and 4.
          Significant quantities of CPE must be
used and properties are going to vary with the
nature of the scrap.   Within certain  limits, the
end product properties can be varied  by the inclu-
sion of some virgin product.  The end use of such a
product will have to  depend on local  marketing
possibilities and local scrap composition.  It is
doubtful if a centralized research effort can give
more than general guidelines as to uses.  The final
success of a program  to utilize scrap by this
method will again depend on the ability of local
distributors and formulators to solve local prob-
lems.  Tile, plastic  pallets, certain toys and many
other applications are possible outlets.
          Other methods of recycle are being
investigated and discussed.  Many of  these recog-
nize the difficulty of increasing the value of
scrap and tend to utilize it as something other
than a thermoplastic.  One company has made a light
weight concrete that  is said to have  good proper-
ties.  Compressed building blocks are said to be
feasible when the right combination of plastic
scrap is mixed with other waste.  A form of recycle
that must not be omitted is the use of plastic
                         102

-------
waste as a fuel.  Petroleum is the starting raw
material for all of the major polymers and the
chemical changes that we perform do not greatly re-
duce the BTU content.  PVC does have a lower BTU/lb.
than does petroleum but based on carbon content all
of the major polymers are nearly equivalent to the
fuel from which they were derived.
          In summary, I think that several points
should be repeated.  Waste thermoplastic articles
can be recycled into a second generation of
fabricated articles.  This can be accomplished by
reprocessing a single type of polymer, or by
compatibi1izing the mixed plastic from the waste
stream.   The problems associated with the recycle
of a single  type of polymer are primarily waste
management and marketing.  Technology problems
still exist  before compatibilized blends can be
perfected but again marketing is a real  obstacle
in this  approach to recycle.   Plastics do have
recycle  value as fuels or fillers although such
recycle  does not take advantage of the physical
properties built into the polymer molecule.   Some
of the recycle problems have  been identified and
solutions, or at least leads  to solutions, have
been found.
          Why do we have a plastic waste recycle
                         103

-------
problem?  We know that recycle is technically

feasible.   In the past the economics and the quan-

tity of plastics in the waste stream have not

warranted  the development of methods for collec-

tion, separation, distribution or marketing.  The

programs described in this discussion indicate that

the economic climate may now be right for the

beginning  of a new phase in the plastics story, but

this must  be proven "case by case" at the local

1 eve! .
K. L. Burgess
4/21/71
                         104

-------
                    TABLE 1
  PHYSICAL PROPERTIES OF ACTUAL PLASTICS SCRAP

      WITH INCREASING LEVELS OF CPE 42/2/4

           COMPRESSION MOLDED SAMPLES
                      *         c,
                               ^
100% Scrap          11          1450       0
Plastic Mix

15% CPE/85%         11.7       1715       0.45
Scrap Plastic
Mi x

17.5% CPE/          12.7       1690       0.54
82.5% Scrap
Plastic Mix

20% CPE/80%         15.7       1715       0.76
Scrap Plastic
Mix

22.5% CPE/          17.7       1712       1.5
77.5% Scrap
Plastic Mix

25% CPE/75%         20          1600       1 .6
Scrap Plastic
Mix

27.5% CPE/          22          1600       2.83
72.5% Scrap
Plastic Mix
                       105

-------
                     TABLE 2
           COMPOSITION OF SCRAP  PLASTIC*
          LDPE approximately          44%



          HOPE approximately          19%



          Polystyrene approximately    31%



          PVC-ABS-PP approximately      6%
*Plastics in total  were less  than  4% of  the  waste,
                        106

-------
                   TABLE 3
   PHYSICAL PROPERTIES OF SIMULATED SCRAP

                                          TJ 'X
                                          ^> 'V.


                                          r ^ c,
Mixture A          0       0     10%    1960





  Plus 15% CPE     0       0     15%    1790




  Plus 33% CPE     2.6     0     50%    1500




  Plus 50% CPE    10.7   925    415%     964
Mixture A = LDPE/HDPE/PVC/PS (25% each]
                      107

-------
                   TABLE  4
    PHYSICAL PROPERTIES  OF  SIMULATED  SCRAP
                      £?
                     •v \
Mixture B         0        0     60%     1650





  Plus 15% CPE    2.29     0     98%     1530




  Plus 33% CPE    6.08     0    115%     1100




  Plus 50% CPE   14.1     862    278%      940
Mixture B = 50% LDPE/25% HDPE/12.5%  PMC  &  PS
                      108

-------
     POLYTRIP®, THE RETURNABLE PLASTIC MILK BOTTLE SYSTEM
                      Karl H. Emich
               U. S. Industrial Chemicals Company

          We in this  country  as well  as  a  good

deal of the world are faced with the  fact  that

pollution of air, water, and  land  has  reached

proportions that are  enormous.  The demand for

correction is justified, but  some  impatient  voices

want a change over night without realizing what

gigantic problems must be solved to achieve  this

goal.  A number of these problems  require  the

development of new technologies before they  can be

successfully attacked.

          Hand in hand with these  problems goes the

the one we are concerned with  at this  conference:

the disposal of solid waste.   One  portion  thereof

deals with waste created by the food  packaging

industry.  Competition and the intent  to focus the

customer's attention  on the package as a selling

point have created a multitude of  packaging  shapes

and forms from a wide variety  of materials.

          The effective, yet  efficient disposal of

solid waste generated in the  U. S. has become a

social and economic problem.  While we are only at

the beginning of this battle  it seems  that a number

of methods offer possibilities to  help bring about

a satisfactory solution.

          I would like to present  to you one

solution that U. S. Industrial Chemicals Company,

                        109

-------
a division of National Distillers and Chemicals



Corp., has to offer in the realm of liquid milk



packaging.  It is known under the trade name of



Polytrip ® Systems and consists of the returnable



polyethylene milk container and an inspection



device, a volatile organic contaminant detector.



          In 196l and 1962 several dairies exper-



imented with single trip plastic gallon milk con-



tainers to test public acceptance.  These early



tests showed encouraging results and dairies



expanded their efforts to commercial status.  In



1963 there were just 4 dairies packaging milk in



plastic, by 1964 there were 65; in 1965 - 135; 1966



over 500;  and by 196? over 700 dairies throughout



the country were using plastic milk bottles.^



          The polyethylene bottle has a number of



advantages over its competitors, the glass bottle



and the polyethylene extrusion coated paper con-



tainer :



          it is light weight;



          it is tougher and less breakable;



          its translucency gives milk a rich,



          creamy appearance;



          it has excellent appearance; and, it can



          be designed in many appealing shapes.
                        110

-------
          In 1966 there appeared in the dairy
market a new development which offered the dairy
operator the advantages of plastic containers
combined with cost efficiencies exceeding those of
the glass bottle.  This was the returnable poly-
ethylene milk bottle system.
          The basic problem previously prohibiting
the use of the plastic bottle on a returnable basis
was its tendency to absorb hydrocarbon contaminants.
If the consumer had been using this bottle for the
storage of hydrocarbon based chemicals, no dairy
washer could remove the so Induced contamination
from the container.  The consumption of milk
packaged in contaminated containers could produce
health problems.  Since dairies could not predict
the customer's reuse of the returnable bottle before
its return for refilling, there was an evident need
for a device that was able to detect hydrocarbon
contaminants, such as those contained in gasoline,
kerosine, paint thinner, etc.
          The successful development of the detec-
tor was the result of a long and carefully
researched project which started in early 1963 in
Spokane, Washington.  It was  tested by the City of
Spokane Health Department, the U.  S. Public Health
Service (USPHS) and Washington State University.
                        Ill

-------
Only when these groups were satisfied that the
detector provided an effective safeguard against
such contaminants did the USPHS judge that the
system met applicable provisions of the Public
Health Service Grade "A" Pasteurized Milk Ordinance.
          Further development of this instrument
was necessary to keep pace with the steadily in-
creasing bottling rates in the dairies.  While the
first instruments were only capable of testing 20
bottles per minute, the present detectors can
handle about 130 bottles per minute.
          The detector is located between the
bottle washer and the filler directly over the
conveyor line.  As a bottle passes underneath, a
sample of air is taken from it.  A flame ionization
detection system determines the total amount of
hydrocarbons present in the sample.  If the analysis
shows a contaminant level which is of public health
significance, a punch mechanism is actuated which
renders the bottle unuseable.
          The needed hydrogen for the flame is
produced inside the detector cabinet.  A built-in
test mechanism allows checking of the proper sensi-
tivity level at any time.  Interlocks are provided
to shut the bottle washer or the conveyor line down
should the instrument malfunction.  U.S.I, maintains
                        112

-------
a complete service organization throughout the




United States to prevent costly downtime in the




dairies and to install newly purchased units.




          The Polytrip ® returnable plastic milk




bottle is blow molded of high density polyethylene




and is especially designed for reuse.  At about 170




grams for gallon bottles and 126 grams for half




gallons, the strong walls and sturdy construction




eliminate container collapses at the filling line




and let them stand up for more than 100 trips.  Half




gallon and one gallon sizes with blown or Glass




Container Manufacturer's Institute (GCMI) finishes




are now available to the industry.




          The Polytrip ® bottle is annealed to




insure that it does remain constant in volume after




repeated washes in the dairy.




          The type of resin used for the returnable



container must meet Pood and Drug Administration




(PDA) requirements in the Federal Register, Subpart




P, Section 121.2501 for food packaging applications.




Furthermore it must meet the 1965 recommendations of



the USPHS for single service and multiuse milk con-




tainers, as stated in the Grade "A" Pasteurized Milk




Ordinance.   As for the milk bottle, some states




require approval of the Department of Health and the




Department of Agriculture.   Most accept the findings



                        113

-------
of the USPHS regional office in their area.  Some




require approval of even small local and municipal




boards of health in addition to the state agencies.




There are no known requirements for milk bottle




resins as stipulated by the National Bureau of




Standards (NBS).




          Milk volume in linear polyethylene




bottles can qualify as a prepackaged commodity which




meets the requirements in Handbook 67 of NBS.




          Only polyethylene resins of high density




are suitable for use as fluid milk containers.




Presently used resins have 90-95% crystallinity and




0.965 g/cm3 density to maximize rigidity, surface




hardness, permeation resistance, and surface




friction resistance.  Bottles with these properties




withstand easily over 100 trips from dairy to cus-




tomer and back.




          To the dairy the advantages of this




system are significant.  The returnable polyethylene




containers are practically unbreakable, which when




compared with glass, greatly reduces production




down-time and delivery losses.  No breakage means




a safer, cleaner, filling operation for the dairies.




Easier handling and stacking in the plant result




from the lighter weight of the bottle when compared




with the other returnable container - glass.



                         114

-------
Distribution by truck becomes more economical be-




cause of the light weight.  Up to 20% more milk in




polyethylene containers can be placed on a truck




when compared with its main competitor glass.




          Prom experience we have found that in




places where the returnable milk bottle was intro-




duced it was very well received by the consumers.




The majority of dairies experienced an increase in




volume output, in a number of instances very signif-




icant ones up to 100?.




          And now let us take a closer look at how




the returnable plastic milk bottle fits into ecolog-




ical viewpoints.  Compared with glass containers,




the polyethylene returnable container outperforms




it in the number of trips about 5 to 1.  All other



forms of containers, be it plastic or paper, are of




the single trip variety and do not help to reduce



the amount of solid waste.  According to Public




Health Service (PHS) publication 1855, packaging



materials on a tonnage basis will increase at  a rate




of 3.6? annually in the 1966 to 1976 period.  Ex-




pressed in pounds this means a change from 103-^




billion pounds in 1966 to 1^7.0 billion pounds in




1976.^2)  These gigantic figures give an idea  what




is in store for us in the future.
                        115

-------
          One obvious way to reduce waste is the



reduction of the quantity of packaging wastes gen-



erated.  Reuse of the package is one way to achieve



this goal.  If we assume only 100 trips for the



polyethylene returnable milk bottle we have 100



disposable bottles for each 1 polyethylene reusable



container, or about 4-5 glass bottles for the same



one polyethylene multitrip bottle.  This shows a



drastic reduction of waste generated.



          But sooner or later the fact becomes



clear that even these long lived containers must be



disposed of.  They then become a part of the plastic



waste disposal problem.  Recognizing this problem



the Society of the Plastics Industry has undertaken



two tasks:



          1.  an effort to help find solutions to



              solid waste problems, particularly the



              safe and efficient disposal of



              plastics, and,



          2.  a program of information and education



              on the role of plastics in solid



              waste.(3)



          Our present methods of disposal need



revisions or replacements by more efficient and



appealing systems.  Added consideration must be



given to the fact that we need to recover more and




                        116

-------
more of the valuable raw materials to prevent the



rapid depletion of our natural resources.



          Open dumping, landfill, composting, and



incineration are still the prevailing methods of



disposing of solid wastes.  Here is a quick look at



them:



          Open Dumping.  This is still the most



widely used method of waste disposal.  More than



3/4 of all municipal refuse is discarded in dumps.



This method has numerous drawbacks and its use is



increasingly being banned.



          Sanitary Landfill.  This method has more



positive features and, if properly done, is an



excellent way of disposing waste.  Polyethylene is



well suited for this method because it does not



decompose.  However, desirable sites for landfill



are becoming very scarce.  Only about 10$ of the



country's refuse is disposed of in this way.



          Composting.  Although composting is an-



other feasible method of disposal, in practice, it



was found that only a very small market for com-



posting is available with limited growth prospects.



At present, only 1% of refuse goes into composts.



          Incineration.  Although not ideal, incin-



eration is a practical means of disposing of many



types of solid waste.  Efficient incineration can



                        117

-------
result in a volume reduction of 12 to 1.   Until



better methods of disposing of solid waste are



found, incineration seems to be the logical process.



The reason tnat incineration has a bad name is, and



I quote from the September 1970 Position Paper by



The Society of the Plastics Industry:  "because



most incinerators are obsolete and inefficient,



providing poor reduction of refuse and polluting the



air.  There are only about 300 municipal inciner-



ators in the country and 75% of them are inadequate



by Bureau of Solid Waste Management standards."*-^'



          Again and again voices have been heard



protesting incineration of plastics because of the



poisonous gases produced during this process.   The



truth is that emissions from burning polyethylene



are no more and in many cases less toxic than those



from other burning organic materials.



          It would be ideal if polyethylene could



be recycled.  This way waste would be eliminated



and raw materials could be saved.  In reality re-



cycling today Is far from being feasible.  Therefore



we have to resort to the known methods of disposal



mentioned earlier.
                         118

-------
          In the meantime we should try to find

useful means for the disposition of plastic waste.

In Europe, polyethylene waste is used to generate

power.  The Btu content is about the same as coal

or three times the solid waste average.  Addition

of polyethylene to garbage aids the combustion in

incinerators.

          We are only at the beginning in the

development of really effective methods of solids

waste management.   With our growing population we

will be faced with increasing amounts of solid waste

while on the other hand drastic changes are indi-

cated to counteract the rapid depletion of some of

our natural resources.   It cannot be left to one

group or another to take action, but industry,

science, and government must work together to find

solutions for the  pending solid waste problems as

well as for the preservation of our resources.

                     REFERENCES

Technical Papers

      (1)  Eder, Peter, "Plastic Containers, The
           Challenge,"  presented at American
           Management Association, Dairy Packaging
           Seminar, Chicago, Illinois (May 1967).

      (3)  The Society  of The Plastics Industry,
           Inc., "The Plastics Industry And Solid
           Waste Management", Position Paper,
           (September 1970), p. 5.

      (4)  Ibid, pp. 7-8.

                         119

-------
Books
      (2)  Darnay, A. J. Jr., and Franklin, W. E.,
           The Role of Packaging In Solid Waste
           Management 1966 to 1976. Public Health
           Service Publication No.  1855, Washington
           D. C., U.  S. Government  Printing Office
           1969, p. 99.
                         120

-------
        RECLAMATION OF PLASTIC-PAPER COMPOSITES
                   Safford W. McMyler
                 Riverside Paper Corporation
                    INTRODUCTION


          The   Riverside    Paper   Corporation  in

Appleton, Wisconsin, has for  the past  twelve years

successfully  operated a plant  which   removes ad-

hesives, wax and  plastic   coatings from paper and

paper board in order to recover  the wood pulp fi-

ber for use in the  manufacture  of fine papers in

its paper mill.

          This was  commenced  and continued so that

the company, which  had no captive   source of manu-

factured wood  pulp, could,   through the substitu-

tion of these fibers  reclaimed  from  waste, main-

tain  a competitive position  with  those fine paper

manufacturers  which  have   integrated  paper/pulp

mills.

          The economics of  this process are proven

to our satisfaction.  A savings, which  ranges be-

tween 15 and 30% below the  commercial  market price

of pulp, has been realized  for a  number of years.

This savings recognizes  all  of the processes re-

quired to produce fiber matching   the  characteris-

tics of virgin fiber - the  initial  chemical proc-

ess which I am here to describe, plus  the cleaning

and bleaching  processes  necessary for  the high

                         121

-------
grades of business  and school  papers we manufac-




ture .




          But what has now  become  equally impor-




tant as the  economic  benefits is  the ecological




benefits:  There are  some  plastic  film  removal




methods employed in  recovering waste  fiber - the




mechanical or wet systems - which  result in seri-




ous solid waste disposal or stream pollution prob-




lems;   whereas  our method is, in  effect, a  dry-




cleaning process producing wood pulp fiber, essen-




tially 1OO% free  of the  undesirable  contaminant




which is disposed of by utilization as fuel in our




boiler.  The reclaimed  fibers are  completely un-




impaired in physical properties.




          The original patent  on this process was




issued under U.S. Patent  No. 3,058,871 on October




16, 1962.




          Recent  technical  improvements  in this




process, known as the Polysolv Process, are cover-




ed by a patent application Serial No. 17,892 which




was issued on March 9, 1970.




          In  Summary:  This  is  a  revolutionary




method of waste fiber  preparation by a non-pollu-




ting process.
                         122

-------
    Advantages of the Polysolv Process







1.   It is a dry furnish process  and the re-




     covered fiber is in the same  form as it




     entered the reactor.




2.   The treatment  of  the  waste paper  and




     board at  high  temperature  softens any




     wet strength resins present resulting in




     more efficient pulping of  the reclaimed




     fiber .




3.   The process is 100% efficient  in remov-




     ing polyethylene  and  wax coatings, and




     polyvinylacetate  and other  similar ad-




     hesives .




4.   It is a closed system  and there  are no




     problems of air or stream pollution.




5.   The exotic coatings can be mixed without




     discri mination .




6.   On printed waste, if the  ink is on  the




     coating, solvent  extraction   dissolves




     the coating  and simultaneously  removes




     the ink leaving the reclaimed  fiber es-




     sentially ink free.




7.   Tests show no strength loss between sol-




     vent extracted and non-extracted fiber.
                    123

-------
                PROCESS DESCRIPTION







          Basically,  this  simple, solvent extrac-




tion process  can be   described  as  consisting of




three phases:




          Dissolving




          Solvent recovery, and




          Removal and utilization of the reclaimed




          contaminants.




          The  chemical  processing  equipment  for




the existing plant occupies about 4000 square feet




on four floor  levels.




          The  waste is delivered to  our plant  by




rail in bales  weighing approximately 1500 Ibs.




          Phase  I -  Dissolving - The  Rotary  Re-




actor is loaded  with coated  unused milk cartons,




converter cuttings, or shredded large sheets.  The




reactor is then closed and  the extraction  cycles




are carried out  in three  (3) stages  using trich-




lorethylene, a common degreasing solvent.




          The first extraction  stage is made with




the "dirtiest" solvent,  i.e. solvent  already used




twice.  The second extraction  stage with  solvent




used once.  The third  extraction stage with clean




solvent.  After each stage, the  solvent is simply





                         124

-------
syphoned out  of the  reactor;  therefore, the ex-


traction  efficiency  is  rather  low.  During the


charge, the solvent is instantaneously  heated, in


a heat  exchanger, up to 240°F  (boiling  point of


trichlorethylene is 188°F).   In the  reactor, the

                                               o
temperature drops to the neighborhood of 19O-205 F.


The vapor phase of the  superheated  solvent main-


tains an operating pressure in  the reactor of ap-


proximately 15 psig.  No steam is added to the re-


actor at this stage, but only to  the solvent heat


exchanger.  After the last extraction, the solvent


is syphoned to the semi-clean  tank  as thoroughly


as possible.  Steam is then fed to  the reactor to


strip the residual solvent  from the fibers.  This


operation is carried out  at 8-9 pounds in the re-


actor with available  superheated  steam  and  re-


quires 6O  to   9O minutes according to the amount


of trichlorethylene remaining in the reactor. When


the pressure in the reactor starts  to drop, there


is no more recoverable solvent.  The  steam supply


is shut off and a.  light vacuum is  applied to the


reactor.  All the solvent  vapors from  this final


stripping operation  are recovered in  a  separate


water cooled  condenser;  the mixture  of  solvent


and condensed steam is fed  to a  water separator.


The clean solvent  is pumped to  the clean solvent



                        125

-------
tank.  The burnish, now solvent and  poly-free and




only slightly moist because of the steam stripping




operation, is dumped to subsequent equipment.




          Phase II - Solvent  Recovery  - The dirty




solvent recovered in the first stage of Phase  I  is




fed batchwide to a conventional still with natural




circulation heat exchanger, operating at 200-220°F




and 6-9 pounds  pressure.  The vapors   of  solvent




are condensed in a water cooled condenser with the




condensation  creating a vacuum  of  approximately




2-5 inches.  The system  is also  provided with   a




refrigerated  after-condenser and finisher  still.




The residual plastic  which   tends to   remain  as  a




sticky and  jelly-like mass  at the bottom  of the




still, is kept in  a fluid condition with  the in-




troduction  of No. 2 fuel  oil making it  easy   to




handle or pump.




          Phase III - Disposal - After  completion




of the distillation  in the  finishing  still, the




removed wax or  poly and fuel  oil are  dumped  into




a tank for incineration  or injection into a plant




boiler to reclaim the  heat value of the fuel  oil-




poly mixture.




          Figure I, is  the  entire  process   flow




diagram.




          The production capacity of this plant  is





                         126

-------
now 12 to 14 tons per day   of waste  processed.   We




have long considered this   capacity  as  hardly more




than pilot sized.  Last year, having analyzed  the





condition of the existing   plant  (then  12  years  in





use), the potential  for   expanded sources  of  raw




material, and the economic  return   expected on  an




expanded capacity, we decided   that  the investment





for a 50 ton per day capacity plant  should be made





as quickly  as possible.   This  would   satisfy  all




our needs for waste  fiber  in   our existing paper





products.




          Subsequent to this decision such a plant




became available,  and it   was  purchased  and dis-




mantled and  is being  reinstalled at   our mill  in





Appleton. Startup of  this  facility   is scheduled,




for July 1, 1971.





          With this  startup, Riverside paper Cor-




poration will have completed the  steps  from exper-




imental  process, through   successful   pilot plant




operation (at a rate  of 14 tons  per day   for  the




past 3 years of  continuous  operation)  to commer-




cial plant production.  It will provide  5O% of  the




fibers required  for our  paper   mill's  total pro-





duc tion .




          We intend now to  turn cur  efforts  toward





extending the utility of  the process to other ma-





                        127

-------
terials  and  contaminants.  Preliminary  advanced




research has already  offered  encouraging results




on contaminants heretofore considered unassailable.




With the shutdown of our old small plant, which we




intend to  leave intact, we will  have a  facility




available for full-scale trials on was te materials




which offer promise.




          We are testing a program for  collection




of the  plastic-paper  composites  from large  and




concentrated users  such as  schools   and institu-




tions .




          Today, with the  high degree of interest




in recycling and environmental  ecology  being ex-




pressed by the public, government and  industry, we




are encouraged by the attention being  given  to our




no pollution Polysolv Process.









                      HISTORY







          A brief  description  of   the background




and development of our patented process:




          In  the  early  1950's, Riverside   Paper




Corporation tried to use secondary   fiber that was




generated  in  the manufacture  of juice and milk




cartons.  This fiber was white bleached board con-




taminated with polyvinylacetate (PVA),  other  similar







                         128

-------
adhesives, and also wax.  The  percentages of   PVA




and adhesives  ranged up  to 2% by weight, and  wax




up to 12%.  All of this fiber  was free from other




contaminants such as ink.




          When this secondary fiber  was repulped,




screened  and  used to make  conventional  writing




grades of  paper, the PVA  would show up as yellow




shiners  in  the sheet;  the  wax would  cause  ex-




cessive slip;  and contaminant  build-ups  occured




on paper  machine dryers  causing excessive  down-




time for clean-up.  These  repeated  problems pro-




moted extensive laboratory work, followed by a  re-




search program, which developed a  solvent extrac-




tion process.  This was followed by the  construc-




tion in 1958 of a 24 ton per day operational plant.




          After several years of successful opera-




tion, polyethylene slowly became a  contaminant in




the secondary fiber.  A second research effort  was




conducted.  This resulted in a modification of  the




process and a rebuild of the existing plant to  re-




move polyethylene.









                    DEVELOPMENT







          Early laboratory  trials   at   removing




these  contaminants  involved  the use of  caustic







                        129

-------
soda, wetting  agents, soaps, de-inking  formulas,




and  solvents.  These  cooking  formulations  were




followed by a series of aqueous  washings, screen-




ings, flotations  and  centrifugal  cleanings, all




designed to wash  out the waxes, and  mechanically




remove  the agglomerated  particles of PVA and ad-




hesives.  Although some  of these  trials were en-




couraging,   when they were applied  to large scale




production and  the secondary fiber  used in manu-




facturing  paper,   the  same  problems  of  yellow




shiners, excessive slip, and  coating of the dryer




surfaces reappeared.  As a  result  these investi-




gations were terminated.




          In 1955, a review of  patent  literature




and published material encouraged the approach to-




ward continuous  hydrocarbon  solvent  extraction.




With the use of a large laboratory  extraction ap-




paratus, a  series of  trials  was run  evaluating




different solvents to remove the PVA and wax.  All




of these extractions proved to be successful. This




prompted the construction of a pilot plant design-




ed to treat the  waste paper  board trimmings on  a




continuous  basis, since at  this time  batch pro-




cessing was thought to be  uneconomical.  The ini-




tial solvent (of several tried) was  carbon tetra-




chloride, but because of deficiencies in the pilot





                        130

-------
plant, the  solvent  losses  were   high.   This  re-




sulted in high toxicity and undesirable economics.




Battelle  Memorial  Institute  was  then engaged to




investigate the idea  and in  October, 1956,  their





studies concluded that "the  solvent  extraction of





waste paper  probably would be  feasible with com-




mercial equipment."  The Riverside  Pilot Plant  was




then  disassembled  and  transferred  to  Columbus,





Ohio  for  more  intensive work.  As  a  result   of





Riverside's preliminary  work  and  the  studies by




Battelle, several conclusions were  reached;





     1.   The Riverside  process  was both techni-





          cally and economically feasible.




     2.   The process lent itself better   to  batch




          than continuous operation.





     3.   Battelle's experiments developed a very




          effective  means of  recovering  the sol-




          vent.





     4.   The waste contained several types of  ad-




          hesives such  as  PVA  and  in some  cases




          considerably more than had been realized.




          As a result, it was decided that River-





side  would  build a  new Pilot Plant  in  Apple ton





employing a  batch  process  and the  new   recovery





phase.  It was this pilot  plant that prompted  the





decision to proceed  with design and  construction





                         131

-------
of a 24-ton-per-day commercial solvent  extraction




plant.




          Upon start-up of this solvent extraction




plant,  no major problems were encountered  and the




plant's performance  exceeded  expectations.  How-




ever, the  availability  of  the small  (ink-free)




carton punchings was not as expected.  This forced




the plant to use printed milk  cartons, set-up wax




cartons, and any other  wax carton  stock that was




available.  These types of broke  were not consid-




ered in the design  of  the plant, but with  minor




adjustments,  these  were  also   reclaimed.  This




created a new and unexpected  problem -- disposing




of the  tons of contaminated   wax  removed in the




process.  This was resolved when a buyer was found




for the reclaimed wax.




          After several years, polyethylene coated




pieces slowly began showing up in  the baled waste




and concern was  felt regarding the future  avail-




ability  of  raw material.  The  Battelle Memorial




Institute  was  again  consulted.  Their  research




report revealed that it  was  feasible to  extract




polyethylene from board and paper under the proper




conditions, using the  existing  solvent, but that




the recovery  of  spent solvent  and  polyethylene




would have  to be  investigated in  the full scale





                        132

-------
plant.




          Therefore, another  pilot plant was con-




structed.  It confirmed the Battelle opinions.




          The operating plant was then rebuilt and




upon start-up one glaring  problem  resulted:  The




dissolved poly plugged the  evaporator in the dis-




tillation process.  This  was  not completely  re-




solved  until  a later date, but  was  temporarily




solved by saving all wax  waste and  blending this




with poly coated  waste  in  the extraction phase.




When the solvent  was then  reclaimed  in the dis-




tillation process, the distillate or waste did not




plug the operation and recovery  could  be carried




out at  lower  temperatures.  This  was  practiced




until waxed waste  became  increasingly  scarce and




almost non-existent.  It was then  determined that




No. 2 fuel oil could be  utilized as the catalyst.




The patent was  modified to include  this develop-




ment .




          The plant capacity, when rebuilt for the




new operating conditions,  was  reduced to 12 to 14




tons per day. Even at this output,  the very favor-




able  economic advantages  mentioned earlier   are




enjoyed.
                        133

-------
-I
o
o
      OOOt-HUJ±UJX?UJ|-O —




      — M rO * in VON- CD O O — OJ K>
                                134

-------
                 PAPER INDUSTRY PLANS
                    Judd H. Alexander
                   American Can Company
          In San Francisco,  there  is  a  solid

waste transfer station which serves the whole

peninsula.  Standing near the head of the  dumping

pit, a visitor can watch the wastes produced by

two million people being plowed  toward  the loading

chutes.  An occasional can is visible in this  vast

quantity of material, and bottles, orange  peels,

and telephone poles.  But, the overwhelming impres-

sion is of paper.  The garbage is  made  of  paper—

50% by weight and nearly 70% by  bulk.

          Yet, a conference  of this nature devotes

half days to plastics, metals, and glass and a

half hour to paper containers.   Does  this  suggest

the solution to the paper in our waste  is  near

at hand?  There .is an obvious answer  to the prob-

lem, so obvious that advice  on the subject is

available from nearly every  concerned club woman

and schoolboy:  recycle, recycle the  paper to

solve the solid waste problem; and, as  a bonus,

every ton of recycled paper  will save 17 trees.

That is a good, simple answer, but it may  not  be

adequate for this terribly complex problem.

                        135

-------
          Before talking about designing contain-




ers for recycling or reuse, it might be well to




explore the potential, the limitations, and the




economics of recycled paper today.




          But, first, one misconception should be




discussed.  Recycling paper does not necessarily




"save trees."  Save them for what—for rotting in




the forest?  Trees die; and it makes sense to




crop them at the peak of their maturity and to




replace them with fresh growth.  A young forest




will produce about triple the oxygen of a mature




forest.  Do not think of pulpwood trees as the




spreading chestnut in front of the smithy, the




charter oak, or the graceful elms around the




village square.  Pulpwood trees are grown as a




crop—some, in our Southeast, are harvested as




soon as 13 years after planting.  Forest manage-




ment and tree genetics have increased the yields




so that, in spite of increased harvesting, our




nation is a net gainer on trees—the United States




grows more trees and more board feet of timber




each year than is cut.







                        136

-------
          During World War II, we recycled 35%

of all our paper.  By 1970, the amount recycled

had dropped to 19%.  But, percentages can be

misleading, particularly when discussing a com-

modity whose usage is increasing rapidly.  Note

these two facts:

1.  In 1970, we recycled about 60% more paper

    than we did in 1944.

2.  If we increase the recycling percentages to

    World War II levels by 1985, as suggested by

    the National Academy of Sciences, we will still

    have 60% more paper in our wastes then than

    we have today.

          Perhaps we have not done such a terrible

job in the past.  Perhaps recycling is not the

whole answer in the future.

          What happened since World War II to

cut that recycling percentage so drastically?

The answer lies in technology, consumer preference,

and economics—mostly economics.

          The wastepaper markets have always

been subject to violent price swings.  To meet

their growth requirements,  the paper companies
                        137

-------
turned to virgin fiber as a more stable and




dependable supply source.




          At the same time, the potential sources




for virgin fiber expanded considerably.  We noted




that 19% of paper is made from recycled paper,




but another 26% is now made from other wastes




which were not utilized 25 years ago.  I am think-




ing of sawdust, chips, slabs, and other lumber




mill waste which were formerly burned in the




wigwam burners so familiar in the West.




          New pulping techniques brought in many




new species of trees as prime fiber sources:




aspen, cull hardwoods, and Southern pine.  This




expanded the pulp source and created far better




timberland utilization and better markets for the




woodland farmers.  New forest management tech-




niques expanded forest yields, particularly in




the South, by as much as sevenfold.  Finally,




technology made tremendous increases in the speed




and the efficiency of paper and board machines




designed to run the dependable quality of virgin




fiber.







                        138

-------
          Society has paid a price for this paper

explosion in overflowing garbage dumps, but society

has been a beneficiary, too.  Paper has played

a key role in the packaging-distribution-self-

service revolution which has, in just one genera-

tion, dropped the relative price of food by one-

third to 17% of disposal income, quadrupled the

number of items available to the shopper's choice

in a supermarket, and cut by half the time spent

by homemakers in food preparation.

           Improved paper packaging has also played

an important function in reducing urban wastes.

For example, some 238 million pounds of orange

juice is shipped into New York City annually.

But, because it is packaged, nearly 60% of the

orange in the form of peels and pulp is left

behind in rural Florida to be recycled into

animal feed.  Frozen food packaging keeps the

50% of fresh foods—bones, innards, and stalks—

which become wastes out of our cities.  Excello

claims that if all milk now packaged in paper

containers would go back to returnable glass

bottles, our total wastes would increase by
                        139

-------
30 million tons, including broken and discarded

bottles, bottle caps, detergents, gasoline, water,

and heating fuel.

          In the meantime, wastepaper usage has

received a minimum of technological help.  As

much as 90% of the cost of wastepaper is involved

in the collecting, sorting, and transporting of the

material.  Highly labor intensive, collection

costs spiraled with wage increase and little

relief from mechanization.  Traditional wastepaper

products began to lose markets to virgin materials

and to plastics.  Technology is, finally, offering

some help to recycled materials.  A new type of

paper machine—ultraformers—give better-quality

recycled products at much higher speeds.

          Recycled fibers are, at present, used

for a relatively narrow line of products, and they

are collected from an equally narrow line of

products.  An improvement in the economics of

collection and recycling, a change in political

and public attitudes on recycled products, and

the development of new products or markets are

essential to expanded use.
                        140

-------
          The public concept for making all paper

from recycled paper remains unrealistic.  First,

about 12% of paper production is unrecoverable.

It is in permanent use in building material or in

books, or it is lost in residential fireplaces or

in sewage systems  (tissue).  Second, paper is not

like metal.  In recycling, it cannot be made  "as

good as new."  Each time paper is recycled, the

fibers become a little shorter and a little more

frayed,  and the resulting paper product gets  a

little weaker.  In some products, where strength

is not a factor, recycled fiber can be used as a

substitute.  In other products, some carton boards

for example, the weaker fiber must be compensated

for by additional bulk or caliper.  This could

actually increase the waste from some products.

          There are other limitations.  Our com-

pany is a large manufacturer of food packaging.

We guarantee to our customers that paper products

which will come in direct contact with food will

contain no materials or substances which are not

approved by the Food and Drug Administration.  We

do not believe we can fulfill this pledge when
                       141

-------
using paper fiber collected from unknown sources

or paper that has been contaminated with printing

ink or other unapproved FDA substances.  This

applies particularly to cartons for milk, ice cream,

baked goods, etc.  It does not apply to carrier

cartons in which the food is protected by a

pouch or innerwrap.

          Cartons made from virgin fiber can be

produced in very low calipers while maintaining

the performance characteristics required by high-

speed packaging machines.  For example, the familiar

TV dinner cartons are now made from low-density,

virgin paper board 13/1000's of an inch thick.

The minimum caliper for recycled fiber board may

be 16/1000's of an inch, and the increase in the

weight of the carton would be more than 30%.

          Combination  (recycled) paperboards can

do many jobs well.  But, the economics, which

determine board grades consider performance as

well as original cost.

          Corrugated shipping cartons are good

users of recycled fiber now—25%—and they have

prospects for expanded growth.  However, new fiber
                        142

-------
must be added to the recycled material to retain

the strength.  At the moment, it does not look

like they could exceed 40% reuse, and even that

would put a difficult economic burden on the

industry.

          Perhaps the most difficult complexity

in a mandated increase of recycled fiber is the

social-economic problem.  Let me illustrate it

this way:

          My company, American Can, has a large

paper mill on the Tombigbee River in rural Choctaw

County, Alabama.  We are the largest employer in

the county.  We are the largest buyer of agricul-

tural product in the county  (trees).  All of the

wastepaper produced in the county would run that

mill for about three hours a year.   If recycled

paper is to be a mandated requirement for tomor-

row' s paper products, this mill is in the wrong

place.   Question:  In a nation which already has

80% of its population concentrated on 2% of its

land,  should we advocate a national policy which

tends to drive the paper mills off the Tombigbee

rivers and onto the Hackensack,  the Chicago,  and
                        143

-------
the Detroit?  Are not sociological considerations

important, too?

          Actually, you could build today a

wastepaper mill for substantially less money

than you build a forest pulp and paper mill.  On

the other hand, almost all the mills built in the

last 20 years were virgin fiber mills.  They

exist.  They are not suited by location or equip-

ment for running wastepaper.  They represent a

tremendous investment.  They are economic only if

running near capacity.  They are not portable.

Two thirds of all pulpwood is purchased outside

the paper industry, and these pulpwood producers

have a substantial investment, too.

          The paper industry is making a substantial

capital commitment over the next five years to

better control equipment for water and air pollu-

tion.  The additional demand for the special stock

handling and cleaning equipment required for

wastepaper use and the addition of new pollution-

control equipment for the special problems of

recycled paper would bring economic chaos to the

paper industry if handled on a crash basis.  On
                        144

-------
the other hand, a gradual move to increased recy-

cling, stimulated economically, could be handled

by normal growth falling to new mills designed for

the new policy.

        Incidentally, I mentioned the "special

pollution problems" of recycling.  Since many

people suspect there would be no pollution poten-

tial with recycling, it might be well to give the

problem brief mention.  Recycling often required

the removal of the ink which represents a disposal

problem.  The average deinking plant loses about

25% of its input to waste.  Second, the paper

itself decreases by about 10% with each recycling.

The lost material escapes as suspended solid in

the waste water and must be controlled.  Recycled

mills produce substantially more suspended solids

than virgin fiber mills.  Coated magazine stock,

such as is used for LIFE and LOOK, will give off

as much as 50 pounds of sludge (ink and clay)

for each 50 pounds of fiber recovered.  That is

why the wastepaper dealers always sort out the

magazines from the newspaper bundles after they have

been collected from well-meaning citizens.
                         145

-------
          So much for the production of waste-

paper products.  Let us examine the collection of

these materials.  Remember, collection cost

represents more than 90% of all costs for waste-

paper.  The mill wants paper that is clean and

homogeneous.  The collector wants maximum quan-

tities at each stop for efficiency.  These two

requirements have limited most wastepaper to four

collection sources:

1.  Scrap from carton plants, paper converters,

    and printers.

2.  Used corrugated boxes collected from indus-

    trial plants and retail stores.

3.  Newspapers from the publishers and from public

    drives.

4.  Writing paper waste from office buildings.

          As the market for wastepaper expands,

the demand on these four sources will expand first.

Although almost all other paper products can be

recycled, it is impractical to collect them, clean

and in quantity by type, with present technology.

The Black Clawson concept and some long-range

work done by the Forest Products Laboratory in
                        146

-------
Madison, Wisconsin, can change this situation.

In the meantime, the potential for increased

collection from the four basic sources can support

the anticipated and desired growth in this market.

          The economics of collection remain dif-

ficult.  They can be illustrated by some studies

conducted by Garden State Paper Company, the

nation's largest manufacturer of recycled news-

print.  They think their type of product will

never penetrate more than 10% to 15% of the news-

print market.  First, an efficient mill size is

350 tons a day.  They do not expect to get more

than 15% to 25% of the papers back from a city,

and with annual per capita consumption of news-

print at just under 100 pounds, there are relatively

few locations in the U. S. that could support a

mill with collections.  Significantly, Garden

State's three mills are located near New York,

Chicago, and Los Angeles, our three largest cities.

Now,  one point of promise on this is the experiment

being run in Madison, Wisconsin.   There, through

the cooperation of the city government and the

citizens,  40% of the newspapers are being collected.
                        147

-------
It is a noble experiment.  Still, it would take

a courageous businessman to build a $65 million

recycling mill on the hope that that rate of return

could be maintained or duplicated in other cities.

          One of the stimuli to wastepaper use

always under consideration is a municipal subsidy.

Most cities pay more than $30 a ton to collect

and dispose of their waste.  If the city would

subsidize paper scavengers $15 a ton to remove

paper be fore the city collected it, the economics

would favor the growth of recycling and reduce the

cost of the city's sanitation department.

          There seems to be two problems here.

First, most cities already charge commercial

establishments for pickup and disposal so they

would be saving no money.  Second, and more dif-

ficult, political leaders are reluctant to commit

themselves to a contract which could appear to be

aiding business at the expense of the taxpayer.

The public expects industry to pay for wastepaper,

not get paid for taking it away.  This attitude

must change.  A recognition of the present nega-

tive value of the waste is essential to support
                        148

-------
the economic incentives for recycling mostly all




products.




          Now, with that rather lengthy preamble,




we are prepared to discuss designing paper con-




tainers  for recycling and reuse.  We have said




there is little potential for recycling hetero-




geneous  contaminated materials collected in small




quantities.  That eliminates most household




packaging.  Let me come back to that in a minute.




          Corrugated containers do have some




potential.  Recyclers tell me they would like to




get rid  of asphalt tape, wax linings, hot melts,




and pressure-sensitive materials.  If the cases




were marked conspicuously when these contaminants




were used, the offending cartons could be sorted




out visually.  The result would be better quality




in the recycled corrugated,  but it would also mean




higher collection costs.  First, there would be




more sorting.  Second,  the mills would refuse the




contaminated material so the scavengers would need




to find  a second outlet.  However, it is an idea




that should be explored further.







                        149

-------
          Another possibility is to restrict the

use of contaminants on corrugated by law or penalty.

This is a more complex problem.  The recycling

contaminants add utility and versatility to the

carton's original function.  If you deny them this

flexibility, you decrease their ability to compete

with their competitors including wire bound

boxes, steel strapped containers, plastic shippers,

etc.  Would this serve the objectives of better

solid waste management?  Certainly, such a move

would require careful study.

          Designing the rest of the containers

in the waste for recycling or reuse still has some

promising potential.  We are facing a massive

change in our waste handling systems.  Concepts

like Black Clawson call for the recovery of all

fiber.  If the quality problems can be worked out,

this has potential for recycling or for a second

use.  The fiber might be combined with water

soluble plastics to be compressed into building

blocks.  This might work some places, but not

everywhere.  The market for building blocks is

just not that strong.
                        150

-------
           Some work has been done  in  converting  the

wood  sugar in paper fibers to  a high  protein

animal  feed.  It works in theory,  but here, too,

a  severe problem of contamination  must be  faced.

           In the concept of redesigning  for either

disposability or reuse, I want to  caution  against

sacrificing the original function  of  the package.

Paper containers are involved  in extremely com-

petitive markets.  If mandated recycled  fibers

decrease the quality or performance or increase

the price  of the paper container and  the market

is lost to plastic or some other material, the

objectives of solid waste management  and resource

utilization will not have been served.

           Although overpackaging does exist, it

reaches nowhere near the proportions  credited by public

opinion.   Is an inner stack wrap for  crackers

which prevents staling of the last portions over-

packaging?  How about a foil-laminated overwrap

which prevents dry milk from absorbing moisture or

a blister  card which allows small  items to go self-

service without excessive pilferage?  Is this over-

packaging?  I think not,  but much of the public
                        151

-------
perceives that it is.

        In spite of the growth of packaging, there

is a natural "brake," too.  Few packages are pur-

chased by consumers; they are bought by profes-

sional buyers.  To keep their costs at a minimum,

they are constantly pushing their suppliers to

reduce caliper, density, and square inches.  It

goes on all the time, and it is successful.  In

the last 20 years, the familiar square half-

gallon ice cream carton has improved in product

protection, convenience, graphics, and machin-

ability.  But, it now weighs 33% less, and in

spite of inflation, its price is lower, too.

        Plastic-coated and foil-laminated con-

tainers may be more difficult to recycle.  However,

they allow paper to replace glass, plastic, or

metal containers which may represent greater solid

waste challenges.

        There is one more second use with great

potential for the paper in our wastes.  I am think-

ing of energy, of course.  The incinerators of

the future will be expected to be producers of

power as well as disposers of waste.  Paper is an
                         152

-------
ideal energy source.  It has a caloric value half

that of coal and one-third as great as fuel oil.

Unlike those fuels, however, paper is a replaceable

resource.  It is a non-polluting fuel.  Under

controlled incineration, its only by-products are

carbon dioxide and water vapor, both natural to

air.  The plastic and wax coatings which now retard

the degradability of paper would enhance its value

as a fue1.

        I am pleased to note that the Solid Waste

Office of the EPA has placed a major contract to

determine the relative value of resource recovery

in the form of energy instead of in physical prod-

ucts.  This report is a necessary prerequisite to

decisions under consideration for paper recycling

and container design.  Without that information,

such programs as the recently announced GSA pur-

chasing specifications are premature.

        Paper recycling must grow,  and collection

incentives  offer the most promise.   Gradual develop-

ment of supply and market will be more effective

than crash  programs.  Do not forget alternate use

and disposal.  They will remain important to
                        153

-------
handling our paper wastes.




        We do need a national program and a national




direction for solid waste handling.  The EPA is




researching this long-term course now.  The exis-




ting thrust of supply and demand laws will tend to




favor increased use of recycled fiber in the years




ahead.  In the meantime, mandated programs by




public or government may be forcing industry into




the wrong course of action.  The solid waste problem




has been building for 2,000 years.  We have the




facility and the organization at the EPA to develop




proper solutions in the near future.  I am hopeful




that environmental emotion will not force us into




intuitive programs when factual ones are so near




at hand.




        Thank you.
                         154

-------
       CONFERENCE BANQUET
    Keynote Address by R. L. Lesher
National Center for Resource Recovery, Inc.

-------

-------
           INCENTIVES FOR REUSE AND DISPOSABILITY
                      R. L. Lesher
             National Center for Resource Recovery, Inc.
          Good  evening.   I  am delighted to be here

at this important  conference.   Sometimes I think I

must be one of  the most  fortunate men in the world.

In this age of  apology when we sometimes cringe be-

fore the problems  created by the very magnificence

of our achievements, when the white light of cor-

roding criticism almost  blinds us to our opportun-

ities, I've had the  chance  to work on the side of

the future, time and again.

          I was on the team that tapped our enor-

mous resources  of  imagination, technology and guts

to meet the greatest challenge mankind has ever

tackled.  It took  some years,  and it took the whole-

hearted effort  of  government and industry along with

public support, but  we landed Americans on the moon

and brought them safely  home.

          And now  I'm on the team represented here

today — the team  that will tap those same resources

to solve a problem that  directly effects all of us.

     The challenge of pollution has been called the

moral equivalent of  war.  Certainly, if we fail, our

fate — though  slow  in coming — will be worse

                          155

-------
degradation than victor ever imposed on loser in any




war in history.  And the ultimate fruits of victory




are a prize more dazzling than any that can be won




by arms.




          The problem of solid waste disposal has




been with us for a long, long time.  The trash




heaps of prehistoric man mutely testify that even




in those uncomplicated times, it was daily concern.




          The problem grew, along with the slow




growth of civilization.  Then about the middle of




the last century, the industrial revolution quick-




ened the pace.  Slow growth gave way to quantum




leaps, and ever since then, people, products and




problems have multiplied explosively.  I won't re-




cite the shopworn statistics on the magnitude of the




problem, but I would like to emphasize that the




problem is largely a function of :  (1) population




growth, (2) affluence, and  (3) archaic municipal




solid waste collection and disposal practices.




          While our economic system changed radical-




ly from an agricultural system to a highly efficient




industrialized society with an ever increasing level






                         156

-------
of productivity, that is — increasingly capital




intensive and decreasingly labor intensive, our




municipal solid waste practices, for the most part,




changed very little and still bear a striking re-




semblance to the practices in vogue hundreds of




years ago.




          We have all been far too happily occupied




with using the products industry provides — to pay




more than sporadic attention to the problem of dis-




posal.  But now, when it's becoming obvious that




these problems threaten to get out of hand, people




are getting frightened.




          As usually happens when the alarm goes




off, the immediate peril has been exaggerated.




There's not denying that a tidal wave of trash




hangs over us, and it's a healthy sign that people




are taking note of it.  The panic button has served




that purpose; now it's time for a good,  clear look




at the problem.  Fright doesn't make for clear




vision, and people — being human— are saying and




doing some foolish things.  However, our clear look




shows that the same industrial revolution that







                        157

-------
helped to balloon the problem to these proportions




provides the technology for managing it.  The af-




fluence that contributes greatly to the problem




will enable us, as a Nation, to solve the problem.




This is one of the world1s crises that can be




solved.  We can harness that tidal wave, and make




it work for us.




          The most heartening thing I discovered




when I joined this effort was the quality — and




quantity — of both manpower and mindpower already




engaged.




          Technology is the key to the solution and




technology is pre-eminently the creation and the




tool of industry.  Industry does in fact deserve a




share of blame for pollution, but it is ready to




take the lead in controlling it.  It is also able.




With the example of the moon landing before us, I




would hesitate to say what U.S. industry is NOT




able to do when resources are available.  NASA con-




ducted the moon program, and NASA is a government




agency, but everyone at NASA realized that twenty




thousand industrial contractors built the invisible
                        158

-------
 bridge across space that took them there.




           "The National Center for Solid Waste Dis-




 posal, Inc. is a non-profit corporation recently




established by 13 industries and American labor.




The Center is a different and unique kind of response




to the solid waste challenge.




          The Center1s 30 member Board reads like a




Who's Who is American industry and labor.




          There are three points I would like to




make with regard to our Board.  First, the board




members represent their industry rather than just




their own company.  In the case of labor, Mr. Abel




and Mr. Minton represent all of American labor




joining together to help solve the solid waste prob-




lem.




          Second, this problem has the attention of




Top Management.  These board members — although




very busy — all come to our meetings and actively




support, finanacially and organizationally, the ef-




forts of the National Center.




          Third, the industries represented in the




National Center at the present time are representa-




tive of those here today — they are for the most





                        159

-------
part either producers or users of packaging.




          The Center1s purpose is to "put it all




together" to coordinate the work of industry and




labor to work with government agencies at all levels




within a total systems approach.




          What spurred the organizers was the need




for a permanent center, national in scope, where




all of industry who work with problems of solid




waste can pool their experience, expertise, research




money and research findings — and where each can




draw from the pool what he needs.




          The basic objective of the National Center




is to mobilize industrial effort on a nationwide




scale to achieve lasting solutions to the problems




of municipal solid waste disposal, litter control,




and conservation of natural resources.




          The program of the National Center will




have four main elements — 1.) Research, and, at the




outset, our emphasis will be on the economics of




new systems.  The technology is rapidly emerging.




The main gaps, at the moment, are economic gaps,




markets  for by-products. 2.) Analysis, which will be







                        160

-------
largely demographic analysis, data gathering of the




nature of the problem, 3) hardware demonstrations




and applications, and 4)  a public awareness program.




This will not be a public relations program of win-




dow dressing.  It will be an active, imaginative,




and factual education program about the nature of




the problem and the nature of the solution.




          Now lest you think I have strayed too far




from the assigned topic — let me come back to it.




The topic of "incentives for Reuse and Disposability"




 — That certainly raises some questions, doesn't




it?  Almost a contradiction of terms.  But let's




put this in perspective.




          Today, we heard cited the Midwest Research




Institute Study on "The Role of Packaging in Solid




Waste Management 1966 to 1976."  That study started




all this, but everyone is overlooking some key re-




commendations of that report.  Let me quote for you




a couple of important paragraphs from that study:




          ''Least fruitful, in our view, would be ef-




fort expended on changing the characteristics of




packaging materials.  The primary reason for this is
                         161

-------
that exactly those characteristics which make it a




package difficult to handle in disposal are those




which make it desirable as a package.  This is a way




of saying that any container which is easily dis-




posed of is a poor container; and while such a gen-




eralization could not be applied to all packages, it




is applicable to those packaging categories which




create difficulty in disposal.




          "Most of the difficulties created by




packaging are due to inadequate technology or the




absence of technology in waste disposal.




          "Materials research does not offer fore-




seeable near-term success.  Research to improve the




technology of salvage, particularly development of




materials separation techniques, is cited as the




most promising activity of those discussed."




          Basically — designing any product to be




good garbage strikes me as a highly questionable




approach.




          Reuse of beverage and food containers




dwindled a long time ago.  There are a number of




reasons for this.  First, convenience.  The second







                         162

-------
one which is implied is economy.  But the third one,




which everyone ignores, is environmental. The two-




way containers have dropped out of sight, especially




in the food case, because of the health and hygenics




problems associated with taking them back through




a non-systems approach.




          Well, let's look at our terms.  Let's




understand the problem before we can solve it.




What do we mean by disposability?  There is nothing




in our system today that can't be disposed of with




the existing practices in solid wastes from coast




to coast.




          All of us have heard the statistics that




about 85% of our cities and towns are burning or




open dumping the waste of our society.  So what do




you mean you con't get rid of it?  You can.  What




you are really asking is: how can you make those




products more compatible with solid waste management




systems which aren't in place yet?  We'll have to




come back to that question.




          As we meet here we can make some very im-




portant predictions of the future.  Virtually all







                         163

-------
of the states of the Union have laws in the books




against open dumping and open burning.  Dick




Vaughn's leadership at the Solid Waste Management




Office with Project 5000 is going to succeed in em-




barr^ssing those cities and towns into obeying those




laws and closing the dumps.




          Now think for a moment what that does to




the state-of-the art of solid wastes management.  It




forces them up both the technology curve and the




cost curve.  And where do they go from there?  The




first obvious answer is the sanitary landfill.  Like




all of the subjects on this venue, you have pros




and cons about each of these technologies.  I was




told that the City of Los Angeles does a pretty




good job in sanitary landfills, so I went out to




see what they do differently to get their cost




down and not have an environmental problem.  The




city is running the lan'dfill system at about $1.00




a ton and because so much land is available, they




tell me that they will be doing it for the next 500




years.  They have no problem with any product that




is in the solid waste stream.  But Los Angeles' good






                         164

-------
fortune is unique.  Theirs is not the answer for the

whole country, obviously.
          Let us look at the advanced systems that

are here today - not tomorrow.  They are not in place

and they are not in use - but they are here today.

We have much better technology than the caveman

technology that we're using.  The Solid Waste Man-

agement Office has done an excellent job of doing

research in a broad-faced manner in all areas of
collection and disposal.  You looked at the film

today and say some of the more promising of those

technologies.  The fiber-recovery system that will

be going on-line here in Ohio at Franklin next

month is one technique that does, in fact, work.
The CPU-400 is another bright and promising system.
This is a Combustion Power Unit with front-end sep-
aration and energy conversion on the backend of the
system.  Garbage is burned to power gas turbines to
produce electricity.

          There are all sorts of experiments going

on in pyrolysis, some of which produce oil and

gases that can be economically consumed, thus re-
ducing the costs.  T^e incinerator will be with us
                        165

-------
for a long time in certain municipal situations/gen-




erating steam or other energy as a by-product.




          All of these systems, incidentally, will




have one thing in common: - on the front end of




that System, size reduction and resource recovery




and recycling of your minerals - thus helping to




solve many of the problems of resource conservation.




There will be grinding and air classification or




other such systems.  These are technologies that




are here today, and while they are not perfect, they




will get better.




          For a moment, let's turn from talk of ex-




ploitation from waste to exploration of space 	




and what I believe is a fitting analogy.  In the




early 1960's there must have been a thousand pro-




posals for exploring the heavens and the planets.




But, when President Kennedy set the goal of sending




men to the moon within the decade, that set the pace




for the technology.  NASA at that time had a very




vigorous, advanced research and development program,




which is still being carried on today.  But when the




Apollo Mission was set, we had to take the state-of-






                        166

-------
the-art and fly it with that technology.




          Today, the technology is here to solve the




solid waste problem.  The missing gaps are largely




economic.  One is the creation and sustaining of




the markets of the byproducts of that technology




and, the second gap is the financing of the system.




The National Center will be working very vigorously




in both of those areas.  In a very short period of




time, over the next several years, the whole new




industry will spring out, populated by many compan-




ies that are already in or close to this industry




to solve this problem and to eventually, and I em-




phasize 'eventually', to make money doing it.




          We at the National Center have just begun.




We put together our top management team and in the




very near future we will begin providing services.




          One thing I am sure of is that tomorrow1s




systems will be radically different that the prac-




tices that we have today, and it would be a shame




to disrupt things that don't need disrupting and




cause needless changeover and then come back to that




system later on.  I am confident that when we do







                        167

-------
these things, we will have a way to control any




volume of solid waste that is generated in this




country.  I am very optimistic that we as a Nation




will solve this problems, and I am damned tired of




the doomsayers that seem to spring up all around




us.




          Today, we have the carrot and the stick.




The stick is made up of those extrapolations that




show us what we must expect if we do fail.  The




stick has us all concerned: the government, public




and industry, and that concern is our guarantee




that we will solve the problem.




          The carrot is the wealth to be reclaimed




from that tidal wave of trash.  Solid waste is what




we call it.  The clearest threat to our environment




is the label pinned on the 250 million tons of




municipal waste by some other spokesman.  But there




is one man working on a recycling plant for the




Bureau of Mines who has a different view of solid




waste.  He is Max Spendlove and Max calls it "urban




ore." And he is right.  Our tidal wave of trash can




just as truthfully be called our world's richest







                       168

-------
mine, one that possesses the fairytale capability




for replenishing itself.  Everything useful,




everything solid that was ever used eventually




comes back to that mine.




          The Center's ultimate goal, and I think




the goal of all of us, is to realize man's age-old




dream: the dream of a self-renewing horn-of-plenty,




a natural resource that can never be used up.




Thank you very much.
                      169

-------

-------
    SESSION III

GLASS CONTAINERS
                 Chairman:

                 C. A. demons, Chief
                 Reclamation Branch
                 Division of Research and Development
                 Office of Solid Waste Management
                 U. S. Environmental Protection Agency

-------

-------
           DESIGN TRENDS IN GLASS CONTAINERS
                   Richard L. Cheney
            Glass Container Manufacturers Institute, Inc.
                   INTRODUCTION


          A new dimension  has  been added to the

marketing of such  household products as:  foods,

beverages, drugs,  cosmetics and household cleaners

and chemicals.  It has  to  do with the impact on

our environment of the  making, distributing and

discarding of the  materials marketed, including

their packages.

          It is within  this context that I assume

you wish me to discuss  "Design Trends in Glass

Containers."

          I think  we will  all  agree that the

primary purpose of a package is to protect and

preserve the contents;  to  hold the original fresh-

ness, goodness and strength within and to prevent

contamination from without. Thus we encounter a

basic contradiction in  the aims of the packager

and of those charged with  managing solid waste.

The packager wants a virtually indestructible,

impermeable material and the solid waste manager
                        171

-------
would like something that would disappear into




thin air as soon as its job is done.  However,




these aims are not irreconcilable, at least as far




as glass containers are concerned, as those who




follow me on this morning's program and I, myself,




shall hope to demonstrate.







           ENVIRONMENTAL CONSIDERATIONS




          What we are concerned with here is the




impact of our actions upon our environment.  Max




Ways, in the February 1970 issue of Fortune Maga-




zine, puts it well in an article entitled, "How




to Think About the Environment."  He says:




          "Although environmental issues do




          have a grave moral content, there's




          little sense in the tendency to present




          the case in the dominant art form of




          a TV horse opera.  This isn't really a




          confrontation between  'the polluters'




          and the good guys in the white hats."




and  further on he states:




          "The wastes that besmirch the land are




          produced in the course of fulfilling
                        17Z

-------
          "widespread human wants that are in the




          main reasonable and defensible."




          Surely modern packaging has done a superb




job of supplying legitimate human needs and wants.




          I, for one, am convinced that the same




technology that has brought us the highest stand-




ard of living ever known,- if coupled with a




strong sense of individual responsibility,- can




solve our highly complex environmental pollution




problems.




          They are highly complex and are not




susceptible to simplistic solutions, and time and




energy devoted to pursuing impractical, simplistic




solutions such as the suggestion to ban certain




useful packages, is worse than wasted, for it




postpones the practical solutions which must




eventually be embraced.




          Our environment, like charity, begins at




home.  The most intimate part of our environment




is, of course, the home and, here, modern packaging




has done much to improve our environment.




          Packaging has provided "built-in maid




service," thus liberating women from many household





                       173

-------
chores and permitting over half of our country's




housewives to hold jobs outside the home by making




possible prepared foods of all kinds, applicator




packages, packages which reseal to preserve fresh-




ness, and disposable beverage containers which




need not be taken back to the store.




          And packages have eliminated from house-




hold garbage pails a substantial quantity of




putrescible agricultural solid wastes, ranging




from orange peels and pulp, vegetable and meat




trimmings, and spoiled remains of unused fruits




and vegetables,- by making possible pre-processed




packaged foods, such as, bottled orange juice and




prepared and pre-cooked foods of all kinds.




          And, in addition, packaging is, of




course,  the automation factor in the distribution




of household products.




          With rising labor costs, particularly at




the retail level, packaging changes and technology




have streamlined the distribution process.




          Packaging thus permits streamlined,




sanitary, low-cost retail outlets, such as super-




markets , which can operate on a narrow profit





                       174

-------
margin and give the consumer more for his money.




          At no time in history and in no other




country in the world does the average citizen




spend so small a portion of  his total income for




food as he does in this country today.




          Few realize that the average supermarket




operates on less than one percent profit on dollar




sales.  This means that when a homemaker gives the




check-out boy a tip of 25
-------
as a packaging material.  In the first place,




glass is made of highly abundant raw materials --




silica sand, limestone and soda ash.  Sand accounts




for 73 per cent of the materials in container




glass.  Thus, glass manufacturing is not a serious




drain on our natural resources.  If properly




crushed in disposal processes, the glass fragments




return to the soil in virtually their original




state.  And being inert, they do not leach, rust,




rot, mold, putrefy, cause disease or noxious gases,




nor pollute in any way.




          Several recent studies reported in the




proceedings of the American Society of Civil




Engineers reveal that glass constitutes an average




of only about 6 per cent by weight of residential




solid waste, and an almost negligible per cent by




volume, if the glass is crushed in efficient land-




fill, incineration and composting operations.




          Even to the scientist, glass is still




somewhat of a mystery.  Although regarded as a




solid, physicists say it is actually a super-




cooled liquid, which is why it can so easily be




blown into bottles.  It is transparent, although





                        176

-------
made of opaque raw materials and, in its pristine




state, it is one of the strongest materials known




to man.  Glass fibres have been drawn which have a




tensile strength of over 300,000 Ibs. per square




inch,- much stronger than the strongest steel.




          As a packaging material, it is chemically




inert, so that it cannot react with, nor add any-




thing to, or take anything away from its contents.




It is absolutely impermeable to gases or moisture,




transparent, non-porous, sanitary and odorless and




may be formed in an infinite variety of shapes,




sizes and colors.  No other packaging material can




say as much.




          Incidentally, that great strength of




glass is a big factor in the plans of a noted




scientist who is planning to package people in




glass!  Dr. William B. McLean, known as "the Navy's




handyman" (he invented the side-winder missile) is




designing a 56 inch glass sphere (called a




"bathysphere") in which two men will descend deeper




in the ocean than man has ever gone before.




          Dr. McLean points out that not only is




glass transparent, so that they will be able to





                        177

-------
see in all directions, but (and I quote him), "It




is not theoretically possible to make a metal




vehicle that can stand the ocean's pressure with-




out being far too heavy.  The big advantage of




glass, beyond visibility, is that glass is lighter




than any metal and about 5 or 6 times as strong




as steel."




          Now Dr. McLean's container will operate




under heavy external pressure, which puts the




whole glass structure under compressive stress.




Ordinary glass containers are subjected in normal




handling and, as a result of internal pressure




from carbonic gas (such as in soft drinks) or




propellants (such as in aerosols), to forces




which result in tensile stress, and if a bottle




fails, it does so when its tensile strength at




some point is exceeded.




          Today in glass bottles we are utilizing




only about one percent of the theoretical tensile




strength of glass exhibited by the glass fibre.




When we learn to lift this only to five percent,




we shall be able to make glass bottles and jars




much lighter (that is, with much less glass in




                       178

-------
them) than today, and much stronger.  This will




not only make it a more desirable package to the




consumer and save on shipping weight, but it will




obviously reduce the weight of waste glass in the




solid waste stream when it is discarded, substan-




tially reduce the amount of protection required




in the corrugated shipping container,- thereby




reducing that load on solid waste.




          You will hear later this morning of new




developments in lighter glass containers and




research is well along on a process of chemical




tempering which will put the surfaces of the con-




tainers under compressive stress and so result in




the lighter containers I have described.  We hope




to see a breakthrough in this area soon.  One of




the beauties of this development will be that such




containers when broken in disposal will fall into




harmless granules about the size of rock salt.




          Meanwhile, research and development has




already brought about a reduction in weight of




some 30 percent in glass containers over the past




20 years.  One factor in this progress has been a




marked advance in the techniques for surface




                        179

-------
treatments which have resulted in substantial




progress in protecting and preserving the pristine




strength of the surfaces of beer and soft drink




bottles which have to withstand the internal pres-




sures of carbonation.  Much of this research has




been conducted jointly through GCMI.




          The other outstanding characteristic of




glass, its chemical inertness, which guarantees




complete compatibility with its contents and




virtually unlimited shelf life unless the contents




breaks down of itself, was recently dramatically




demonstrated by an incident reported in the New




York Times.




          In 1968 an English lord discovered in




his wine cellar three glass bottles of Canary




Island wine, bottled in 1740.  He and his son




sampled this 227 year-old wine and found it to be




delicious.  They put one bottle away for a future




family occasion and a London autioneer sold the




third for them at a fancy price.  That is real




shelf life and, of course, could be equalled by no




other modern packaging material!
                        180

-------
          This brought to mind another incident




when, in 1954, 18 bottles of beer were washed




ashore on the Kentish coast of England, after




spending 250 years under the sea in a wrecked




ship.  They were intact, with their contents, and




neither the corrosive sea water nor its crushing




pressure had violated their integrity as a package.




The beer was potable, but had definitely not im-




proved with age.




          One further example of the efficiency of




glass as a package was cited in the April 9, 1971




issue of Research Institute of America's bulletin.




A graduate student at University of Maryland has




found that nitroglycerine tablets, used by heart




disease sufferers, may lose up to 30% of their




potency within six months in one type of package




made of a material other than glass, up to 72%




in another, and up to 907» in a third; while they




lost only 57o of their potency in glass bottles




over that period, either with glass stoppers or




tight screw-on caps.
                       181

-------
        THE ROLE OF GLASS IN SOLID WASTE




          I cite these examples to show that glass




as a packaging material has such important advan-




tages to the consumer that it would, for example,




be a very serious mistake to recommend substituting




some biodegradable material for it in the hope




(which is open to question) of decreasing our solid




waste problems.  You will, however, hear later in




the morning of research directed toward the possi-




ble use of a different type of glass itself, which




has unusual disposal characteristics.




          Finally, glass is one of the most easily




recycled of all the materials found in solid waste




and we have already uncovered markets for all of




the waste glass that could be generated in this




country.  We are supporting research to develop




systems for automatically separating it from




municipal solid waste so that it can be re-used




for these purposes.  You will hear more of this




later in the morning.
                       182

-------
                     SUMMARY




          In summary,  as I have pointed out:




1.  The use of glass containers conserves limited




    raw materials.




2.  They benefit our home environment and are




    essential to our present mode and standard of




    living.




3.  The properties  of glass which make it an




    excellent container material also make it a




    beneficial factor in all accepted waste dis-




    posal systems.




4.  Glass containers constitute only 67o of muni-




    cipal solid waste by weight and, when crushed,




    less than half  that by volume.




5.  Through research and development we are moving




    toward lighter  weight glass containers which




    will benefit the consumer and further reduce




    the solid waste load.




6.  Glass containers represent one of the most




    easily recycled and re-used of all the ele-




    ments of municipal solid waste and present




    reclamation programs and research are directed





                       183

-------
6.  Cont'd.




    towards maximum use of waste glass as a




    secondary material.
                       184

-------
                  RE-USING SCRAP GLASS
         Ward R. Malisch, Delbert E. Day, and Bobby G. Wixson
                  University of Missoun-Rolla
                    INTRODUCTION

          The use of waste  glass  as  aggregate in as-

phaltic concrete has been under  study  at  the Univer-

sity of Missouri-Rolla for  nearly two  years under a

grant from the Solid Waste  Office of the  Environmen-

tal Protection Agency.  Since  containers  constitute

over 75 percent of  the waste glass present in muni-

cipal refuse, the properties of  waste  glass would

depend, to a large  extent,  upon  the  properties of

containers.  Thus,  changes  in  composition and design

of consumer containers might be  expected  to be of

concern.  The degree to which  this potential for

waste glass reuse is influenced  by container design,

is discussed in this paper.


        PROPERTIES OF GLASS-ASPHALT MIXTURES

          Aggregates which  are normally used in as-

phaltic mixtures may vary from porous  to  nearly non-

porous  materials with rough to smooth  surface text-

ures.   Angular materials such  as crushed  stone have

been used as well as rounded gravels and  river

sands.  Generally,  particles which are nearly equi-

dimensional are preferred to flat and/or  elongated

particles.  A range in sizes from up to 1 1/2-in.

particles graded down through  sand and dust sized

                         185

-------
materials is generally used if a dense mass is de-




sired but the maximum sized particle used will vary




with the source of supply and the thickness of the




pavement layer to be placed.




          Waste glass particles can be characterized




as nearly non-porous, smooth surfaced and angular




with a preponderance of flat particles in sizes re-




tained on a No. 4 sieve.  The non-porous nature of




glass is advantageous in that lower drier tempera-




tures are required in plant mixes since only surface




moisture must be expelled.  However, the low poros-




ity and smooth surface texture combined result in




less internal friction in the asphaltic mixture and




thus a lower strength or stability.  The large num-




ber of flat particles in the larger sizes is not un-




expected since an average bottle wall thickness is




approximately 0.11 in. and particles with any dimen-




sion greater than 3 times this value would be classi-




fied as flat and/or elongated.  While excessive num-




bers of flat or elongated particles are undesirable,




due to lower densities and strengths obtained when




using them, research currently being conducted has




indicated that by changing the particle size grada-




tion, denser mixes can be achieved with flat and




elongated particles.  It is necessary to have a




graded mixture of glass particles in order to obtain





                         186

-------
adequate density and strength.



          Asphaltic mixtures satisfying standard de-



sign criteria have been designed using penetration



grade asphalts and aggregates composed entirely of



glass   .   While the stability of these mixtures is



somewhat lower than stabilities obtained using



crushed conventional aggregates, values greater than



the minimum required stability for medium traffic



categories have been obtained.  In field installa-



tions using a mixture of glass and conventional ag-



gregates,  stabilities have been considerably higher


                                             ( 2 )
than those obtained with all-glass aggregates



These stabilities have met the requirements for



heavy traffic categories suggested by The Asphalt



Institute(3).



          Resistance to loss of adhesion between as-



phalt and  glass in the presence of water is poor if



no additives are used to improve adhesion.   However,



the addition of hydrated lime in an amount  equal to



one percent by weight of the aggregate resulted in



very much  improved adhesion so that specimens which



had been soaked in water at 140F for 24- hours re-


                                      (4 )
tained 100 percent of the dry strength



          Skid resistance and tire wear on  glass ag-



gregate surfaces have not yet been fully evaluated.



In Fig. 1, the surface texture of a patch containing




                         187

-------
Fig. 1  Glass-asphalt surface containing 94.5%
        glass 4 months after placement
Fig. 2  Glass-asphalt surface containing 94
        glass 17 months after placement
                        188

-------
94.5 percent crushed glass and 5.5 percent asphalt




is illustrated.  The picture was taken 4 months af-




ter placement.   It should be noted that the larger




flat glass particles lie flat in the pavement sur-




face with no jagged edges protruding.  Fig. 2 shows




the same surface 17 months after placement.  Since




hydrated lime was not used in this mixture there




has been considerable ravelling of the surface, but




note again that there is no indication of potential




tire cutting edges appearing.  A similar surface




texture has been observed in field installations



using glass particles up to 3/4-in. in size, and




thus we feel that there is little danger of actual




cutting of the tires due to exposed glass edges.




          Whether or not glass aggregates contribute




to an increased rate of abrasion for tires can not




be answered yet.  Schallamach    states that rate of




abrasion of typical tread compounds on tracks with




different surface characteristics can vary by a




large factor but it is not so much size as shape of




track asperities which determines severity of wear.




This would seem to indicate that the more angular




glass particles would result in greater wear than




rounded or semi-rounded aggregates.  However, re-




search has shown that wear also occurs on smooth




surfaces due to fatigue of the rubber.  According to





                        189

-------
Schallamach, tire surface temperature is the basic




parameter from which practical tire wear ratings




can be derived, and while the possibility must be




left open that road surface affects ratings, it is




still expected that tire surface temperature governs




wear ratings on any given road, irrespective of its




characteristics.  A laboratory apparatus for assess-




ing tire wear on varying surfaces is currently under




construction since it appears that the only method




for obtaining a quantitative comparison of wear on




surfaces with conventional and glass aggregates is




by direct testing.




          Skid resistance tests have been conducted




on several of the field installations of glass-




asphalt mixtures using the British Portable Tester




and the ASTM two wheel skid trailer.  The results




obtained to date indicate primarily the initial




skid resistance, and the effect of traffic upon




these skid resistance values has not been fully




evaluated.  However, initial skid values obtained




have been acceptable.  The results of these initial




determinations are given in Table 1.




          One property of glass-asphalt mixtures




which has been noted by contractors placing the




material in field installations is a slower cooling




rate.  Hot mixed asphaltic concrete is generally





                         190

-------
































rH
W

CQ
<^
EH







Pi
Q H
H CQ
X XI
GO D
S3


CO it- CO
CO LO LO


IT]
P
00
S3
0
M
EH

j
<£
EH
GO
^
H
P
,J
H
H
PH

EH

<£j
ffi
PH
00
CD

p^
0

00
EH
GO
H
H
P
1 	 (
X
GO
EH W
00 W
H ft
H GO
ft ft ft
e e e

0 O O
CN CM HT


P
EH 0
00 K
H EH
EH H
S

^ ^ ^ H/- ^ H^
EH P- EH P- EH c—
00 CM 00 CM 00 CM
< W < H < H




CD
Q
W H
H EH
< GO
P W
EH
CO
^ 0 H
CO t^- [~^
1 — 1 \ '^
^\ CD CM
0 v^
rH CO


P
H
J
H i 1
H <
<£ EH
P GO
S3
H

O
CD O t~^
CO !>- ^
•v. ^^ CD
Hf CD CM
-^ CM \
o-^o
rH CO iH





CD
LO




1
1



0)
CO ,Q fn
•H nS CU
+J +-• 4-1
•H !H CO
!H O CU
CQ PH EH



0
o
\
CM
rH
\
[^





CD
L-^
\
O
rH
-^
r~



X
GO
J
H
EH
H
M

PH
0

00
EH
J
^)
00
H
Pi








S
O
H
EH
<£
O CO
0 -H
P O O
C-rl
•H fl
H O
j — 1
H «
1 O
CO T3
q cu
CU r-t
3 0
0 EH









•
o
o
IT]
CD T3
co nj
(ft p3
i — I fT]
CD O

C «
O O
•H -H
C fi
•H Cl5
S +J
0 C
P 0





.
ft fd
rl -H
o c
0 , CO
-p -H
•H S,
CO
CL) r.
W nj
> H
•H rH
C 0
D Pi
                                         ft
                                        ID
                                         CU
                                        -H

                                         rl
                                         0)
                                         o
                                         o

                                        •a

                                         rfl
                                         ft
                                         6
                                        T3
                                         CU
                                        -M
                                         O
                                         P
                                        •a
                                         q
                                         o
                                         o

                                        +J
                                         co
                                         CU
                                        EH
191

-------
delivered to the job site at temperatures ranging




from 250F to 30QF.  It is then necessary to complete




compaction before the asphalt viscosity increase




due to cooling progresses to the point that further




compaction is impossible.  During cold weather ex-




cessive cooling is a problem which can result in




high void contents and premature deterioration due




to inadequate compaction.  Since several contractors




commented on the apparent slower cooling rate for




glass-asphalt mixtures, several laboratory tests




were conducted to compare these mixtures with con-




ventional asphaltic concretes.  Companion specimens




were fabricated using conventional crushed limestone




and river sand for one set and glass aggregates for




the other.  Properties of the mixtures are shown in




Tables 2 and 3.  They were compacted in standard



Marshall molds in which the metal base plate had




been replaced by a plywood plate of the same dimen-




sions.  A groove in the base plate contained a




chromel-alumel thermocouple for measuring tempera-




ture.  Each of the two specimens was compacted using




50 blows of the standard hammer on one side only.




They were then placed in an oven at 120C for 24




hours to stabilize temperatures, before placing




them in a cold room at OC.  The specimens remained




in the compaction mold while temperature readings




                         192

-------




















GO
W
M
O
D
EH
GO

O
53
M
p-J
O
0
O
PS
O
CM [A_,

M GO
>J W
CQ H
EH U
W
CD
O
PH
O
^
O
M
EH
<£
O
PS
C9















O
M
EH
i—]
<£
5c
DH
GO W

53
O
0















EH
J
<£*
p-J
P-.
00
J
O



















!2;
o
i — i
H
<
O
<
K
U
























CD
53
M
W
GO
<£
DH

o\°


























tJ-I
N]
M
GO
W
W
H
GO







-H
rH
IT!

p(
LO CO
rd
OC^i — ICQCDOOC^OCD , — 1
OCOC-QJ-OOOIrHp-H bj)
pH
c
M


X •
•H 13
g 0)
ra
H 3
rt)
& a
o T)
•H Z

C -H
0) to

C T)
O
O CO
CO
G T)
W)

1) TD
LO pH CD

r3[^! 	 IfjocrjcOt^OLO -H CO
OCOtDJ-COCMrHrH MH3
1 — 1 P-)
i— 1 O
IT)
0) LO

•a

O it)
a)
T3 Ei
0) -H
to H
3
(U CD
C I '
O H)
^ -P fn
"3 CO 13
^ Q) >,
° o g f:
O3 CD O O O -H
HrCOH^LOHCM rHo\°
Z - O
\^OOOOOOO CUH
1 I ' -i-, ^i, ^ ^ ^, ^ ^ r£_,
to •>
D X
£-1 "H
0 6


193

-------
W

PQ
o
1 — I
EH
5;
K
D-,
GO W
< EH
H
^ Pi

O
o

CN
EH
GO
W
EH





rH

EH
GO
H
H








Cxj

EH
GO
EH
J
<5^
UH
0-!
GO
<
CD
W
EH






EH
GO
W
EH













                                              en
                                              t-
                                        >H
                                        H
                                        Pi
                                        W
                                        PL,
                                        O
                                        Pi
                                        FU
 en
•O
•H
 O
                                                   O

                                                   CO
                                                   r-


                                                   LD
                                                    dP


                                                    0)



                                                    bu
                                                    bfl
                                                    bO
 0)
 C
•H
s

 c
•H
                                                    •rH
                                                     O
                                                          00
                                                          CD
                                                           hD
                                                          •H
                                                          •H
                                                           C
T)
 (D
-P
 O
 0)
 a
 e
 o
o
                                                                o
                                                                H
-P
C
cu
•p
c
o
o

-p
                   PH
                   cn
                                       194

-------
were taken at time intervals varying from one to
fifteen minutes.
          Results of two such tests are shown in
Figs. 3 and 4-.  In test one, air contents of the
compacted specimens were almost identical while in
test two, the glass-asphalt mixture had a higher
air content.  However, in both these tests, the
temperature of glass-asphalt mixtures was consis-
tently higher than the conventional mixture very
soon after cooling had begun.  More study is needed
in order to confirm this behavior and to evaluate
its practical significance, but if the higher heat
retention is confirmed, extension of the paving
season in colder climates would be possible.

               ECONOMIC CONSIDERATIONS
          In a paper concerning economic factors of
mineral waste utilization, Vogely    divides wastes
into three groups based upon their economic value
and the social cost inherent in their generation
and existence.  The first category includes wastes
which have a value, such as iron mine rejects with
a substantial percentage of iron but not immediate-
ly marketable because of technological and economic
problems.  Vogely also includes in this category
wastes which have no significance from the point of
view of the materials which they contain but are
                        195

-------
                                UJ

                                K-
                                 i

                                0)

                                UJ

                                X
                                <
                                z
                                o
                                I-
                                z
                                ui

                                z
                                o
                                o
                                o
                             UJ <

                             2 X
                             S3
                             3 o
                             o u.
                             o o

                             ° UJ

                                <
                                cr
                                o
                                o
                                o
                                o
196

-------
                   LJ
                   Ul
                   X
                   z
                   o
                   UJ
                 1 <



                 I!
                 o en
                 o <
                 o -i
                   o

                   UJ
                   i-
                   <
                   cr
                   o
                   o
                   o
197

-------
important for their structural characteristics in




that they could be used as aggregates.




          The second category includes  wastes which




are worthless but which generate spillover costs to




the rest of society in the form of health and safe-




ty hazards, retarded land development or destroyed




aesthetic values.  Finally, there are those wastes




which are worthless but exist in such small volume




and are so remote from population centers that they




do not generate any social costs.




          Until recently, waste glass from munici-




pal refuse was included in the second category, be-




ing viewed only as a worthless material to be dis-




posed of.  However, in the past two years, the value




of this waste component has been recognized    and



several possible means for reusing waste glass have




been suggested.  The possibilities include use in




making more bottles, as an aggregate for road pav-




ing, and as a raw material for glass bricks, fiber-




glass, or other high silica building materials.  In




choosing among these possible uses, a market allo-




cation problem is evident.  According to Vogely,




the issue is whether or not the market  place ade-




quately measures the potential value as a source of




minerals (cullet) against a current value in a use




(aggregate) which destroys that value.   It would





                         198

-------
appear that the choice will hinge upon several



factors.



          If we assume that a separation facility



for municipal refuse is installed to produce metal-



lic (both ferrous and non-ferrous), paper, plastic



and glass  fractions, the economic feasibility of



using the glass as an aggregate will depend upon



the amount of further processing necessary in order



to make glass suitable for use as an aggregate, the



cost of conventional aggregates in the area, and



the volume the waste glass fraction produced annual-



ly.  The  most desirable situation would be one in



which the glass emanating from a separation facility



could be  used as an aggregate with no further crush-



ing, screening or washing operation.  Assuming that



ten percent by weight of the refuse processed was



glass and that this glass could be used to replace



aggregate costing $2.00 per ton, the glass component



would generate an income of $.20 per ton of raw



refuse processed.  In the Black Clawson hydrasposal/



fiberclaim system, separation costs for a 1000 ton



per day unit are estimated at $7.50 per ton of raw


                C 8 )
refuse processed   .   The $.20 per ton revenue gen-



erated by the glass thus represents a small percent-



age of the separation cost.  However, in this par-



ticular system, revenues realized through the sale




                        199

-------
of recovered fibers are expected to bear the brunt




of separation costs as it is estimated that reclaim-




ed paper worth $5.00 can be recovered from each ton




of raw refuse.  Credits to offset part of the re-




maining $2.50 would be expected from the sale of




ferrous metals, aluminum and glass.




          Samples of the glass fraction produced by




the hydrasposal system have been analyzed to deter-




mine the particle size gradation and amount of con-




taminants present.  Results of the sieve analysis




are shown in Table 4.  Based upon a visual and mag-




netic separation, roughly 15 percent of this frac-



tion consisted of non-glass materials such as alu-




minum labels, ferrous metals, plastics and rubber.




The gradation indicates the material to be too



coarse for use by itself in glasphalt.  However, by




blending it with a sand or rock dust the gradation




could be improved enough to make it usable without




the further cost of crushing or screening.  The ef-




fect of the 15 percent impurities is presently being




studied, but no conclusions can be drawn as yet.




          If crushing, screening or washing were




required to make the glass fraction suitable for use




as an aggregate, the glass fraction would not con-




tribute as much toward offsetting separation costs.




Due to the need for purchasing specialized equipment,





                         200

-------
W

m

EH
                   O
                   o
         CD

         CM
 C
•H
                                          o
                                          co
                             201

-------
it would be necessary to process some minimum vol-



ume of glass in order to reach a break-even point.



The minimum volume necessary would be dependent upon



processing costs ,  including equipment,  and upon the



cost of aggregate  to be replaced by glass.  From the


                                          ( 2 )
results of a preliminary economic analysis    in



which it was assumed that crushing and screening



equipment were purchased for the processing opera-



tions and conventional aggregates cost $2.00 per



ton, a break-even  point of roughly 30,000 tons of



glass annually can be estimated.  At volume below



this figure, the cost of processing the glass for



use in glass-asphalt mixtures would exceed the sav-



ings as a result of reduced use of conventional ag-



gregates.  The only justification for using the ma-



terial as aggregate under these conditions would be



a case in which disposing of the waste glass in a



landfill would be  more costly than using it as an



aggregate.  It might also be argued, in accord with



Vogely's point, that with further processing such



as removal of nearly all contaminants and color sep-



aration, the glass could better be used as cullet.



The choice to be made, in this case, would depend



upon other factors such as the cos.t of cleaning and



color separation,  costs for transporting the cullet



to the nearest bottle factory, and the amount of




                        202

-------
glass which could be disposed of in this manner.



          In summary, if glass from a separation



facility is used as an aggregate, and no futher pro-



cessing is required, the maximum contribution to-



ward offsetting separation costs would be made, but



this amount would represent only a modest percent-



age of the separations costs that are currently pro-



jected.  If crushing and screening of the glass are



required, the contribution toward offsetting separa-



tion costs is diminished and a minimum volume must



be produced annually in order to balance the addi-



tional processing costs.  These estimates are based



upon prevailing aggregate prices and projected costs



for separating refuse in a facility which is cur-



rently under construction.  The economic feasibili-



ty of this approach would be enhanced by higher ag-



gregate prices, for instance, if it were found that



the thermal properties of glass-asphalt mixtures



justified a premium price for the aggregate.





    IMPACT OF DESIGN CHANGES IN GLASS CONTAINERS


                                          ( 9 )
          According to Darnay and Franklin    sever-



al changes in glass container design might be anti-



cipated within the next decade.  Lighter containers



produced using thinner walls and stronger glass are



expected since the higher weight of glass containers



is considered to be one of their major disadvantages.

                        203

-------
Glass-plastic containers of exceptionally light




weight are also being developed    .   Advances in




glass technology have resulted in more colors being




available and decoration by fusing enamel onto the




glass surface directly.  More novel color-shape com-




binations are also expected to appear.  Easy-open




closures in the form of twist-off caps have already




been introduced, with the twist-off caps leaving a




slender ring of aluminum around the neck of the




bottle.




          Changes in color, shape, or decorating




method will have no effect upon the potential use of




waste glass as an aggregate in asphaltic mixtures.




Only an alteration of the glass surface texture




would influence the mechanical properties of asphal-



tic mixtures and, since the smooth surface texture




of glasses currently being used represents the worst




possible condition for high internal friction and




strength in the mixture, any changes in surface tex-




ture caused by decorative technique would probably




be beneficial.




          Thinner walled containers will result in




more flat and elongated particles being present in




the larger size fractions of crushed glass.  The ef-




fect of these particles would be to decrease density




and strength of the glass-asphalt mixture





                         204

-------
However, there is some evidence that these effects

can be mitigated through alteration of the glass

gradation used.  A commonly accepted means for cal-

culating a so-called maximum density gradation for

granular materials is the Fuller formula:
                   P = 100 (d/D)n
where
          P = percent passing a sieve having
              an opening of d inches

          D = maximum size of aggregate

          n = a coefficient related to
              physical properties of the
              aggregate

                          (12 )
          Goode and Lufsey     have suggested that

for maximum density, n be taken as 0.45.  However,

                          (13)
it has also been suggested     that, depending upon

the shape of aggregate particles, the coefficient

producing maximum density may vary.  In laboratory

studies aimed at establishing an optimum gradation

for crushed glass, the density of various gradations

of glass beads and crushed bottle glass indicated

that for the equidimensional, rounded beads the 0.4-5

coefficient did produce maximum density but that for

crushed bottle glass, a coefficient of 0.375 was

necessary for maximum density.   These results are

shown in Fig 5 and it should be noted that in all

cases the glass beads gave higher densities.  Thus,

it appears that while increased flat particles do

                        205

-------
  BULK UNIT WEIGHT vs. GRADATION COEFFICIENT.n

                  FOR

  GLASS SPHERES AND CRUSHED BOTTLE GLASS

               O	O GLASS SPHERES
               A	a  BOTTLE GLASS
  144
  140
O
0. 136
X
e>
ID
  132
  128
CD
  124
          .35     .4    .45     .5     .55

              COEFFICIENT, n

FIG.5 UNIT WEIGHT OF GLASS SPHERES AND BOTTLE
                   GLASS

                    206

-------
cause a loss in density, changes in the gradation
used can minimize this loss.  Tests are currently
being conducted on asphalt specimens utilizing the
varying gradations to determine strength values us-
ing the optimum density gradation.
          The effect upon glass-asphalt mixtures of
contaminants such as aluminum rings , bottle caps,
and plastic residues from composite containers have
not yet been fully investigated.  Research sponsor-
ed by the Glass Container Manufacturers Institute
is currently underway at the University of Missouri-
Rolla to assess the effect of several contaminants
upon the properties of glass-asphalt mixtures and
results to date have indicated that up to 1.5 per-
cent aluminum by weight of the glass aggregate used
has no adverse effect upon strength or void charac-
teristics of the mixture.  The effects of plastics
have not yet been evaluated.

                     CONCLUSIONS
          In summary, changes in container design
which might be expected to occur over the next ten
years should have little effect upon the suitability
of waste glass for use as an aggregate in asphaltic
concrete.  The major barriers to effective utiliza-
tion of the glass in this manner are economic ones
which are related to the costs of separation and
                        207

-------
the costs of any further processing of the glass

which is necessary after separation.


                   ACKNOWLEDGMENTS

          This investigation is supported by Envi-

ronmental Protection Agency Grant No.  USPH 5 R01

EC329-02 and by a grant from the Glass Container

Manufacturers Institute.

          Skid resistance data on glasphalt field

installations were furnished by Ohio  Department of

Highways, California Division of Highways and the

Ontario Department of Highways.

          Samples of glass recovered  from the hydra-

sposal fiberclaim system for refuse separation were

furnished by the Black-Clawson Company.

          Thomas Keith and John Doyle, Research

Assistants in Civil Engineering, at the University

of Missouri-Rolla, aided in obtaining laboratory

data concerning thermal properties and effects of

flat and elongated particles in waste glass mixtures.


                     REFERENCES

(1)   Malisch, Ward R., Day, Delbert  E., and Wixson,
      Bobby G., "Use of Domestic Waste Glass as
      Aggregate in Bituminous Concrete," Highway
      Research Record, (307) 1-10, (1970).

(2)   Malisch, Ward R., Day, D.E., and Wixson, B.G.,
      "Use of Salvaged Waste Glass in Bituminous
      Paving," paper presented at special symposium
      on Technology for the Future to Control Indus-
      trial and Urban Wastes, Rolla,  Mo., (Feb. 1971)

                        208

-------
(3)    Mix Design Methods for Asphalt Concrete,
      Third Edition,The AsphaltInstitute,College
      Park, Maryland (October 1969)  p.  39.

(4)    Foster,  Charles,  W., "Use of Waste Glass  as
      Asphaltic Concrete Aggregate," Masters Thesis,
      University of Missouri-Rolla,  Rolla, Missouri,
      (1970) ,  p. 29.

(5)    Schallamach,  A.,  "Recent Advances in Knowledge
      of Rubber Friction and Tire Wear," Rubber
      Chemistry and Technology, U_l (209), 221-241
      (1968).

(6)    Vogely,  William A., "The Economic Factors of
      Mineral  Waste Utilization," In Proceedings of
      the First Mineral Waste Utilization Symposium,
      Chicago,  Illinois (March 1968).

(7)    Abrahams, John H., "Utilization of Waste  Con-
      tainer Glass," Waste Age, I (4)
      (July-August  1970).

(8)    Marsh, Paul,  Private Communication, April 1971.

(9)    Darney,  Arsen, and Franklin, William E.,  "The
      Role of  Packaging in Solid Waste  Management
      1966 to  1976," Public Health Service Publica-
      tion No.  1855, Washington, 1969,  p. 34-35,
      131.

(10)   Owens-Illinois, Annual Report, 1969, p.  20.

(11)   Bituminous Materials in Road Construction,
      First Edition,Her Majesty'sStationery Office,
      London,  England (1962), p. 13.

(12)   Goode, J.F.  and Lufsey, L.A.,  "A  New Graphical
      Chart for Evaluating Aggregate Gradations,"
      Association of Asphalt Paving  Technologists
      Proceedings,  _31_,  177-180, (1962).

(13)   Smith, M.R.  and Kidd, G.M., "Concrete  Techno-
      logy and Aggregate Production  for St.  Lawrence
      Seaway,"  American Concrete Institute Journal,
      56 (11),  361-376, (November 1959).
                         209

-------
                 TECHNIQUES FOR SELF-DISPOSAL
                        Samuel F. Hulbert
                        Clemson University
                        INTRODUCTION
          Improperly discarded containers such as glass

bottles or metal cans are not only unpleasing litter, but also

provide homes or water receptacles for common disease carriers

such as rodents or mosquitoes.  Furthermore, broken bottles

and sharp-edged metal containers are a major hazard in streets,

playgrounds, and parks.  Unlike some types of metal contain-

ers, which will eventually corrode and disintegrate, glass

objects and fragments will last indefinitely.  With rising

costs of pickup and disposal of litter and trash, it has

become increasingly difficult to dispose of about 26 billion

glass containers per year, which are manufactured in this

country.

          Since littering cannot be stopped completely, it has

been suggested to construct packaging containers from degrad-

able compositions.  Biodegradable materials have not yet been

developed or fully accepted.  Alternatively, it has been

considered to utilize water soluble container structures,

which will dispose of themselves upon prolonged contact with

surface water.  Compositions are well known for producing

water soluble glasses that would be inexpensive and suffi-

ciently strong to contain the pressure within bottles of car-

bonated beverages.  However, effective ways must yet be found

to establish a suitable barrier between the water soluble

structure material and the contents of the container.  The


                             210

-------
container as a whole must eventually be economical and dur-




able, and the barrier formulation must effectively prevent any




appreciable permeation of contaminants into the contents of




the container.  Furthermore, the coating must also be able to




withstand on a short term basis any heat treatments that are




required for sterilization procedures prior to filling the




containers.





       DISSOLVABLE GLASSES FOR CONTAINER UTILIZATION




         It is well known that glasses prepared from the




silicates of alkali metals are water soluble.  Among these




the sodium silicate compositions are least expensive,




although somewhat higher in inherent cost than ordinary




soda-lime glasses.  The difference in cost may be compensated




for to some extent by savings in fuel costs that arise




from the attainment of melt viscosities suitable for manu-




facturing at lower temperature with soda glass, as compared




to conventional glass formulations.  These insights into




manufacturing problems have been gained by collaboration




with investigators of the Anchor-Hocking Corporation, who have




actually pressure-molded some glassware from soda glass as




a demonstration project.   Most of such work was performed




with a glass composition of 35%Na2O65%Si02, at which com-




position the dissolution of glassware objects in water at




room temperature would require several weeks.  Samples of




the soda glass have under some conditions exhibited higher
                            211

-------
flexural strength (28,000 psi under four-point loading)



compared to ordinary soda-lime glass (about 10,000 psi under



the same test conditions).   These findings can be attributed



to interactions with moisture at the surface of the soda



glass, and surface cracks will become blunted effectively



with the more reactive glass composition.



          Actual dissolution of soda glass is likely to form



a slimy precipitate of silica gel, along with some sodium



hydroxide.  The latter product is likely to react with carbon



dioxide from air or from decaying organic matter; or other-



wise the base may react with widely occurring acidic compo-



nents of the soil or with acidic solutions that reportedly



leach out from landfill material.  Dissolution of our glass



composition is slow, and under agitation at 25 G it has been


                                       — 5             2
determined to proceed at about 3.0 x 10   g/min per cm  of



surface (see Fig. 1).  A steady dissolution rate has been



observed if carbon dioxide is excluded carefully from the



solution.  Less careful experimentation can readily come up



with unsteady dissolution rates due to accumulation of some



surface layers that form and flake off intermittantly.



Presumably, any dissolved carbon dioxide will contribute to



such layer formation.





         APPLICATION OF POLYMERIC BARRIER COATINGS



          The utilization of soluble glass for container



structures depends significantly on our ability to develop




                             212

-------
                                                         0)
                                                     ixi  0)
                                                         -p
                                                         3
                                                         C
                                                         •rH
                                                     in  g
                                                        -H
      (uidd)  q.usuia;tDUi
                                          uinjpos
FIGURE 1.  ACCUMULATION OF SODIUM  IONS  IN  200  CC OF AGITATED
WATER AT 25°C, DUE TO DISSOLUTION  OF A  3MM DIAMETER ROD OF
SODA GLASS, AT I INCH IMMERSION.
                            213

-------
coatings that will act as barriers between the glass and the




contained aqueous phase.  Application of coatings will




enhance container cost, but if a polymeric material is used,




some shatterproofing may be attained.  Someday the consumer




may be required to pay for such shatterproofing anyway, but




the cost of applying polymer coatings from solution is not




anticipated to be excessive.




          Rather special requirements must be met by the




polymer coating in order that long-term contact with aqueous




media and short-term heat exposure will be tolerated. During




application the glass surface must be wetted by the polymer




reliably, and very good adhesion must persist during all




stages of actual use.  Even though some moisture will be able




to permeate the coating, the generated osmotic pressure must




not be capable of prying the coating membrane away from the




solid substrate.  The tendency for this latter effect to take




place has been encountered with several coatings of inadequate




composition (see Fig. 2).




          In efforts to attach a polymer coating firmly onto




the sodium silicate surface, a priming coat of polyvinyl




hydrogen phthalate has been employed.  This polymer can be




applied at one mil  thickness by dip-coating from solution,




with methyl ethyl ketone as solvent.  The polymer is only




sparingly soluble in water, and it does not even dissolve




readily in sodium hydroxide solution.  Adjacent to the soda
                             214

-------
.FIGURE 2. TYPICAL BALLOONING EFFECT, DUE TO LIQUID ACCUMULA-
TION BETWEEN SODA GLASS AND A DEFORMABLE COATING.
FIGURE 3. TYPICAL ASSEMBLY UTILIZING A FIREPOLISHED GLASS ROD
TO CARRY A COATING SYSTEM AND A PROTECTING HANDLE.
                             215

-------
glass structure and In the dried state, the polymer offers




functional groups for establishing strong dipole-dipole




interactions with the glass surface.




          A second dip-coating process has so far been




employed to apply a durable barrier coating of a different




composition.  As yet we do not know of any suitable barrier




coating that will also prime the glass surface effectively.




However, several different polymer compositions have been




found to be suitable as the top coating.   Thus Saran-type




polymer can be seated firmly on top of the priming coat, or




a methacrylate lacquer can be employed as the barrier film.




Most experience has been gained with the latter type of




polymer, i.e. with a 50-50 copolymer (approximately) of




methyl methacrylate and butyl methacrylate, equipped with




some free carboxyl groups.  The lacquer composition was




supplied in solution with a mixed solvent of toluene and




isopropanol by the DuPont Company under the tradename




"Elvacite 6014."  Other lacquer formulations from this




acrylate family of products have also been tried, but they




were found to be less adequate in our testing procedures.




          A great deal of testing work was done with fire-




polished rod pieces of soda glass.  The rods served as pieces




of material to carry the subcoat and topcoat compositions and




as a convenient handle as well.  After application of the




polymer coatings in separate dipping and drying cycles, the
                             216

-------
uncoated rod section was covered by rubber tubing (see




Fig. 3) for protection against moisture during subsequent




partial immersion in thermostated aqueous solutions.  The




immersion tests were performed in order to evaluate quanti-




tatively the rate of sodium permeation across the coating,




along a measured area of the coating composite, under steady




agitation at controlled temperatures.  At various time




intervals, aliquot samples of test solutions were withdrawn




from the reservoir of known volume, and sodium concentrations




therein were eventually determined by atomic absorption




determinations, using a Perkin-Elmer apparatus (Model 403).




Each coated rod specimen was used in several series of




experiments, which finally revealed the temperature depend-




ence of the sodium permeation process.




          The sensitive analytical equipment enabled a




determination of the slow permeation rates for the hydrated




sodium ions (see Fig. 4).   Subsequently, the temperature




dependence of the permeation rates were summarized in an




Arrhenius plot (see Fig. 5).  A discontinuity in this plot




appears at 60±1 C, which is interpreted as the glass




transition in the barrier coating.  Below this temperature




the glassy state prevails in the coating,  and an activation




energy of 35 kcal/mol has been calculated for the permeation




process.   Experimental data obtained with acidic (pH=2.7),




neutral or basic solutions (pH=10.7)  are in agreement on this
                            217

-------
218

-------
 0°
  o'
  in
  U
 O
  o-
  CJ
 O
  o -
                     o
                     o
                     r-t
                     n
                     o
                     o
                                                          I


                                                          o


                                                         rH
                                                          I

                                                          "«
                                                           M
                                                           D
                                                          JJ
                                                        o rfl
                                                        o M
                                                        o
                                                        o
                                                           0)
                                                           EH
                 in

                 CN
                       (N

                        I
CTl


 r
                                                        o
                                                        01
                                                        (N
                                                       ' o
                                                        o
m
 I
n
I
FIGURE 5. ARRHENIUS PLOTS  SHOWING SODIUM PERMEATION RATE
ACROSS THE COATING SYSTEMS AS  A FUNCTION OF TEMPERATURE AND

SOLUTION pH.  IN ALKALINE  MEDIA AT HIGH TEMPERATURES THE

PERMEATION RATES ARE NOT REPRODUCIBLE DUE TO DETERIORATION OF
THE COATING.
                             219

-------
value for the activation energy.  In the higher temperature



range it was found that the alkaline medium was effective in



damaging the coating system, and the activation energy for



the coating in the rubbery state could not be determined with



any comparable certainty.  However, no great loss is incurred,



since no end use applications in this temperature range are



to be contemplated.



          The low temperature data from the Arrhenius plot



are suitable for extrapolation into the temperature range of



actual use for the coating system, i.e. to room temperature



and below.  According to experience with many polymer



systems, one does not expect to encounter any further dis-



continuities in the curve at temperatures below the glass



transition.  Rather one would expect linearity to prevail



on this plot, in conformity with the fundamentals of per-



meation kinetics.  Finally, one can calculate that our best


                                      o
estimate of the permeation rate at 25 C would contribute


        -5                    2
5.5 x 10   g glass/year per cm  of surface, under steady



agitation.  This permeation process would only introduce a



few parts per million of sodium into the container contents



in the course of an anticipated shelf life of a year.



          The Arrhenius plot can be employed in correlating



our accelerated immersion tests to the long term permeation



phenomena at room temperature.  At elevated temperatures it



was possible to speed up the permeation process to the point
                             Z20

-------
 where atomic absorption measurements can detect a reliable




 rate.  However, such accelerated testing is only informative




 if testing is performed at temperatures below the attain-




 ment of the rubbery state within the coating.




           The described polymer coating systems stand  up




 well under accelerated testing.  No tendency has been




 detected for the coating to blush or craze, and a continuous




 coating has no tendency to come loose from its solid




 substrate.  The actual long-term durability of the coating




 system is presently under investigation.







SURFACE MODIFICATION OF SODA GLASS USING INORGANIC REACTANTS




           Various approaches have been employed to alter




 the surface of soluble glass by reaction with inorganic




 salts.  Such procedures can potentially attain insolubility




 of surface layers without producing conspicuous changes of




 appearance or gloss with the glass objects.  Any broken




 object of the desired structure would be almost completely




 soluble, without leaving any polymer residue.  But shatter-




 proofing may not be accomplished as readily as by application




 of a polymeric coating.




           Some efforts are under way to modify the glass




 surface by ion exchange, i.e.  by immersion into aqueous salt




 solutions that contain ions other than sodium.   Various salts




 have been employed, and it seems that the sodium ions can




 readily leave the glass surface, and other metal ions can







                             Z21

-------
then be substituted into the surface structure.   These




processes have succeeded in positioning into the glass




structure ions of the following metals: magnesium, calcium,




zinc, copper, tin, and nickel.   These metal ions seem to




form layers of silicates that are insoluble, and rates of




sodium permeation across the formed layers have  been found




to be decreased substantially.   However, no completely




satisfactory surface insolubilization has been attained so




far by the exclusive use of this ion exchange technique.




          At the present time it appears to be particularly




promising to perform ion exchange with cuprous chloride




solution and then - after drying - to follow up  with a




surface "dealkalization" step.   The latter procedure involves




deposition of a strong acid, such as S0~ or SO  in gaseous




form.  The procedure is sure to neutralize any alkali that




may reside on the glass surface, but it may conceivably




involve a change in oxidation state of the metal ions which




became positioned at the surface by the ion exchange pro-




cedure.  The latter mechanism may enable the cuprous ion to




become a complexing agent in the oxidized state; and a




complexed, insolubilized layer can thus be established at the




surface as a barrier between glass and any aqueous phase




brought into contact with it.  The dissolution of soluble




glass across this barrier will produce a basic solution, and




phenolphthalein indicator can then be used to demonstrate
                             222

-------
the effectiveness of the barrier preparation.  Such testing




has shown qualitatively how the untreated glass material




allows the basicity in solution to increase, while no color




change in the indicator comes about with samples of the




surface-treated glass.  Testing methods of a more quanti-




tative nature are being employed currently as an aid to the




development of effective surface treatment methods.







      INORGANIC COATINGS APPLIED BY VAPOR DEPOSITION




          Other research methods have aimed to lay down in-




organic barrier coatings on top of the soluble glass by




exposing the latter to suitable vapor streams.  The procedure




is carried out with a special apparatus (see Fig. 6) that




allows a decomposable liquid to be introduced into an inert




gas sweep, and finally the vapor is decomposed in a heated




zone around the object to be coated.  If liquid tetraiso-




propyl titanate is used as the vapor, one can thus deposit




a thin coating of titanium dioxide.  Alternatively, one can




employ ethyl orthosilicate or ethyl triethoxy silane in




this procedure to yield a coating of SiO^.




         Since the glass must be heated during the coating




application, it is difficult to obtain the coating in an




unstrained state (see Fig. 7); for the expansion coefficients




of the glass and the coating do not match precisely.  Other




difficulties with the process arise because the vapors may




deposit films of different thickness at various locations,






                             223

-------
                                           CO
                                           o
                                           UJ
                                           CO
                                           CO
                                           UJ
                                           ir
                                           Q.
                                           2
                                           o
                                           o
          ^                \r
             UJ
FIGURE 6. SCHEMATIC OF THE CHEMICAL VAPOR DEPOSITION

APPARATUS.
                       224

-------
FIGURE 7. PHOTOMICROGRAPH SHOWING RESIDUAL STRESSES IN A TiO
DEPOSIT. COATING WAS PREPARED BY BUBBLING N  AT 212°F FOR
15 MINUTES AT 8 cfh.  DEPOSITION AT 4 INCH DISTANCE, AT 780°F.
VERTICAL WIDTH OF DIAGRAM CORRESPONDS TO ABOUT 250 MICRONS.
                             225

-------
and orientation of the sample with respect to the vapor




stream was found to be very critical.   Nevertheless,  the




deposition rate was found to be linear with vapor concentra-




tion (see Fig. 8) and essentially linear with respect to




deposition temperature increases (see Fig. 9).




         The deposition process is affected by many variables




such as sample orientation, sample distance from the nozzle,




sweep rates and vapor concentration within the sweep, sample




temperature, etc.  In particular, it has been noted that




TiO  coatings turn out to be crystalline above a process




temperature of 630 F, and   below this limit an amorphous




coating will be obtained (see Figs. 10, 11).  The crystalline




films are inferior, since the grain boundaries are potential-




ly sites at which mass transfer can take place, when the




coated structure is brought into contact with an aqueous




medium.  Small samples bearing amorphous films have been




found to be quite acceptable in simulated end use, but no




detailed investigations have been performed yet with glass




objects that resemble actual containers.









                    ACKNOWLEDGEMENT







          This work was supported by a research grant from




the Environmental Control Administration of the U. S. Public




Health Service.
                             226

-------
                                                        o
                                                        ID
                                                           a.
                                                           CL
                                                           o

                                                           t-
                                                           <
                                                        - o
                                                           o
                                                           o

                                                           h-
                                                           z

                                                           t-
                                                           o
                                                           UJ

                                                           *
 U)
                                     (VI
                             aiva
FIGURE 8. TiO  DEPOSITION RATE AS A FUNCTION OF REACTANT

VAPOR CONCENTRATION.  DEPOSITION FOR 15 MIN. AT 780°F, USING

CARRIER GAS FLOW OF 8 cfh.  IMPINGEMENT DISTANCE WAS 4 INCHES.
                            227

-------
                                                     o

                                                     8
                                                       LL
                                                       o



                                                       Ul

                                                       cc
                                                       UJ
                                                       ui


                                                       z
                                                       o
                                                       o
                                                       0.
                                                       UJ
                                                       o
                                                     o
                                                     o

                                                     o
                                                     o
                                  NOIllSOd3Q

FIGURE 9.  TiO  DEPOSITION RATE AS A FUNCTION OF DEPOSITION

TEMPERATURE.   DEPOSITION AT  4 INCH DISTANCE FOR 60 MIN. AT

10 cfh SWEEP  RATE.
                            228

-------
                                     rV"" •:'*    ,v'  U*v~"
                                    w  & t  •_•     ;-.    >      3
                                    J ? i'v   c,*  «< -     • '   •-
                      ,                    r-   .,    / .- -•,"-
                                  ".>   -. •   V"/ ^jS   u    -.   -t
              -  ,         '        -tv.-j '' £>*JC ,   ty ph-1     *" '

         ^  '^ ''' .  — .''•-':•   > A ' -4^  V**-^-, ^
         f-'.v  *  ' :".P -    '-,  ,   ^ri>y  *** r-v  r  '-'-    *-».•»
         u  -c^> - o ' ^  V..    »-. * w. ,Ci>
         *- «. C'  '£»:.   .W,  .     .»-,,  ,1,1
       ' <;;;.-.  4iXX-%- ^,*- •"!>•" «//.-•' v - v
           V.l\f*%^> * //.» 'r( r,_4- :y >",/'{/-"-.,.'••
FIGURE  10.  PHOTOMICROGRAPHS OF TYPICAL  SECONDARY STRUCTURE
IN CRYSTALLINE Ti02 DEPOSITS.  (A) DENDRITES,  (B) CROSSES.
VERTICAL  WIDTH OF THE  PHOTOGRAPHS CORRESPONDS TO ABOUT  250
MICRONS.
                              2Z9

-------
FIGURE 11. PHOTOMICROGRAPH OF SURFACE TOPOGRAPHY ON TYPICAL
AMORPHOUS TiO  FILM. THE COATING HAD BEEN CRACKED INTENTIONAL-
LY TO SHOW DETAIL.  VERTICAL SIZE OF PHOTOMICROGRAPH
CORRESPONDS TO ABOUT 350 MICRONS.
                             230

-------
            COMPOSITE BOTTLE DESIGN AND DISPOSAL
                        Philip Williams
                      Owens-Illinois, Inc.
          The glass container industry has made packages for

many different industries from small perfume bottles to five

gallon water jugs.  The inherent flexibility of our manufac-

turing process has allowed us to make many distinctive and

unique items.  Our business, like most others, has changed

over the years, especially in those end uses that are most

important to us.  New competitive containers and outside

forces, such as legislative, have created dramatic shifts in

our business.  The prohibition era, of course, affected our

beer and liquor ware business drastically.  More recently the

switch to plastic packaging has virtually eliminated bleach

bottles and liquid detergent bottles from our sales.  Ours is

an ever changing business and our marketing and research

people try to focus on where our business is going and what

the new needs will be.


          In the middle 1960s, any evaluation of the future

of the glass industry resulted in the conclusion that the

growth areas of beer and soft drink packaging were going to

be really exceptional.  We, therefore, made an evaluation of

our present flexible manufacturing process to determine

whether it was going to be able to keep up with this growing

demand.  At that time, the inputs of the environmentalists

were relatively low key.  We decided to design and develop a


                             231

-------
new standardized package to meet the growing demands of the




beverage industry.  The result of this Advanced Systems De-




velopment group was the GCP or glass composite package.






          As our development emerged, we factored in the re-




cycling concept.  We will cover the recycling of the GCP



package in greater detail later on but let us say that we do




not see any major problem in fitting it into our glass re-




cycling programs.






          We are also going to discuss a new glass composite




package that was announced only April 20, called Plasti-




Shield.  This package has been developed within the last




eighteen months and from the very beginning the environmental




aspects have been important inputs on our design.  I will



discuss it later in some detail so that you can be familiar




with its attributes.  Therefore, we would like to use these




two new packages as examples of how package design can be




melded with constraints such as disposal.






          The GCP (glass composite package) is an important




part of a total system that Owens-Illinois is developing to




supply the growing needs of the beer and beverage industries.




We intend to supply soft drink and beer customers a totally




new_package, designed specifically for them, for 10 to 16




ounces of their product to compete with the standardized can.




GCP consists of a lightweight glass globe seated in a plastic






                            232

-------
base which can be colored and preprinted.  The glass walls



are thin and the design provides a widemouth drinking lip,




plus convenience closure.  The GCP utilizes basic low cost




but recyclable raw materials, glass and high density poly-




ethylene, in a very sophisticated way.  (The glass globe is




an ideal pressure vessel and will both contain and preserve




the product and its flavor.  The plastic base acts as a




coaster and provides protection and identification.)






          The choice of polyethylene as the base material




resulted from a complete screening of all possibl3 plastic




and metal materials.  The rigidity of the high density poly-




ethylene to support the plastic base was essential to the




concept, but the fact that it is also a nontoxic material




when incinerated was also important.  The design of the glass




globe, which is a nearly perfect pressure vessel (both the




products have internal pressure requirements) allowed us to



reduce the glass weight dramatically.  For example, on a 10



ounce package, the glass weight is approximately 2-3/8 ounces




compared with a minimum of 7 ounces on soft drink packages.




We have indicated the function of the plastic base earlier




and we feel it definitely enhances the durability of the




package.






          As the second part of the system, we have developed




a totally new manufacturing process.  It consists of a ribbon




glass machine and five auxiliary machines.  Attributes of the





                            233

-------
new process are high speed, good efficiency, consistent qual-




ity, and low labor content.






          Early in our development, it was apparent that we




needed the third component of the system - a packaging line




to match the efficiencies of can lines and preserve the total




economics of glass packaging.  We, therefore, set out to de-




velop a customer packaging line for handling glass at high




speeds and efficiencies.






          In taking the total systems approach, one must of




course be aware of the disposal of the package too.  We are




developing answers to the disposal of the GCP as well.






          During the past three years, we have conducted a



number of marketing research concept tests to evaluate all




variables of the GCP concept.  The key finding of all the




marketing research, we feel, is that almost without exception




among beer and soft drink users, the GCP package produces a




favorable response.  There are many apparent consumer bene-




fits.  For example, the consumer likes the wide mouth because




GCP is easy to drink from and they perceive the plastic base




as a "coaster" that will prevent moisture rings from forming




under the bottle.






          An important part of our development program is to




continually test the package performance in all of its as-




pects - technical and consumer particularly.  Careful screen-





                           234

-------
ing and testing is the only way to prevent putting a product
on the market that has serious flaws.

          We are at a point in our development where we must
take another important step.  This summer we will put the 10
ounce GCP, containing cola products, into the consumer's home
and have it used in real life conditions.  Providing there
are no major problems encountered, we plan to move promptly
into selected stores in certain markets for longer term test-
ing later this summer.

          At the present time, our pilot production and de-
velopment center in Toledo is still in the development and
refining stage.  Barring any unforeseen difficulties, we hope
to be commercial late in 1973-  Once we have proven the rib-
bon process for beer and beverage containers, we will begin
to investigate other potential uses such as fruit juices,
premixed cocktails, infant formula, etc.

          Now I would like to detail for you the Plasti-
Shield package which we mentioned earlier.  This package is
made on our conventional forming equipment but is lighter in
weight due to its design, (like GCP it is a pressure vessel
basically) and has a foamed polystyrene jacket shrunk onto it.
This package will be offered commercially to our customers in
September of 1971 and is currently in in-home placement and
market testing with three major soft drink companies.  The
plastic sleeve or jacket allows us to substantially reduce
                            235

-------
the weight of the glass packages in the 16 ounce and family




sizes.  For example, the quart soft drink package has over 7




ounces less glass than standard quart nonreturnable glass




containers.  Weight reductions in the smaller sizes are sig-




nificant but not as great.  The choices of plastic materials




that will shrink and adhere to the glass envelope are many




but again we have tried to choose materials that are both




functional and yet not inherently a major disposal problem.




The foamed polystyrene protects the glass from abuse and




makes this weight reduction possible, therefore, we are deal-




ing with a package that has substantially less solid waste




problems.






          When commercialized, considerably less multiwrap




materials will be required and inner packaging on family




sizes can be eliminated thus cutting down the packaging ma-




terials required to market each gallon of soft drinks or bar-




rel of beer.  By adding the polystyrene to the package, we




have raised some of the same questions in your minds, I am




sure, that exist with the polyethylene base on the GCP con-




tainer.  We feel that the answers to the disposal of both




these packages are quite similar and that they are just as




recyclable as conventional glass containers.  We will go into




this reasoning in just a moment but first we would like to




touch on the litter and solid waste aspects that we feel are




applicable to the glass container industry as a whole.
                            236

-------
          We are dealing with convenience packages for beer
and soft drinks which are high on the list for legislative
action.  There are "both litter and solid waste ramifications
and being new and highly publicized containers, our profile
will be high as we approach commercialization.  Let's first
put the problems in perspective.

          The present distribution systems for beverages have
been established by both industries at a significant invest-
ment with the objective to get products to the consumer at
the lowest possible cost.  These systems are now based pri-
marily on convenience packages.  For example, approximately
75 percent of packaged beer is in convenience containers and
50 percent of soft drinks;  and these figures are continuing
to grow.  It can be factually documented that convenience
packaging has directly contributed to the substantial growth
of both the beer and soft drink industries.   More people are
enjoying them because they are easier to buy and use.

          Any interference in the natural flow of these sys-
tems will lower the efficiency and increase the costs to the
consumer.  The lack of understanding by the general public of
these distribution systems and the concern by the public about
the environment have resulted in increasing pressure for leg-
islation to ban convenience  packages.

          Even though their products represent only a very
small percentage of litter and solid waste,  the beer and
                            237

-------
beverage industries are being singled out as exceptional prob-



lems.  Because roadside litter is a visible, irritating form




of consumer-generated pollution, the problems surrounding its




existence are obviously more publicly discussed.






          We are convinced that the ultimate solution to the




litter problem is through public education like KAB's programs




starting with our children in the very lowest grades.  We re-



peat that education, coupled with enforcement of realistic




laws against littering and provision of adequate disposal and




collection facilities represents the only practical solution




to the litter problem.






          We believe that the ultimate solution to our solid




waste problem must be the salvage and reuse of much of what is




now deemed waste.  Actually, we make a value judgment by the




name we assign to our discarded materials.  We call them solid




waste.  It seems to us that we must turn this around and call



them solid assets or resources that can be reused.  The con-




servation of raw materials demands salvage, and long range ef-




ficient management calls for the reuse or recycling of many of




the components of waste.  We are convinced that salvage and




reuse will materially reduce pollution and conserve our finite




resources.






          The recyclability of glass containers has been well




established.  There is nothing new or novel about reusing




glass containers, as cullet has been an important raw material



                             238

-------
in glass manufacturing for hundreds of years.  This group,




here today, certainly is aware of the work that is going into



devising methods of allowing us to obtain glass waste.  This



is the major problem today, not what to do with it after we




get it.  In our thinking, primary recycling is getting our




glass materials back into our hands so that we can make anoth-



er glass container with it.  Secondary recycling is devising




other uses for the recycled material and, here again, I am




sure most of you are aware of the programs in this area such




as described by Dr. Ward Malisch from the University of




Missouri at Holla.






          The separation of glass from the waste cycle can be



accomplished at a number of points in the disposal system.  We




see consumer separation and reclamation as now being practiced




at the over one hundred centers sponsored by the GCMI as one




possible route, but in our long range thinking we believe




systems which can separate mixed collected garbage, such as




Black Clawson's Hydrasposal system or the Bureau of Mines



project to be the real answer.  We are convinced that since



we have such a recyclable material, practical and economic




methods are being devised to assure the reuse of glass over




and over again.






          Now, how do the two packages fit into the environ-




ment?  We feel that the possibilities for recycling both of




these packages are very similar so we will deal with them to-






                             239

-------
gether except where there are obvious differences.






          First, let's consider primary recycling.   We have




made a number of tests on the technical feasibility of melt-




ing the entire package - glass and plastic - in our furnaces.




It appears from these tests that we can use up to 10 percent




of this product in our flint melts without discoloration and




up to 50 percent in our amber melts.   Both polyethylene and




polystyrene will burn off at our melting temperatures with the




resultant dispersal of COg and water into the atmosphere.  We




feel it is unlikely that we would get large quantities of




either package back in the early stages of development, so the




percentages mentioned would seldom be reached as cullet.  How-




ever, should our collection system change so that large quan-



tities of either package were accumulated, separation of the



glass and plastic materials would then be undertaken.  Crush-




ing and floatation very simply separate the two materials.  We




plan to use this process in our own plants on off-ware as a




matter of course.






          In secondary recycling of the packages, we are talk-




ing about end uses which could combine the glass and plastic




materials into useful products.  To develop good economics, it




is essential that you require only a crude sort of the package




from other solid waste materials - that is, there does not




have to be a high degree of efficiency in the sorting system,




and there can be room for error.  By developing the right end






                             240

-------
uses, the reuse application might permit the complete range of




glass colors to be lumped together, as well as all thermoplas-




tics.  This would make segregation much simpler and practical.




It would be highly desirable if, for example, conventional




glass containers, GCP, and plastic bottles could be included




as a segregated commodity in the collection system.  A corol-




lary of this first consideration is that the materials one




makes from the recycled packages should not have highly de-




manding technical specifications as to colors, physical prop-




erties, etc.  To make useful products that fill high volume




needs, the end product must have good utility, but appearance




should not, if possible, be of great import.  This does not




mean that the product could not be made to satisfy utilitarian




needs, but what we do mean is that products that rely on a




close control of color, texture, or sophisticated physical




properties should not be considered.






          We have experimented with ground up GCP packages,




extruding into a molded glass-plastic material.  The kinds of




products we visualize being made from this glass-plastic com-




bination must necessarily be high volume uses, therefore, we




are considering such products as tier sheets for our pallet




loads, cap sheets, possibly pallets themselves, and reshipper




trays and cases.  Being able to utilize this recycled material




in our delivery system to our customers could be of definite




economic advantage to all of us.  Other high volume needs are



being investigated too.




                            241

-------
          If we visualize the manufacture of this composite
material at one of our GCP facilities, we could work any un-
balance in glass-to-plastic ratio quite easily if we kept, for
example, our own scrap segregated by glass and plastic frac-
tions so that either ratio could be corrected in our mixing
operation.  The separation of the polystyrene sleeve from the
Plasti-Shield package is even easier than with GCP.  The poly-
styrene sleeve material could be reprocessed into products
that are basically nonfood use intended.  This is already be-
ing accomplished today in the development of coffee cup lids
which are an "ecology buff" in color and made from recycled
material.  The polyethylene base originally designed for GCP
package must be made from virgin material.  We are examining
very closely another design concept for the base which is a
direct result of our endeavor to fit the package into the re-
cycling system.  This new design, which I am going to explain
to you, is really only in the feasibility stage but I felt it
was important enough to brief you on it today.

          We visualize the possibility of utilizing a poly-
styrene sleeve similar to the one used on the Plasti-Shield
package.  I think you can visualize that simply wrapping the
sleeve around the GCP globe would make a very unstable package.
We are testing, at this time, a concept of seating the globe
in a doughnut made from recycled glass-plastic materials and
then shrinking the sleeve around it.  Here is what the package
might look like.  This doughnut support base is made from ex-
                             242

-------
truded glass-plastic recycled materials.  It is too early to




determine the complete economic and technical feasibility of




this concept but we did want to share it with you today.






          While the separation from mixed garbage of the re-




cyclable materials is, of course, the ultimate answer, we are




going to have to live with less than perfect solutions for




sometime to come in many urban waste disposal systems.  The



combined glass-plastic waste of GCP and Plasti-Shield can be




disposed of in incineration or land fill with no particularly




obnoxious results.






          It is clearly apparent to us from discussions with




our major customers that the litter and solid waste problems




are of critical importance to GCP and Plasti-Shield.  To have




successful projects and to really provide our customers with a




total systems approach, we must have satisfactory answers to



these problems.






          I have covered a lot of material in this period al-




lotted to me and we have not been able to go into all the




ramifications of these two packages in as great detail as I




would wish.  However, I think it is apparent that the design




of both of these new packages has been affected by the new




environmental emphasis and we hope that you will agree that




these two products can make some real contributions to this




problem.
                             243

-------
         SEPARATION OF GLASS FROM MUNICIPAL REFUSE
             R. J. Ryder, Brockway Glass Company, Inc.
      J. H. Abrahams, Jr., Glass Container Manufacturers Institute, Inc.
                       INTRODUCTION

          Environmental pollution—and its control—has been

a concern of the glass container industry for many years.  As

long ago as 1953, before the problems of litter and solid

waste generally were recognized as threats to the quality of

life in our environment, the Glass Container Manufacturers

Institute and its member companies were instrumental  in the

founding of Keep America Beautiful, Inc., the national litter

prevention organization.  Since that time, the glass  container

industry has continued to furnish significant financial and

service support to KAB for its various education and  litter

law enforcement programs.  Four years ago GCMI broadened its

environment-oriented activities by establishing an Environ-

mental Pollution Control Program in order to seek solutions

to problems related to solid waste management and air and

water pollution.  We believe we were one of the first in-

dustries in America tu organize programs of solid waste

management and litter prevention on an industry-wide  basis.

          Today's discussion, however, will deal only with the

role of glass containers in solid waste and the pertinent pro-

grams and research currently being sponsored by the glass

container industry.  Recent studies show that glass constitutes

                            244

-------
an average of about six and one-half per cent by weight of




municipal solid waste.  Of this, about five per cent comes




from container glass.  In fact, according to a study by the




Midwest Research Institute, all packaging accounts  for only




about 13 per cent of total municipal (residential  and commer-

-------
working to reduce or eliminate such problems as may exist.



It is important to understand that utlimately a discarded



glass container can meet only one of three possible fates:

-------
                  SEPARATION AND RECYCLING
           Recent studies have shown that there are potential
uses for every bit of waste container glass available in the
country now or in the foreseeable future.  As a first step in
the direction of total salvage and reuse of waste container
glass, the nation's glass container manufacturers are conduct-
ing an industry-wide reclamation and recycling program.
           Today GCMI member companies are operating a net-
work of nearly 100 bottle reclamation centers in some 25 states.
Since the program was inaugurated on an industry-wide basis
on June 30, 1970, many tons of glass containers have been
salvaged from solid waste and litter.  These salvaged bottles,
now being reclaimed at a rate of close to one-half billion a
year, are being recycled back into the bottle-making process.
           Reports by member companies indicated that crushed
waste glass, called cullet, can provide 30 per cent or more
of the industry's raw material requirements.  Our bottle re-
clamation program is able to supply only a small  portion of
this amount.  Therefore, in order to obtain salvaged glass in
greater quantities, GCMI is cooperating with various research
organizations and federal, state and local government agencies
to develop efficient, low-cost, highly automated systems for
separating the components of raw refuse.
                            247

-------
          One example is at Stanford Research Institute,
where GCMI and the U.S.  Environmental  Protection Agency spon-
sored investigation of a process known as the Zig-Zag  Air
Classification System which utilizes forced air currents to
separate refuse materials into its components.   To date a
major separation of paper and plastics from heavier matter
has been achieved.  Samples containing between 75 per  cent
and 90 per cent glass have been obtained readily from  the
heavier fractions.  Further separation, however, becomes more
difficult because of the similarity of densities of materials
in the heavier fractions.  More work is needed to test the
efficiency of separating waste glass for metals, but the out-
look for this research appears promising.
          The industry is working also with various organiza-
tions to further refine glass from these preliminary pro-
cesses for recycling in glass furnaces.  To this end GCMI  is
supporting studies at the Sortex Company at Lowell, Michigan
to optimize the means of optically sorting the glass that  has
been reclaimed from solid waste into its various colors.   On
a pilot basis this research is producing color-sorted  glass of
a quality that can be recycled by our industry.  When  perfect-
ed, it will enable glass container manufacturers to consume
large tonnages of salvaged glass.
                           248

-------
           Further, we have been following and working
closely with the U.S. Bureau of Mines on its  development of
a process utilizing standard ore dressing methods  to separate
usable materials from incinerator residue and high-intensity
magnetic forces to sort glass by color.   The  Bureau estimates
that after the salvage of metals the separation of clear or
flint glass costs only an additional 77  cents a ton, using
figures for its 250 tons-a-day plant.  From a practical
standpoint, the potential benefits are enormous.  Sorted by
color and refined, glass from incinerator residue  could  be
used as cullet to make new bottles or used in secondary  pro-
ducts .
           Also, a number of solid waste management systems
are presently in various stages of development by  private in-
dustry.  Some, in fact, need only the opportunity  of a full-
scale demonstration in a typical community to prove their
worth.   One such development, which will be discussed in more
detail  later in this presentation, is a  unique wet system
capable of crushing and separating paper pulp, metals and
glass from other materials at a reported cost of approximately
$3.60 per ton of raw refuse after allowing for pulp and
ferrous metals salvage.  This includes operating costs and
                           249

-------
amortization in a plant designed to handle 500 tons  of waste
a day.  This system is being constructed at Franklin,  Ohio
by the Black Clawson Company with the assistance of  a  demon-
stration grant from the Solid Waste Management Office  of  the
U.S. Environmental  Protection Agency.

                    SECONDARY MATERIALS
           Ue define secondary materials as those products
other than new glass containers that are made from waste
glass.  GCMI's research on secondary materials has been
directed largely toward determining those products which  can
incorporate waste container glass which is not sufficiently
refined to be used in glass manufacturing furnaces.   Generally
speaking, these secondary products are in the nature of con-
struction materials where the glass must compete with  relat-
ively cheap raw materials.
           For example, GCMI and the Environmental Protection
Agency for several  years have supported studies at the
University of Missouri at Rolla which show that glass  frag-
ments may be substituted for stone aggregate in glasphalt,
one of the better known potential secondary products.   But  the
cost of stone aggregate averages around $2 to $4 a ton.  In
this case it would not be practical from an economic stand-
point to pay processing costs in excess of $5 or $6  a  ton
                           250

-------
for the waste glass alone.  However, the cost for processing



the refuse mix must be distributed proportionally among all



of the salvageable components.  This approach must be con-



sidered for both the Black Clawson system at Franklin, Ohio



as well as for the U.S. Bureau of Mines incinerator residue



reclamation system at Edmonston, Maryland.



           Intitial calculations indicate that glasphalt



alone could use up all the waste container glass  available in



municipal waste systems now and in the forseeable future.



Estimates for waste container glass in refuse today range



between 10 and 15 million tons annually, whereas  the amount



of stone aggregate used in asphalt approaches third of a



billion tons annually.  If waste glass were to be substituted



for even three or four per cent of the aggregate, all  the



glass still would be utilized.



           Furthermore, GCMI is funding a study at the



University of Missouri at Rolla which will evaluate the amount



of foreign material which could be tolerated in glasphalt.



If a certain amount of metals and organic materials could  be



tolerated, then less processing of municipal wastes from



proposed mechanical separation systems would be needed and



the costs reduced.
                           251

-------
           Another well known secondary product  utilizing




waste glass is the brick made from glass-enriched incinerator




residue.  In the U.S. Bureau of Mines process of removing




metals for recovery, a mixture containing some 98 per cent




glass is left over.  This product can be used directly for




making bricks using various binders, such as 10  to 30 per




cent of regular brick clay.  In general, regular brick making




equipment can be used.




           In addition to these products, GCMI and its mem-




ber companies have been conducting studies of some 10 other




secondary products which are made from waste container glass.




           In one process bricks using waste container glass




can be made by using high pressure and cement, and certain



chemicals such as those developed by the T-A Materials Com-




pany.  These bricks can be made to such close tolerance that




a paste material can be used instead of standard mortar.




With this system various shapes of bricks and blocks can  be




designed.




           Blocks and bricks -- even large panels -- can  be




made by a variety of other processes.  Studies with GCMI




support are being conducted by the Colorado school of Mines




Research Institute to use waste container glass as the bind-




ing medium for panels 4 feet by 16 feet and up to 4 inches





                           252

-------
thick.  The composition is 6 per cent clay, 13 per cent to




94 per cent glass and 0 per cent to 81 per cent rubble,




yielding a bulk density of 130 pounds to 140 pounds per cubic




foot depending upon the proportions used.  The crushing




strength was found to be as high as 12,000 pounds a square




inch.  Panels containing the higher glass ratio can be polish-




ed for decorative effect.




           Stanford University is conducting studies using




glass and silica with cement and other materials to make an




expandpd or porous material for insulated wall panels.




           Furthermore, glass wool  insulation can be manu-




factured using up to 50 per cent waste glass.  This is being




done by the U.S. Bureau of Mines using glass recovered from




incinerated residue and by at least one commerical  manufacturer.




The Bureau is also making such other products as glass beads




and lightweight aggregate from glass rich incinerated wastes.




           In the case of the bricks, blocks, and wall panels,




each use could easily absorb the waste container glass in a




municipality.  Preliminary studies  show that many of these




products using waste glass could compete with standard con-




struction materials if separation systems were utilized and




markets developed.
                           253

-------
           In California, standard 5/8-inch terrazzo flooring



has been developed which itilizes reclaimed glass  in place



of marble chips.  In addition to the regular flooring thick-



ness, a second type, also using waste glass but featuring  a



new matrix, has been created by the American Cement Technical



Center.  By incorporating small amounts of a polymer substance



into the product mix, the company has been able to produce a



terrazzo finished to a 1/4-inch thickness with two or three



times the flexible strength of normal terrazzo.  This new



product  provides a significant weight saving which can be a



major factor in high-rise buildings.






                         UASTE DISPOSAL METHODS



           As we have already indicated, glass containers



contribute only a small portion of the solid waste mix.  How-



ever, if glass is properly ground for disposal in sanitary



landfills it returns to the soil in almost its original form



and the volume is reduced substantially.



           The Institute has sponsored independent studies



to determine the degree to which glass containers constitute



a solid waste problem.  These studies have indicated that



waste container glass, when properly handled, is not a pro-



blem in present municipal disposal systems.





                           254

-------
           In solid waste landfills, for example, Drexel




University determined that glass does not contribute to any




physical problems or chemical pollution.  When crushed or




ground, glass mixed with the soil becomes a permanent and




firm fill which will not settle or erode.  In addition, there




is virtually no leaching from the glass to cause pollution




of ground and stream waters.




           Similarly, and despite widespread views to the con-




trary, glass has not been found to be a significant problem




in incineration.  Glass containers generally break into frag-




ments due to the heat blast in incinerators.  Many of these




fragments help aerate from the batch and thus enhance com-




bustion, while other fragments fall through the grates.




           According to data collected in a recently com-




pleted national opinion survey of municipal, county and solid




waste management offifials, glass containers were found to be




among the least difficult of all packaging materials to handle




in refuse collection operations.  This study was conducted by




the Resources Management Corporation of Bethesda, Maryland,




in order to determine directly from officials responsible for




solid waste collection their views on the role of packaging




materials, particularly glass containers.
                            255

-------
           Among other things,  the study found  that almost  70




per cent of the officials believe that no packaging material




is damaging to collection equipment.   Only two  per  cent  of




the respondents felt that glass containers would  harm  such




equipment and only 8.1 per cent considered them difficult to




handle,   Further, the waste management officials  indicated




that glass containers are the least troublesome of  all




packaging materials in landfills and  incinerator  operations,




falling  behind steel, plastic and corrugated  containers.




           However, in general  the refuse systems in most




municipalities are inadequate and antiquated.   Only recently




have municipalities begun to look beyond the  garbage man




and truck concept of refuse collection.  The  labor  intensive




collection systems, in fact, account for 75 to  80 per  cent  of



refuse costs.  It is hoped that Federal funds may be provided




under the Resources Recovery Act of 1970 to finance projects




which will upgrade significantly collection and disposal




systems.






                    LONG-RANGE SOLUTION
           Consumer demand has established a market for con-




venience packaging, and part of the convenience of using such




packages is the fact that they can be discarded.  The refuse






                          256

-------
mix must be separated, but we cannot necessarily expect the




nation's housewives to do this job.




           The nation's glass container manufacturers are




convinced that the Jong-range solution to the presence of




glass in solid waste can be found in the separation sytems




and markets for waste glass which are currently being developed.




These systems are designed to deparate the various  salvage-




able components of refuse, and glass is but one of  these.




The enriched, mixed colored glass is a by-product left after




other materials are separated,and thus it starts with a zero




value, or even a negative value since disposal  in a landfill




could cost several dollars a ton.




           As we have seen, two potential markets are develop-




ing for this glass mixture.  One is the use of  waste glass  as




cullet in the bottle-making process; the other  is its use in




various secondary products.  By using materials handling




methods, glass fragments 1/4 to 3/4 inches across can be




freed of contaminants and color sorted for remelting and  re-




forming into containers.  Less refined or smaller sized frag-




ments are usable in secondary products also.  As indicated




earlier, the U.S. Brueau of Mines id developing a system  using




commercial  equipment which is capable of separating sand-




sized particles by color.



                           257

-------
           Today there are perhaps three major approaches




to separation.  These are wet separation, dry separation,




and separation after incineration or pyrolysis.  The glass




container industry is working closely in the development of




several of these systems in order to evaluate the quality




of waste container glass produced and the potential  markets.




Systems using one or more of these basic systems are nearing




the stage of practical demonstration.




           One of the best known systems is the Hydrasposal




method developed by the Black Clawson Company of Middletown,




Ohio.  A prototype of this wet spearation system is  being




constructed at Franklin, Ohio.  When fully installed, this




plant will be one of the most complete systems in the country



for processing the waste products of our society. The




Hydrasposal and Fiherd aim systems, manufactured by  Black




Clawson, are designed to handle nearly all normal municipal




residue except bulky items.  Coordinated with this is a mod-




ern sewage disposal plant to be built soon by the Miami (Ohio)




Conservancy District which will serve Franklin and the sur-




rounding area as well and will process contaminated  waste




water from the solid waste plant.




           The Black Clawson demonstration plant is  being




designed to handle 50 tons of refuse in an 8-hour day, with




                           258

-------
a salvage potential over 50 per cent of the total  tonnage.
The process will first crush the refuse into a liquid slurry
small enough to pass a 3/4 or 1 inch diameter opening.
Heavy materials settle out, and ferrous metals are removed
magnetically.  Inorganic materials are then removed in a
liquid cyclone, which leaves a residue of heavy materials
consisting of 80 per cent glass and nonferrous metals.  The
light organic portion is reduced into discreet fibers with
contaminants screened out.
           The glass container industry is interested in the
heavy portion containing the 80 per cent glass and has de-
signed a system to refine the glass fraction into  a material
usable in glass manufacturing furnaces.  As such,  the glass
must be clean, uncontaminated, free of metals, and sorted
by color.
           The glass subsystem has been designed by GCMI
and by the Sortex Company to receive this glass-rich mix-
ture from the Hydrasposal and remove all contaminants before
or during color sorting.  A prototype of this subsystem is
planned for installation at Franklin, Ohio with the funds
to be provided by the Federal Environmental Protection
Agency and GCMI.  Several research methods for removing
contaminants will be used, including washing, screening,
                         259

-------
air optical separation.   The initial  steps  will  be  to:

      1.  Receive the mixture and remove strong  magnetics.

      2.  Size to separate the glass  into the fractions
          larger than 1/4 inch and smaller  than  3/4 inch.

      3.  Dry before further processing.

           The glass fragments larger than  1/4 inch will  be

processed further in preparation for  color  sorting  with  the

Sortex machine, and the smaller samples either removed from

the system for use in secondary products, or passed through

an air classifier in preparation for  an experimental  high

tension electrostatic separator to remove the clear glass.

           In preparation for the Sortex separator, the  large

fragments (1/4 inch to 3/4 inch) will be subjected  to a

cyclone air classifier and a zig-zag  classifier. These  two

separation systems will  be in service for this experimental

subsystem, but the most efficient of  the two systems probably

would be used in a second generation  subsystem.   The Sortex

optical sorter scans each fragment as it passes  through  a

filtered beam of light and sorts the  clear glass from colored

glass and contaminants.   A second pass of the rejects would

then sort the greens from the remaining mixture, until  all

economically salvageable glass fragments are removed.

           The glass subsystem is an  experimental unit de-


                           Z60

-------
signed to determine the effectiveness of various  separation




systems for glass.  It is anticipated that the subsystem,




with proper modifications, could be adapted to one or more




of the several  mechanical separation systems being developed.






                         CONCLUSION




           These, then, are some of the steps that have been




taken by the glass container industry to help alleviate its




contribution to the nation's growing solid waste  problem.




The utlimate goal toward which we are working is  the eventual




separation and  salvage of usable waste components and their




return to industry for recycling.




           Hopefully, future generations will see a nation-




wide network of refuse processing stations, perhaps designed




along the order of the Franklin, Ohio pilot project, where




municipalities, or even utilities, will separate  wastes




mechanically and automatically and subsequently sell the re-




cyclable materials to manufacturers or refiners.   Such systems,



we believe, will result in the much needed conservation of




our natural resources and reduce pollution from solid waste.
                            261

-------

-------
      SESSION IV

METALLIC CONTAINERS
                  Chairman:

                  G. R. Smithson, Chief
                  Waste Control and Process Technology
                  Columbus Laboratories
                  Battelle Memorial Institute

-------

-------
        FERROUS SCRAP RECYCLING AND STEEL TECHNOLOGY
                         Wilham S. Story
                 Institute of Scrap Iron and Steel, Inc.
          I am here today representing the ferrous scrap

recycling industry.  And while members of the Institute of

Scrap Iron and Steel also handle non-ferrous metals, my

remarks are confined to ferritic materials with emphasis on

the tin can—whether all steel or with an aluminum top.

          Public concern with the quality of our environment

and the conservation of our natural resources strikes a fav-

orable chord with members of the metal recycling industry,

especially as it applies to scrap iron and steel.  For

years, we have been commenting on the need to better utilize

our resources, through conservation by recycling, but only

now are the words falling on receptive and eager ears, and

only now are we seeing action taken which will serve, over

the long run, to recycle as much of our ferritic metallics

as possible.

          As I am sure you are aware, our industry has been

responsible for recycling millions of tons of iron and steel

scrap annually to steel mills and foundries.  However, be-

cause of changing technology in steelmaking, the volume we

have recycled to steel mills has not kept pace with the rate

of discard of items made from steel and iron.  Had we con-

tinued the high level of recycling which we obtained during

World War II, for example, this nation today would have no

major metallic solid waste problem.  But we have not, and as

a result, we do have a problem.  And while this is primarily


                            263

-------
a container program, let me cite some data for you on the




overall iron and steel scrap picture in order to bring the




matter into somewhat better focus.




          If we are to go back to 1956, we find that in that




year, the domestic steel industry produced 115 million tons




of raw steel, and in the course of this, plus foundry produc-




tion, our industry shipped 37 million tons of scrap.  In 1970,




the domestic steel industry produced 131 million  tons of




raw steel, and purchased scrap sold by the scrap industry




amounted to 40 million tons, an increase of only 3 million




tons versus a 16 million ton rise in raw steel output.




In the intervening time, our throw-away society has come




into full bloom.  It reached its nadir with people literally




throwing away their automobiles by abandoning them on city




streets, in country lanes, or along our highways.  Tin cans




are a modest problem in relation to cars.




          Most of the impact of the decline in scrap demand




in relation to basic steel production has been felt in the




consumer goods area—as exemplified by the old car, which is




so obvious, but to a lesser degree by other consumer hard




goods, such as refrigerators, stoves, washing machines and




the like.




          In its drive to make use of this available raw




material, our recycling industry in the past 10 years has




developed the automobile shredder, an expensive system of








                             264

-------
hammer mills, magnetic separators, conveyors, furnaces,




along with accompanying ail , dust, and water systems.




Large systems cost upward of $6 million, when accompanied by




non-ferrous metal separation devices.  Smaller systems now




start at $600,000.  There are close to 80 such systems in




operation today, and there will, in all likelihood, by 100




by this time next year.




          Within the context of today's program, tbe




automobile shredder stems from the tin can shredder, develon-




ed in the Thirties for providing shredded tin cans for the




copper industry in the West.  Tin can shredding started in




Los Angeles, and, during World War II spread to Houston,




and then to other locations.




          Shredded tin cans are used in large-scale copper




leaching operations in the West.  The method used goes




back to Rio Tinto in Spain in the mid-seventeen hundreds.




Nearly 13 percent of the total copper production in the




Western States in 1965 was obtained from the precipitation




of copper from leach liquors by using metallic scrap iron.




          Virtually all of the copper leaching operations in




the United States use shredded tin cans.  We estimate that




about 350,000-400,000 tons of this material is consumed




annually.  Copper companies are also experimenting with




shredded automobile scrap, sponge iron, and pre-reduced




iron pellets.
                           265

-------
           A member company of my association has told me that




the problem with tin cans West of the Mississippi is not get-




ting rid of the cans, but rather of finding enough tin cans




at an economic price to meet the needs of the copper industry.




Copper producers, I am sure, would not be experimenting with




other iron sources if it were possible to lay down shredded




tin cans at a price and in the volume they require.  But the




leaching process is growing in scope, and we can expect




steadily increasing demands for tin can scrap from this area




providing they can be economically furnished.  But, as you




can readily understand, the volume of tin cans consumed by




this method is modest when compared to the volume of tin cans




arising annually in all parts of the United States.




           The major factor other than demand which inhibits




greater volume movement of cans from the large populated




areas of the Eastern United States, to the copper-leaching




operations of the West, is, of course, transportation costs.




A number of years ago, one of our Southern members was




actually forced to shut down a tin can recovery operation




because of the unwillingness of the railroads to provide rates




which would make it economically possible to move the cans




to the consuming point.




           For the purists, use of tin cans in leaching does




not represent the ultimate in recycling, since the iron goes




into solution with sulfur, but it does represent a viable and




growing method of moving at least a portion of the tin  cans



                            266

-------
which are discarded annually.




           Bat we are really dealing with a much greater prob-




lem— the upwards of five million tons of steel used annually





in ttie production of containers, and the fact that much of




this is not recycled now, but more is likely to be recycled




in the future.




           During World War II, cans from city incinerators,




when baled, went to steelmakers, mostly for use in blast




furnaces.  But in the years since, this has dwindled to





virtually nothing.




           Also during World War II, large tonnages of




suitably prepared used tin cans were detinned, resulting in




the recycling of large quantities of both steel and tin.  The




function of detinning, and the practice of del:inning is well




known, but in the post-war years, the economics have not been




right for detinning ot much other than prime material,  consis-




ting of can industry production scrap and rejects, as well as




steel industry rejects, and scrap left from other manufactur-




ing operations where tinplate has been used.




           It has only been in relatively recent months that




the canmaking industry, in protection of its markets against




the onslaught cf environmentalists who want to ban the  can





or the one way container, has  instructed detinning subsidiaries




it may own to start taking in general run tin cans for  proces-





sing.  This is, however, a modest contribution to the solution

-------
of the overall problem, and, I would venture to guess, not an




easy one for the detinners on the basis of economics and




their productive processes.




           More importantly, as most of you are probably




aware, the can industry has now offered the facilities of all




can plants throughout the nation as collection centers for




cans of any type, whether they be food cans, beverage cans or




aerosol cans.




           This is predicated on the willingness of our




industry to bale the cans and on the willingness of the steel




industry to accept the baled material from the metal recycl-




ing industry.




           Cans in volume have not been acceptable to the




steel industry because of the tin coating and also because of




the lead solders.  I am sure Mr. Makar will be dealing with




the reasons in his paper.  But just so long as the steel




industry is unwilling or unable to accept can scrap,  then our




industry is unable to handle it on a recycling basis.




           However, tin plate makers within the steel industry




have been as concerned for their tin plate markets as the can




industry has been about its markets.  Research, as you prob-




ably know has been conducted at several of  the principal




companies.  National Steel has melted baled tin cans  in its




basic oxygen furnace;  United States Steel  has run cans through




its blast furnace in the  ironmaking department;  and




Bethlehem Steel has handled  the electric  furnace application.




                             268

-------
With the completion of this work, each of these companies has




agreed to work with the can industry and our own industry in




taking back baled tin cans.  Republic Steel will also take




back cans, and some smaller companies are interested.  The




American Iron and Steel Institute is currently working on a




specification for baled tin cans which will meet the needs of




its members, and which will also be applicable for the metal




recycling industry.




           A market at $20 a ton is modest, especially when




the cost of transportation to the consuming point is con-




sidered, coupled with the cost of baling.  In Washington,




recently, members of our industry met with a can company




official to discuss the possibility of setting up a recycling




program for the Washington area.  Freight rates to the princi-




pal consumer, in this case, Bethlehem Steel, are $4 a ton.




Baling costs are about $8-10 a ton.  If cans are collected at




sites which the ordinary citizen can readily reach, such as




supermarkets, the cost of containers, their placement, and




their pick-up will eat up the rest of the $20 figure, accord-




ing to my people.  Nevertheless, we believe wholeheartedly




in the need for such a program in the Nation's Capital, and




will be holding more discussions about implementing this




initial meeting.




           Over the longer-term, the growth of the so-called




"tin-less" can will alleviate some of the metallurgical







                            269

-------
problems, just as the development of thinnei coatings of




tin have made it easier for steel producers to accept cans




back at this time.  Further, if canmakers move to methods




whereby solders are eliminated, the very serious lead problem




can be progressively reduced.  Research on all-steel tops




is well on its way.  These factors obviously will aid in




tan can recycling.  In my estimation, they are extremely




important if we are to be able to recycle all the cans which




are now beginning to be removed from the trash as it arrives




at sanitary landfills and other disposal areas.




          Despite breakthroughs which have been occurring,




and the promise of further changes in the near-future, we




still have a long way to go in this matter of recycling cans.




One thing I can assure you—our own industry has all the




available equipment needed to meet the need.  If every can




produced in the nation annually were ultimately recycled,




our industry would have no need to install any new equipment




whatsoever, except to perhaps replace balers which were worn




out in baling cans.  We have the  tools, and we have  the




knowledge.  We know how to make a profit in handling tin  cans,




providing we have  tonnage markets and a workable price




level.  But the key word is MARKETS.  Thanks to the  steel




industry, these markets are now developing
                           270

-------
      METALLURGICAL ASPECTS OF RECLAIMING CONTAINER SCRAP
                  H V  Makai and H. S. Caldweii, Ji
                       U. S. Bureau of Minos
                         INTRODUCTION

          Municipal  refuse generated annually  in  the  United

States  is estimated  at 200 million  tons.   The  metal values

of the  container scrap contained  therein  represent a  substan-

tial resource potential , but are  irretrievably lost to  dumps

and  landfill areas by current disposal methods.   Based  on

studies by  the  Bureau of Mines and  others,  ferrous cans  re-

present about 4.5 percent of the  total refuse,  or 9 million

tons annually.  Nonferrous metal  content  in  the  refuse  is

estimated at about 1 million tons.  Approximately one-half

of this is  from aluminum packaging.

          These materials do not  pose a particularly  severe

disposal problem when compared to the total  refuse generated,

but once buried, they do represent  an important  loss  of  min-

eral resources and should not be  ignored.  The  ferrous  cans,

for example, have an estimated value of 10 dollars per  ton,

representing an annual potential  of $90 million.  If  upgraded

to pig  iron with a specified analysis, the value  would  be k$

to 70 dollars per ton for an annual potential  of  405  to  630

million dollars.  Based on 200 dollars per ton  for aluminum

can scrap,  the aluminum packaging scrap in refuse has a
                             271

-------
potential annual value of 100 million dollars.  This value




would be substantially greater in the form of secondary




aluminum ingot.




          In spite of the potential value, ferrous and alum-




inum container scrap are not readily acceptable for recycling




by their respective industries.  One major deterrent is the




metallurgical contamination caused by other metallic elements




associated with these scrap materials.  This paper considers




some of these metallurgical aspects and describes research




efforts by the Bureau of Mines to develop effective methods




for refining and utilizing container scrap.




                     FERROUS CAN SCRAP




          Metallurgically, the ferrous can scrap is unat-




tractive because of copper and tin contamination.  Both are




undesirable  in steelmaking, consequently there is little or




no demand for the scrap.  Current market value of the scrap




is estimated at $10 per ton.  Other elements, such as lead




and sulfur, may also reach undesirable levels.  Typical




concentration ranges for these elements in can scrap are




shown in table 1.   Desirable maximum levels for these ele-




ments are also shown for comparison.
                            272

-------
      TABLE  1. - Composition of Ferrous Can Scrap
                   Compared to Desired Analysis

                   Concentration, wt. percent
              Cu         Sn        Pb          S
Can Scrap  0.2-0.5    0.1-0.4  0.06-0.15  0.014-0.042

Desirable   .10         .06       .02        .05

          Emphasis  in Bureau research is on development of

processes to remove and recover copper from the scrap.  In-

vestigations also include removal of the other undesirable

contaminants.   The current status of some of these studies

are described in the following sections of this paper.

                Refining Molten Ferrous Scrap

          Current studies at the Bureau of Mines College

Park Metallurgy Research Center are directed at removal and

recovery of copper by pyrometallurgica1  techniques.  The

process includes use of sodium sulfate (^250^) which reduces

to sodium sulfide (Na2$) .  Copper removal is achieved by the

formation of a copper sulfide which dissolves  in sodium

sulfide.  Tests are conducted  in induction melting furnaces

with capacities ranging from a few pounds to approximately

100 pounds.  Figure 1  shows a  typical test in which molten

sodium sulfide slag is being added to a bath of molten iron.
                            273

-------
FIGURE  1, - Molten Sodium Sulfide Slag Addition to Bath
                         of Molten !ron

Prev i ous Research

          Earlier studies at College Park defined an empiri-

cal relationship between copper removal and amount of sodium

sulfate added.  This relationship is illustrated in figure 2.

These tests included high-carbon synthetic irons  with cop-

per concentrations up to about 1.6 percent, and actual cupola-

melted auto scrap with approximately 0.^*5 percent copper.

Final  copper concentrations ranged down to 0.076 percent.

Subsequent tests showed that copper levels    less than

0.002 percent could be achieved if sufficient sodium sulfate

were added.  Based on tnis earlier work,  it was estimated

that the equivalent of about 800 pounds of sodium sulfate


                            274

-------
    0          10        20         30         40
             SODIUM SULFATE ADDED, percent of metal weight

FIGURE 2. -  Copper Removal vs Amount of  Sodium  Sulfate
                Added  (Surface Additions)

per ton of  iron treated would refine  typical scrap  contain-

ing about 0.40 percent copper to an acceptable  level  of  0.10

or less.  Significant  improvements  in  extraction  efficiencies

were believed possible and additional  studies were  undertaken.

These are briefly described below.

Lance Injection

          Sulfate additions during  the early studies  were

made as a powder onto the molten iron  surface.  This  resulted

in a vigorous action on the surface of the  iron bath  causing

some of the  powder to be ejected from  the furnace crucible.

A lance injection system is currently  being developed to over-

come the inherent inefficiency of surface additions by

                            275

-------
providing controlled additions below the molten iron sur-

face.  The controlled agitation also provides an increased

slag-metal interfacial  area.

          Initial lance injection tests on molten can scrap

containing 0.35 percent copper showed considerable improve-

ments over surface additions.  Copper levels down to 0.06

percent were achieved.   The results summarized in table 2

show the decrease in copper concentration as the amount of

Na2SO/j injected is increased.

          TABLE 2. - Copper Removal by Lance Injection

                               Copper       N32S01, added,
           Copper, wt.  pet  removal , pet  pet of Metal Charge
Series A         0.35
                  .20           42.9             9.7
                  .13           62.9            19.4
                  .09           7^.3            29.1
                  .06           82.9            38.8

Series B         0.35
                  .28           20.0             1.4
                  .23           34.3             7.8
                  .17           51.4            13.8
                  .13           62.9            19.8
                  .11           68.6            24.0

                 Test conditions: 1300° C - 10 g Na2SO//min.

                                  Approximately 1000 g  Iron

                                  charge (3-7-4.5 percent

                                  carbon).

This and the earlier data for surface additions were applied

to a generalized equation expressed as:

          Y = 100 [l-exp(-kX)],
                           276

-------
             where Y = copper  removed, percent


                   X = sodium  sulfate added,  percent of


                       metal charge



                   k = a constant


Average  k  values were calculated for both sets of  data and


used in  the above expression  to obtain separate  curves for



lance injection and surface additions, shown in  figure 3.
 c
 0)
 o

 0)
 a
 a
 LJ

 o
 5
 UJ
 (E

 a:
 UJ
 a.
 a.
 o
 o
      100
       80
       60
40
       20
        Lance injection

        y = IOO(l-e--0507x)
Surface addition

y = IOO(l-e-°323x)
                   10
                     20
   30
40
50
         SODIUM SULFATE ADDED,  percent of metal weight


FIGURE  3- - Copper Removal  vs Amount of Sodium Sulfate

           Added. (Lance  Injection vs Surface Additions)
                           277

-------
 This  preliminary  comparison  shows  that  copper  removal  by

 lance injection  requires  approximately  35  percent  less

 Na2SOi, than  by  surface  additions.

 Slag  Modification

           Adjustments  in  the composition of  the  sodium  sulfide

 slag  are  also being  studied  to  determine  if  different  slag

 compositions can  achieve  effective copper  removal  with  smaller

 slag  additions.   Use of ferrous sulfide (FeS)  in sodium sul-

 fide  slags has  been  found particularly  effective in  improv-

 ing copper removal.  Rate tests on molten  iron with  approxi-

 mately 1  percent  copper were run using  sodium  sulfide  with

10-, 20-,  and ^O-percent additions  of  ferrous sulfide.   The

 test  results, when  compared  to  similar  tests using only

 sodium sulfide  on the molten iron, showed  increased  copper

 extraction with  increased ferrous  sulfide  content.  This

 data  is summarized  below  in  table  3.

           TABLE  3.  - Coppe.r  Removal with  FeS Additions
                                 to the  Slag

1005
10%
2Q%
40%


I Na2S
FeSla)
FeS (a)
FeS (a)
(a)
Initial
1.13
1 .20
1.27
1.11
balance = Na~S
Fi nal
.55
.44
.45
• 31


56
63
65
72

           Test Conditions:  1300°  C,  approximately 1000  g

                            iron  (3.1-5.2 percent carbon),

                            slag  added  in molten form (200  g

                            total).

                             278

-------
Slag analyses indicated that use of ferrous sulfide also had




a beneficial effect on iron recovery.   Iron content of the




final slags were 6.97, 10.2, and 15.6 percent for the 10-, 20-,




and 40-percent ferrous sulfide additions, respectively.   The




initial iron concentrations were 5.42, 10.2, and 22.5 percent,




respectively.  In similar runs where the initial slags were




all sodium sulfide, final  iron concentrations in the slag




ranged from 6 to 14 percent.  The iron in these latter slags




came from the iron bath whereas, in the slags with FeS,  most




or all the iron came from the FeS.




Spent Slag Recycling




          The principal objective in the approaches des-




cribed above has been to reduce the quantity of refining




slag required to effectively remove copper.  Another approach




currently under study is the treatment of waste slag from




the refining process to generate fresh sodium sulfate.  The




principle behind this approach involves oxidation of sodium




sulfide in the slag to sodium sulfate.  Impurity metal sul-




fides dissolved in the sodium sulfide are insoluble in sod-




ium sulfate and should separate into a concentrated sulfide




layer.  The technical feasibility of this approach was first




demonstrated by lancing molten sodium sulfide with oxygen to




convert it to sodium sulfate.   Subsequent tests included sod-




ium sulfide containing dissolved copper,  tin, manganese, and




iron sulfides.  Lancing the molten  sulfide mixture at 1200° C
                            279

-------
with oxygen produced a sodium sulfate top layer and a con-

centrated metal sulfide bottom layer.  An illustration of

the separation achieved is shown in figure k.
FIGURE 4. - Sodium Sulfate
(top  layer) and Metal Sul-
fide  Concentrate (bottom)
after Oxygen Lancing of
Molten Sulfide Mixture.
The amount of oxygen used during the conversion process was

close to the stoichiometric amount  indicated by the sulfide

to sulfate reaction.  Analyses of the original sulfide and

the resultant layers were as  follows  (in weight percent):

          TABLE  *».  - Metal Content  of Slag  Products -
                           Synthetic Slag
                     Cu
Original  Sulfide    5.50
Sulfate  Layer        .02
Bottom Layer       23.5
 Sn
2TPT
<.01
3.87
 Similar  tests were  then  performed  on  actual waste  slag  from

 previous  iron-refining experiments.   Total  copper,  manganese,

 and  iron  in  the  sodium sulfate  product was  less  than  0.1  per-

 cent.  Analyses  of  the waste  slag  and resulting  layers  are

 shown  (in  weight percent)  in  table 5.
                            280

-------
          TABLE 5. - Metal Content of Slag Products -
                             Actual Slag
Waste Slag
Sulfate Layer
Bottom Layer
 Cu
2.91
 .01
4.80
 Mn
2.70
 .01
4.81
Copper Recovery

          Exploratory tests have been conducted to deter-

mine feasibility of recovering  copper from the waste slag.

During one test, a sample of cuprous sulfide (Cu2S) under a

layer of molten sodium sulfate was treated with ferrous can

scrap.  This produced a small copper button and small copper

beads throughout the solidified melt.  A similar test con-

ducted on cuprous sulfide without sodium sulfate produced a

substantial  copper button, representing 78 percent of the

total copper available.  Figure 5 shows the copper button

obtained, analyzing 90.4 percent copper and 7.6 percent iron.
FIGURE 5. - Copper Metal
Obtained by Treating Sul-
fide Concentrate With Iron
Scrap. (90.4% Cu and 1 .(>%
Fe).
                             281

-------
          The overall process concept is thus one of iron re-




fining, slag recycling, and copper recovery to produce market-




able products and by-products for recycling.




          It is important to note here  that  in the studies




to date using sodium sulfate, copper removals have been




achieved without sulfur pick-up in the iron.   In fact, sul-




fur removals generally accompany the copper removals.  For




example, can scrap containing 0.03-0.04 percent initial




sulfur contained only 0.01-0.02 percent sulfur after lance




injection with sodium sulfate.




                  Miscellaneous Research




          A number of other related ferrous scrap research




projects have also been conducted or sponsored by the Bureau




of Mines.  Some of these are briefly described in the follow-




i ng paragraphs .




Increased Use of Ferrous Scrap in Electric Furnace Steelmaking




          Studies are in progress at the Albany Metallurgy




Research Center to develop continuous charging procedures for




electric furnace Steelmaking to permit wider  use of secondary




ferrous materials at lower operating costs.  Compared to con-




ventional batch practice, tests with continuous charging




showed:




          (l)  approximately 50 percent reduction in heat




               t imes;




          (2)  about 20 percent reduction  in  energy consump-




               tion;




                             282

-------
          (3) reduction of residual elements to final con-




             centrations acceptable for most steel products.




          Basing their opinions on results to date, Bureau




engineers believe that ferrous can scrap, as well as prepared




automobile scrap and large appliance scrap, would be accepta-




ble charge materials.




Destructive Oxidation of Ferrous Scrap




         A possible solution to the ferrous scrap problem




is destructive oxidation at elevated temperatures to produce




an iron oxide product and clean scrap products suitable for




steelmaking.  The Bureau has been conducting such research  in




its 36-foot rotary kiln at Twin Cities.




         Early tests were performed on sheared auto scrap at




1100° C.  Seventy percent oxidation was achieved on incinera-




ted as well as unburned scrap charges.  Light gage material




yields a single kiln product consisting of iron oxide.  Heav-




ier scrap charges can be removed as a usable product or re-




cycled through the kiln.  The destructive oxidation treatment




has been shown to be applicable to tin cans as well  as turn-




ings and borings, auto scrap, and appliance scrap.




Foundry Pig Iron From Ferrous Scrap




         Production of commercially acceptable foundry iron




from low-grade ferrous scrap is currently under study at the




Bureau's Metallurgy Research Center in Twin Cities,  Minnesota.




This foundry research is being conducted in an 18-inch, basic-




lined cupola.   The objective is to determine mixtures and





                            283

-------
processing variables to make commercially acceptable foundry

iron from low-grade scrap iron at commercially attractive

costs.

          During preliminary testing iron was produced from

various materials including select auto bundles, cleaned

cans, and kiln processed auto scrap.  Detailed results of

these tests are shown in table 6.

          TABLE 6. - Operating Data From Hot Blast
Cupola Melting

Charge, Ibs/ton hot metal
Scrap
Coke
Limestone
Spar
Ferros i 1 i con
Metal analysis, wt . pet
C
Si
S
Mn
Cu
Ni
Slag Basicity
CaO + MgO
Si02 + A120
Metal Recovery, percent
Bundles (a

2243
425
121
27
41

3.13
.27
.18
.16
.12
.05


.79
89.1
Cleaned
) cans

2339
404
106
29
32

3.8?
.42
.21
.14
.06
.06


.63
85.5
Processed
auto
scrap (b)

2146
331
78
26
29

3.00
.15
.24
.11
.14
.12


.47
93.2
(a)  Approx. 6 X 6 X 12 inches.
(b)  Equal weight of +2-and -2- inch kiln processed scrap
     product.

Copper contents of the melted products were low, particularly

for the product from can scrap which was 0.06 percent.  This
copper level would be considered acceptable for virtually all

appl ications.
                            Z84

-------
Use of Ferrous Scrap as a Reductant

          A large portion of our domestic iron ore reserves

contain iron in the form of nonmagnetic minerals such as

hematite.   Being nonmagnetic, these ores do not lend them-

selves to magnetic separation normally used for concentrating

many low-grade ores.  Bureau engineers at the Twin Cities

Research Center have been developing a scrap iron-ore roast

process that converts nonmagnetic iron minerals to magnetite,

permitting subsequent concentration by magnetic separation.

During the process, a mixture of ore and scrap is processed

through a rotary kiln at 1000° C.  Results have shown that

thin-gage auto scrap, tin cans, borings, and turnings are

the most effective scrap feed.  Heavier ferrous scrap may

not completely oxidize in the kiln, although it can be col-

lected and used as high-quality melting stock for electric

furnace steelmaking.  Other secondary commodities which have

been effectively used in magnetizing roasts include appliance

and household scrap, and municipal  refuse.

          Results of tests on municipal refuse and auto scrap

are summarized below in table 7.

          TABLE 7- - Ferrous Scrap as Ore Reductant

                        Analysis of Ore Con-  Iron Recovery,
                      centrate, wt. percent	Percent
Scrap	      Fe        Cu
Municipal  Refuse            67.5      0.08         90.7

Auto (sheared, unburned)    67.3      0.02         91.2

Auto (ripped)               bk.k      0.03         93.6


                             285

-------
Copper and Tin Removal by a Leach and Roast Process
          Leaching of shredded ferrous can fractions in an
ammoniacal ammonium carbonate solution has shown that final
copper levels of 0.06 to 0.08 percent can be achieved.   Re-
sidual tin levels of O.O'* to 0.06 percent can be attained by
roasting the ferrous can scrap with chlorides in the presence
of an oxidizing agent, followed by a wash and second roast
under reducing conditions.
Utilization of Ferrous Urban Wastes
          Bureau-sponsored research is being conducted at the
University of Wisconsin to investigate the metallurgical
effects of contaminants such as copper, tin, and nickel in
ferrous metal reclaimed from urban refuse.  Physical and chem-
ical tests are being performed on ferrous castings produced
by standard foundry procedures to determine tolerance  levels
for the contaminating metals.
Basic Studies on Iron-Copper Alloys
          Bureau-sponsored research is also being conducted
at Pennsylvania State University.  The object    of these
studies is to obtain basic thermodynamic data on copper in
iron-copper alloys at elevated temperatures.  Such data will
aid in the development of effective processes for copper
removal from ferrous scrap.
Non-Cracking, Copper-Containing Steels
          Scaling characteristics of copper-containing steels
are being investigated at the Bureau's Albany Research Center
                            286

-------
to determine if special additions, such as silicon and alum-




inum, can reduce or prevent ingot cracking attributed to the




presence of copper.  If successful, such an approach could




permit wider use of copper-bearing scrap in stee Imak i ng.




                     NON FERROUS SCRAP




         Research  in the Bureau of Mines is particularly




oriented to instances where salvaged materials may comprise




a large percentage of the total supply of a commodity.  In




this instance the commodity is the nonferrous metal fraction




of refuse and the salvaged materials are aluminum, zinc,  cop-




per, lead, tin, and magnesium.  Many of these metals, parti-




cularly aluminum, are present as a result of disposal and




collection of metal containers.  The reclamation and reuse of




these materials is of primary concern to all of us interested




in meeting rapidly increasing metal production needs and




conserving the diminishing mineral resources.




         Part of the current research concerns the urgent




need for better methods to rapidly identify metals and alloys




in the nation's scrap yards.  Where it can be applied, segre-




gation is the most economical form of refining.  This would




be particularly desirable in retrieving aluminum containers




from municipal wastes.  The composition of aluminum cans is




known, and once segregated from other wastes, they are rapidly




reprocessed.




         Research  is being conducted to develop rapid and




accurate identification methods to minimize costly errors in




                            287

-------
sorting, thereby reducing the quantity of scrap being dis-

carded or processed inefficiently because of its uncertain

composition.  Rapid separation methods based on color reflec-

tance, spot testing with chemicals, electrical  conductivity,

X-ray, and other excitation methods are being explored.   In-

vestigation of methods of identifying aluminum alloys resulted

in the development of simplified and improved chemical spot

tests for the alloying elements:  copper, manganese, zinc, and

magnesium.  Procedures also include a test for differentiating

between the magnesium and magnesium-silicon alloys of aluminum

and between magnesium base alloys and aluminum base alloys.

         The materials required for making chemical spot tests

for copper, manganese, zinc, and magnesium were assembled in

kit form in a 4-inch by 6-inch carrying case as shown in

figure 6.  Electrographic sampling and pretreated papers are
FIGURE 6. - Chemical Spot-Test Kit for Identification of
                     Aluminum Alloy Scrap.

                            288

-------
used  in the tests.  A  few drops of electrolyte are applied  to




a piece of filter paper which has been  previously treated




with  the  indicator.  A sample is dissolved electrolytically




by placing the wetted  filter paper between the alloy  and




sampling  probe.  The alloy  is connected  to the positive side




of a  battery.  An adequate  sample is obtained, and  identifica-




tion is made  in  approximately  15  seconds.




          Research  involving pyrometa1lurgica1 techniques pre-




sently comprise the major part of our nonferrous metal refin-




ing investigations.  To date we have dealt only with  the non-




ferrous metal recovered by  the Bureau of Mines process for




recycling and recovering metal and mineral value from munici-




pal incinerator residues.   The aluminum  and other nonferrous




containers and packaging materials melt  during incineration.




This nonferrous fraction is separated from ferrous and non-




metallic material and  becomes a part of  a complex mixture of




metals and alloys of varying compositions.  The Bureau is




presently erecting a demonstration plant facility for the pro-




cessing of raw refuse.  In  this case aluminum cans and con-




tainers would be readily recoverable for immediate re-smelting




and re-use.




          Typical compositions of the nonferrous  metal col-




lected from incinerator residues  and remelted to form a homo-




geneous alloy are shown in table 8.   Metal yield by remelting




ranged from 80 to 90 percent using  a commercial grade alumin-




um smelting  flux.   Due to the high  amount of  zinc present,



                            289

-------
          TABLE 8. - Composition of Nonferrous Metal From



Metal
Al umi num
Zinc
Copper
Lead
Tin
1 ron
S i 1 i con



#1
69.5
23.0
1.3
4.2
0.4
0.7
0.2
1 ncinerator

1 nci nerator
#2
69.2
10.8
15.0
2.0
0.2
2.1
-
Residue


#3
80.0
14.2
1.7
1.8
-
1 .0
1.6
this type of mixture could not be recycled in large quantities




in the present secondary smelting operations.  It is therefore




necessary to up-grade the metal mixture by additional separa-




tions of major constituents.  Two techniques presently under




investigation are heavy media separation (sink-float) and




vacuum distillation.




                  Heavy Media Separation




          Samples of +4 mesh and -4+20 mesh of mixed non-




ferrous metals from processed incinerator residue were separa-




ted at the Tuscaloosa Metallurgy Research Laboratory at speci-




fic gravities of 2.75 and 2.95 using liquid tetrabromoethane.




The sink-float fractions were then returned to the College




Park Metallurgy Research Center where they were smelted to




produce metal ingots for analysis.  Weight percentages of




the sink and float products and analysis after smelting are




summarized in table 9.




          The results in table 9 show that excellent separa-




tions into aluminum-rich and copper-rich products were achie-




ved.  Metal recovered from smelted floats contained 96 to 98



                             290

-------
          TABLE 9. - Results of Heavy Liquid Separation of
f^ixed
Nonfer rous
Metals
From 1
RCI nera-
tor Res i due






We igh t ,
Product
2.75 sp
+4 mesh
+4 mesh
-4+20 f
-4+20 s
2.95 sp
+4 mesh
+4 mesh
-4+20 f
-4+20 s
percent
•g-
float
s i nk
loat
ink
•9-
float
s i nk
loat
i nk

52
47.
49.
50,

61.
38.
53.
46,

.2
.8
.6
.4

.5
.5
,4
,6
Al

96.
^
98,
u.

96
! ,
97.


,0
,4
.0
.3

.0
,7
,0
,86






Analys i s , percent
Zn


34

34


41

36

.5
.3
. 17
.3

.16
, 1
.25
.5
Cu


54.

49.


47,

49.

,57
.8
,16
,6

.33
,2
27
2
Pb

.2
2,7
. 1
3.6

.1
3.7
.2
10.0
Sn

.036
.35
.027
1 .06

.034
-34
.058
1.06
percent aluminum and metal from sinks was a copper-brass mix-




ture with small amounts of aluminum, lead, tin, and iron.




Sinks from 2.95 specific gravity separations have signifi-




cantly lower aluminum contents than sinks from the 2.75




specific gravity separations.  These results are highly en-




couraging in that separation into a high quality aluminum




product and a copper-rich product, Qualitatively approaching




the composition of radiator scrap, has been achieved with the




inexpensive technique of heavy liquid separation.  Tetrabro-




moethane was used in these initial tests, but as indicated by




previous experience, similar separations can be achieved with




heavy media  suspension, such as ferrosilicon in water.




                   Vacuum Pi st!1lat ion




          Research in vacuum distillation has been highly




successful  in refining  many kinds  of aluminum and zinc base






                            291

-------
scrap.   The Bureau spent several  years during the early 1960's

in developing low cost retort-distillation systems for treat-

ing up to 3500 pounds of scrap per retort charge.  Figure 7

shows the unit during operation.   Figure 8 shows the deposi-

tion of zinc in the condenser during a test with zinc die-

cast scrap.
FIGURE 7. - Retort-Distillation System During Refining
                Operation on Zinc Die-Cast Scrap.

          This type of unit was designed for operation at

850° and 50-micron pressure and would be suitable for re-

moving and recovering zinc and magnesium from nonferrous metal

refuse fraction.
                             292

-------
          Smelting and vacuum distillation  results are sum-

marized by presenting a  typical test of heavy and  light metal

fractions obtained by jigging.  Jigging produces similar

products to  those obtained by heavy  liquid  separation, except

for  the higher  percentage of aluminum  in the heavy metal

fraction.  The  light metal fraction was found to contain

approximately 88 percent metal lies and 12 percent nonmeta11ics.
FIGURE 8. - Zinc Deposition in Opened Condenser of Retort-
                          Di st i11 at ion System

Smelting with or without a flux for either fraction produced

a metal recovery of approximately 80 percent of the available

metallic in the sample.  Smelting temperature for the light

fraction was 750° C for the heavy fraction 900° C.  After


                            293

-------
smelting, metal from each fraction was vacuum distilled at




750" C for 120 minutes.  Analytical results are presented as




weight percent in table 10.




          TABLE 10. - Analysis of Nonferrous Fractions After




A 1 urn i n urn
Copper
1 ron
Nickel
Lead
Tin
Z i nc
Magnes ium
Manganese


Light
Smel ted
96+
0.30
0.66
-
0.05
0.03
0.63
0.59
0.35
Smel t i ng and

Metal Fraction
Di st i 1 1 at ion
98+
0.38
0.66
-
0.11
0.01
0.004
0.04
0.33
Vacuum

Heavy
Smelted
26.9
32.1
0.68
0.48
2.60
1.22
33.0
-
-
Di st i 1 lat ion

Metal Fraction
Di st i 1 lat ion
40.0
56.0
1 .06
0.71
1.30
1.76
0.20
-
-
Distillation condensates were remelted and analyzed.  Major




constituents in the light metal fraction was zinc and magnes-




ium.  The condensate from both the heavy metal  fraction and




light fraction analyzed better than 99 percent zinc.




          Although every research endeavor being carried out




by the Bureau on container scrap and solid waste reclamation




has not been covered in this paper, it should suffice to




point out that  a  serious  and energetic program  is being




undertaken.   It is also hoped that the Bureau of Mines Re-




search effort will help to identify the opportunities and




provide the data for solving some of our container reuse and




di sposal problems .
                            294

-------
     RECOVERY AND UTILIZATION OF ALUMINUM FROM SOLID WASTE
              R. F. Teslin, G. F. Bourcier, and K. H. Dale
                   Rcvriolds Metals Company
          The  author  of the phrase, "Solid Waste

can be likened to  an  Urban Ore," will probably

remain unknown,  bat the relevancv of that single

statement is becoming  more apparent every day.  For

those in industry  who  have undertaken the task of

providing a steady stream  of  raw materials to the

American economy,  this resource, if properly

handled, may someday be a  reliable (and renewable)

source of supply.

          This  paper  discusses  Reynolds Metals

Company's programs regarding  the recovery and

reutilization  of aluminum  from  solid waste.

          Reynolds Metals  has a history of recvcling

consumer products  dating back to 1957 when programs

were initiated to  recover  the ail-aluminum motor oil

can.  The inherent value of scrap aluminum reflected

in the open market scrap price  is 40 percent of the

composite selling  price of mill products compared to

only 23 percent  of the composite mill product selling

price foi scrau  steel,  another  commonly used metal.

It is this value that  provides  the obvious incentive

for reclamation.

          Reynolds interest in  reclamation of

aluminum and other valuable materials from municipal

refuse is directed towaids both the development of

this resource  as a new source of supp.lv and helping

                         :> 9 -A

-------
to solve the industry's "share," if such a statement




can be made, of the Nation's solid waste and litter




problems.  It is further believed that the value of




the scrap aluminum may provide some of the economic




incentives to process, for recycling, the entire




municipal refuse stream.  The ever increasing amount




of aluminum used in the consumer sector, and




eventually discarded, makes the American garbage can




an important (and increasing) source of metal that




is virtually expropriation proof.  Included in the




daily billion pounds of refuse generated in American




homes today are approximately 5 million pounds of




aluminum, as well as some 70 million pounds of steel,




2 million pounds of copper, 1/2 million pounds of



zinc, and lesser amounts of other metals.  The




aluminum currently lost in this refuse heap amounts




to about 20 percent of the total reduction capacity



of this country, and the ferrous fraction amounts to




about 10 percent of the country's production.




          In order to pursue the Companv's aluminum




recovery goals, Reynolds pioneered the reclamation




of all-aluminum beverage cans through a network of




can reclamation facilities that are open to the




general public and pay cash for aluminum cans and




other used aluminum household scrap  (such as foil




and TV dinner trays).




                         296

-------
          Realizing that some of the population would
be unable, or unwilling, to bring aluminum household
type scrap to reclamation centers, the Company is
now pursuing a homeowner separation program on a
pilot basis.  This program is designed to go where
the aluminum is and to determine what is necessary
to extract the valuable aluminum scrap from the
waste stream at the last place it is easily
identifiable, separable, and relatively simple to
handle.
          The third phase of the operation to
recover aluminum from the solid waste stream is
pointed at recovering the aluminum after it has been
converted into "urban ore" by householder discard,
followed by refuse collection and disposal operations.
Several research efforts are currently being
undertaken by Reynolds personnel.  It is planned
that these independent research projects complement
or supplement, but not duplicate, past or ongoing
research at government, university, and private
levels.
          Planning is also being undertaken relative
to what products can be produced from aluminum and
other valuable materials recovered from these various
approaches to resource recovery.  The amount of metal
recovered, the degree of contamination, and the
                        297

-------
potential markets for the recycled nio
-------
          In 1968, a Can Reclamation Center was




begun in Los Angeles  (Figure  1), with cans redeemed




for cash.  The cash pavment was  foand to be the




strongest incentive to turn in  cans and other  used




aluminum household scrap and  is  the current system




used by Reynolds.  The rate of payment is IOC  per




pound or $200 per ton, roughly equivalent to 1/2$




per all-aluminum beverage can.   Revnolds now has




Can Reclamation Centers in San Francisco, Los  Angeles,




Phoenix, Houston, Miami, Tampa,  Jacksonville,  Newark,




and the Bronx and Brooklyn, New  York.  In addition,




we have a Mobile Can Reclamation Center now in




operation in the Pacific Northwest.  This is a




complete reclamation center,  mounted on a semi-




trailer and is scheduled into various communities




on a regular basis.  A fleet  of  these mobile units



is now being constructed.




          At our centers, aluminum is received,




magnetically separated, paid  for, and shredded.  It




is then sent in carload lots  to  one of the Company's



smelting plants in Alabama or Virginia.




          Complementing the Reynolds permanent and




mobile can reclamation facilities, a number of the




Nation's largest brewers and  soft drink bottlers are




coooerating with our program  by providing locations




where aluminum cans may be redeemed for cash.  As



                        299

-------
                                                     c
                                                     G)
                                                     ra
                                                     a)
                                                    rH
                                                     CD
                                                     60
                                                     O


                                                     01
                                                     T3
                                                     r-l
                                                     O
                                                     01
                                                     Pi
                                                     w
                                                     I
300

-------
of this date, over 400 of these satellite collection




depots are now operating in over 20 states.




          In 1970, the Aluminum Can Reclamation




Program brought in over 4 million pounds of aluminum,




equivalent to about 80 million cans, and paid out




over $400,000 to individuals and to organized groups




such as the Boy Scouts.  The volume of metal




collected by this program is continuing to increase.




          In the month of March, 1971, Revnolds Can




Reclamation activities passed the one million pounds




per month milestone (equivalent to 20 million cans




per month) with our Los Angeles Center alone




collecting over 200,000 pounds of aluminum cans.  It




should also be pointed out that the Aluminum Can




Reclamation Program, as it is now constituted, is an




economically viable system.






          Householder Separation Programs






          In order to recover a larger percentage of



aluminum consumer scrap, while the research efforts



pointed at total recycling of municipal refuse are




in progress, an interim approach was decided on.




This approach deals with a homeowner separation




program in two selected geographic areas.  These




programs are being conducted in cooperation with two




private refuse management companies.  The purpose of



                        301

-------
the program is to determine if homeowners will, with




suitable incentives, separate and save the clean,




all-aluminum household type scrap they normally




generate.




          One of these locations, a City in Florida,




is ideally suited for such a homeowner separation




program.  The present method of refuse collection




utilizes appropriately identified plastic bags, which




are purchased by the homeowner from agents of the




refuse collection and disposal company for 40* each.




These agents are grocers, filling stations, and so




forth.  The price of these bags includes bag cost




and collection and disposal costs.  The homeowner




sets out his refuse on collection days and after



collection no garbage cans remain at the curb to




mar the beauty of the area.



          Reynolds is providing 10,000 plastic bags




to the refuse company, which, in turn, will give them




to two separate groups of 500 homeowners each.  One



group will receive one free refuse collection bag and




10 of the aluminum salvage bags; the other group will




be given two free refuse collection bags with 10 of




the aluminum salvage bags.




          Each week, for a period of 10 weeks, the




homeowners will set out a plastic bag containing the




past week's accumulation of aluminum cans and other



                        302

-------
clean household type aluminum "scrap.  Processing of




the scrap aluminum collected will be done at our



Miami Can Reclamation Center.  Later, if volumes




permit, the material will be shredded and sent



directly to one of our smelting plants.




          From this program we hope to get answers




concerning the future of this type of recycling




effort and the incentives necessary to sustain and




expand it.




          The other homeowner separation program,




in California, will involve a number of independent




refuse collectors working through their trade




association.  These collectors will be given a total




of 25,000 plastic bags for distribution to their




customers.  Tentatively, the plan is for the




homeowners to fill the bags with clean household type




scrap and be compensated by the collector for the



amount of aluminum turned in.  The aluminum collected



by the refuse companies will be periodically loaded




into packer trucks and transported to our San



Francisco Can Reclamation Center.




          Both of these programs will be underway in




the next few weeks.  Upon completion, we will analyze




the results of these pilot programs to determine




their practicality for the long-term.
                         303

-------
  Research Programs on the Separation of Aluminum
     and Other Non-Ferrous Metals from Refuse
          In this section some of the in-house

research programs now being conducted by Reynolds

are discussed.

          Reynolds has had a pyrolysis, or

destructive distillation capability, for the last

dozen years.  The current operation is located at

the Bellwood Smelting Plant and is designed to

recover aluminum from paper-mounted foil.  This

material is first shredded, then charged into a

furnace with a controlled temperature and

atmosphere.  As the material is processed in the

furnace, the paper and adhesives are carbonized in

a low oxygen environment and aluminum oxidation is

minimized.  The residue from this furnace is

discharged into a hammermill, where the carbon is

physically separated from the aluminum.  The bulk

of the carbon is removed by air classification and

any carbon residue left on the aluminum is burned

off in a kiln.  At this point, the aluminum

recovered is suitable for any of several reuse

options, depending on the current order requirements,

          Because of this experience background,

much of Reynolds in-house research on separation of


                         304

-------
aluminum from mixed refuse is based on the assumption




that thermal processes—incineration or pyrolysis




will be employed prior to aluminum separation.




          To this end, separation and evaluation




studies are being conducted on metal obtained from




the U. S. Bureau of Mines pilot incinerator ash




recovery system, located at the University of




Maryland, College Park, Maryland.     The Bureau of




Mines system magnetically separates the magnetic




ferrous materials from Washington, D. C. Sanitation




Department incinerator ash.  The non-magnetic ferrous




(some types of stainless steel) and non-ferrous




metals are concentrated in two screen sizes




(-1 1/4" + 20 mesh) and (-20 + 40 mesh).  Samples




of these two material sizes were obtained from the




Bureau of Mines for further separation work.   (This



as-received material was approximately 50 - 70




percent aluminum.)   This material was separated into




heavy and light fractions using dense media



techniques.  Of the (-1 1/4" + 20 mesh) material,




67 percent was lighter than 3.0 gm/cc, and 33




percent heavier  (aluminum density = 2.7 gm/cc).




For the (-20 + 40 mesh) material, 57 percent was




lighter than 3.0 gm/cc and 43 percent heavier.




          In both of these samples, small amounts




of magnetic ferrous material was found in the part



                        305

-------
that was heavier than 3.0 gm/cc.  In practice




magnetic separation would be used to remove this




iron.  Samples from both screen fractions, lighter




than 3.0 gm/cc were melted under a (NaCl 50%,




KC1 45%, Cryolite 5%) molten salt flux at 1500°F.




Recovery of metal from the (-1 1/4" + 20 mesh)




fraction was 74.7 percent, assaying 96 percent




aluminum, and recovery from the (-20 + 40 mesh)




material was 57 percent, assaying 97 percent




aluminum.  Combining these figures shows a net




recovery of 48 percent aluminum in the (-1 1/4" +




20 mesh) fraction, and 36 percent recovered aluminum




in the  (-20 + 40 mesh) fraction.  Bureau of Mines




personnel report that the larger size fraction




represents 75 percent and the smaller fraction 25




percent of the non-ferrous residue which totals



about 2.8 percent of the initial ash load.



Combining these figures shows a net aluminum




recovery of 45 percent of the non-ferrous portion




of the incinerator ash.  When the other elements,




alloyed with the aluminum, are included, the total




aluminum alloy metal uncovered increases to 46.7




percent of the non-ferrous portion.



          Another project being conducted in parallel




with the previous one is an investigation of




techniques to recover aluminum and other valuable




                        306

-------
materials from the char resulting from pyrolysis




of municipal refuse.  The current samples of char




under investigation are from Monsanto's "Landguard"




pilot plant in St. Louis.  The aluminum content of




municipal refuse in St. Louis is relatively low due




to an almost complete absence of aluminum beverage




cans in that area.  Therefore, Reynolds supplied




samples of household type aluminum scrap, to be




added to raw municipal refuse on a controlled basis,




in order to bring the aluminum up to percentages




anticipated in high aluminum can use areas




(~3 percent) and provide for a better yardstick to




measure metal loss and evaluate subsequent aluminum




recovery techniques.




          The pyrolysis operation was conducted at




a temperature of 1000  - 1500 F, based on exhaust




temperatures from the pyrolysis unit,  The char was



water quenched as supplied to Reynolds, with a water




content of 40 percent.



          Initial separation experiments, lust




completed, were conducted as follows:




     A.   Magnetic separation to remove iron




     B.   Wet screen to (+ and - 7 mesh) fractions




          1.  Ball mill the (+7 mesh) material




              to separate the carbon and glass
                        307

-------
     2.   Rod mill the (-7 mesh)  material




         to flatten the metal and separate




         the carbon and glass




     3.   Use dense media to separate the




         ball and rod mill outputs into




         fractions heavier and lighter




         than 3.0 gm/cc




     4.   Dry all material




     5.   Char analysis,  dry, is  based on




         combining similar materials from




         both dense media separations and




         is:




             Ferrous (magnetic)  - 38%




             Aluminum with a small




                amount of glass  - 3.5%



             Glass - 2.2%




             Other non-ferrous - 0.6%




             Balance of char, ash, fines,




                glass - 55.7%




C.  An independent lab analysis  of the char,




    ash, fines, and glass fraction shows it




    to be 13 percent carbon.  These figures




    are tentative, of course, and will be




    verified over a larger group of samples.




    However, these are given to provide




    approximate figures.




                   308

-------
          Reynolds is also considering an




investigation into the use of an applied field,




such as a magnetic field, to be used in conjunction




with ferromagnetic particles such as ferrosilicon,




magnetite, and so forth, as a variable density dense




media separation system.




          This research work, in general, has been




conducted under the following qualitative guidelines:




     1.  Much of the past work conducted on




         refuse recycling has concerned itself




         with reuse of large bulk items, such




         as paper or in the manufacture of




         compost.  This approach can




         alleviate a solid waste disposal




         problem, but can result in the




         anomaly of generating a marginally




         saleable end product.




     2.  The recovery of less bulky, but




         potentially more valuable solid




         waste items, such as ferrous and




         non-ferrous metals has been




         neglected.




     3.  The reclamation of minor weight




         percentage fractions of refuse must




         be preceded by salvage, conversion,




         or destruction of the major bulk




                        309

-------
         items in refuse.




     4.  The removal of the major bulk items




         in refuse, by whatever means, should




         be compatible with the eventual




         recovery of the minor volume and/or




         weight constituents having a high




         potential salvage value.




     5.  Since most metals in municipal refuse




         are in an uncombined state, it is




         best to utilize as many of the




         physical characteristics of the




         individual metals as possible in




         separation and to conduct recovery




         operation in such a manner as to



         preclude oxidation or alloying.




          On the basis of these guidelines and work




done so far, a flow chart of a projected pilot scale



total recycling processing system has been developed.




This approach, it is believed, can maximize the




recovery of theindividual, valuable, low volume




constituents while providing substantial volume and




weight reduction of the major constituents.  The




flow chart shown in (Figure 2) outlines the basic




system requirements.
                        310

-------
           FIGURE  2 SOLID WASTE RECYCLING  PILOT  PLANT
 MIXED    MUNICIPAL
       REFUSE
                                    SHREDDER
0 CHAR  COOLER
       ROD MILL
^ PYROLYSIS  UNIT
                              ®
              CONCENTRATE
                                       1
                              (T)    MAGNETIC
                                   SEPARATOR
                                                      NON MAGNETICS
                                                            ©
                                                               4 MESH  SCREEN
         I
(6AJ    MAGNETIC
       SEPARATOR
  y4 MESH SCREEN
                            -4+20 ME5H
                                                          CHAR,GLASS,
                                                          NON FERROUS
                                          ©
                                             20 MESH SCREEN
                              ROD  MILL
                       ©
                                 I
                                          20 MESH
                                          CHAR, GLASS,
                                          NON FERROUS
                                                               AIR CLASS IF IER
                          3S MESH  SCREEN
                                         |CH»
                                                                CHAR  STORASC
ft)  DENSE  MEDIA

     SEPARATION
   1            T
            (ty HIGH INTENSITY

            MAGNETIC  SEPARATOR
ALUMINUM   OTHER NON FERROUS
             TO COPPER, ZINC
             ELECTROREFINING
              CLEAR
              GLASS
COLORED   TO  CHAR
 GLASS    PROCESSING
                                     311

-------
      Product Potential of Recycled Aluminum






          In parallel with work on one or more




techniques to separate the valuable materials from




raw municipal refuse, incinerator ash, or pyrolysis




char, work is ongoing to utilize the recovered




materials in the new products.  Obviously, there is




a tradeoff involved here.  There is no technical




reason to preclude recovery of 99 percent pure or




99.9 percent pure aluminum, for example.  Presumably,




such refinement could be carried out to the extent




that the recovered metal would be virtually unlimited




it its use wherever aluminum can be normally employed.




At each decreasing level of purity, a smaller




spectrum of products is possible, but the overall




recovery cost is lower.  Hence, at Reynolds, new




product investigations are being conducted as a




function of the purity of the recovered metal so that




cost/benefit determinations can be made for the




recovered product.




          There are many conventional uses for many




of the materials recovered from municipal refuse.




These range from glass cullet being converted into




children's marbles, spun glass insulation, and the




newly developed "Glasphalt" paving material, up to




precious metals recovered from incinerator ash.



                         312

-------
For example, selenium is a metal that is sometimes




recovered from the ashes of coal burning power




stations, since the selenium bearing ores are




sometimes mixed in veins of coal.  Selenium is used




in applications from semi-conductors to dandruff




remover shampoo.




          There are many current, rather conventional




uses for aluminum recovered from our can recycling




programs.  Foremost among these is the remelting of




shredded cans received from the public through our




can reclamation centers.  This remelted metal is




cast directly into new ingots which can then be




rolled into new can making material.  The energy




required to remelt aluminum scrap is so low relative




to some of the other commonly used packaging




materials, that often after two or three recyclings




of an aluminum can, the cumulative energy content of




aluminum cans becomes the lowest of major can




making materials, irrespective of their recyclability.



          In addition to new cans, products such as




highway culverts, residential siding,  industrial



siding and roofdeck, gutters and downspouts, lawn




furniture, and countless other products can be made




directly from recycling aluminum cans.  In general,




the aluminum cans and used household scrap brought




back through the can reclamation program can be used



                        313

-------
wherever it is needed in our product mix.  Because




of the relatively high manganese content in the




3004 alloy can body stock, the ideal use for this




recovered material is back into can making.




          While our experience with aluminum




recycled from municipal refuse is limited at this




time, we know what aluminum alloys go into the




various products that are usually found in the




refuse heap.  Products that potentially can be made




from such recovered aluminum are many if not all of




the products that can be made from recycled aluminum




cans.  We also feel that aluminum for automobile




radiators, aluminum engines, pistons, and so forth,




could be produced, with some addition of other




alloying elements.  Products such as steel deoxidizers,




explosive intensifiers, thermite additives, plastic




fillers, and so forth, could be produced with



aluminum recovered from municipal refuse.  The list




could go on indefinitely with verv few products that




could not be made from this aluminum.




          There may also be new, unconventional uses




for the metallic components, as well as some of the




other materials recoverable from municipal refuse.




          For example, we may be able to cast




recovered aluminum into a billet and extrude it into




structural members for housing construction.  Iron,




                        314

-------
magnesium, silicon, zinc and copper could well be




standard "contaminants" in aluminum recovered from




refuse and would add strength to the final product.




In cold climates, today's aluminum joist conducts




the cold from an exterior wall to an interior wall




and causes condensation at that point.  The affected




surfaces of these extrusions might even be coated




with other reclaimed material such as pulverized




glass, using recovered thermoplastics to bond the




glass to the aluminum and give a thermal break at




these critical surfaces.






                      Summary






          The purpose of this paper has been to




present a brief progress report on Reynolds Metals



Company's activities on reclaiming aluminum from




solid waste and developing uses for this material.




          The Company's Aluminum Can Reclamation




Program is now reclaiming over one million pounds



per month of aluminum cans and other used aluminum




consumer products.  This scrap material is ideally




suited for making new aluminum cans and can readily



be used within the Company's product mix.




          Pilot scale householder separation programs




for aluminum will be underway shortly to explore the




feasibility of this approach as a means of



                        315

-------
supplementing the ongoing reclamation program.

          Preliminary results from laboratory scale

studies have developed processes by which relatively

pure aluminum can be extracted from incinerator ash

and pyrolysis char.  A new Reynolds Product

Development Division program now underway indicates

that there may be a broad spectrum of new aluminum-

based products that can be made from alloy

combinations obtainable from municipal refuse.

          Based upon the laboratory work to date,

flow charts have been developed for a pilot-scale

complete processing system for refuse.

          Reynolds Metals Company is committed to

the concept of recycling as an approach that will

open up new sources of material supply and

simultaneously provide long-term solutions to the

Nation's solid waste problems.  The Company's multi-

front approach to this challenging problem area will

continue and expand in the years ahead.



                    REFERENCES

     (1) Spendlove, M. J., Sullivan, P. M.,
         and Stanczyk, M. H., "Solid Waste
         Report", U. S. Department of Interior -
         Bureau of Mines, undated report.
                         316

-------
                            AUTHOR INDEX

                                                               Page No.

ABRAHAMS, J. H., Jr.                                              244
    Manager, Environmental Pollution Control Programs
    Glass Container Manufacturers Institute, Inc.
    330 Madison Avenue
    New York, New York 10017

ALEXANDER,  Judd H.                                              135
    Vice President, Corporate Environmental Affairs
    American Can Company
    American Lane
    Greenwich, Connecticut 06830

BOURCIER, G. F.                                                  295
    Reynolds Metals Company
    Richmond, Virginia 23218

BURGESS, K. L.                                                    94
    Plastics Department
    The Dow Chemical Company
    2040 Dow Center
    Midland, Michigan 48640

CALDWELL, H. S., Jr.                                              271
    College P.ark Metallurgy Research Center
    U. S. Bureau of Mines
    College Park, Maryland 20740

CHENEY, Richard L.                                                171
    President, Glass Container Manufacturers Institute, Inc.
    330 Madison Avenue
    New York, New York 10017

CONNOLLY, Hugh H.                                                 1
    Deputy Commissioner
    Office of Solid Waste Management  Programs
    Environmental Protection Agency
    Rockville,  Maryland  20750

DALE, K. H.                                                       295
    Reynolds Metals Company
    Richmond, Virginia 23218

DAY,  Delbert E.                                                    185
    University  of Missouri—Rolla
    Rolla, Missouri 65401
                                   317

-------
                             AUTHOR INDEX
                               (Continued)
                                                                  Page No.
EMICH, Karl H.                                                      109
    Manager Technical Services
    U. S. Industrial Chemicals Company
    Polytrip Systems
    Tuscola, Illinois 61953

HULBERT, Samuel F.                                                210
    Associate Dean for Engineering Research and
      Interdisciplinary Programs
    Clemson University
    Clemson, South Carolina 29631

LESHER, R. L.                                                      155
    President,  National Center for Resource Recovery, Inc.
    1625 I Street, N.W.
    Washington, D.C. 20006

MAKAR, H. V.                                                       271
    Supervisory Metallurgist
    College Park Metallurgy Research Center
    U. S. Bureau of Mines
    College Park, Maryland 20740

MALISCH, Ward R.                                                  185
    University of Missouri—Rolla
    Rolla, Missouri 65401

McMYLER, Safford W.                                                69
    Vice President — Manufacturing
    Riverside Paper Company
    800 S. La we Street
    Appleton, Wisconsin  54911

MIGHDOLL, M.  J.                                                    16
    Executive Vice President
    National Association  of Secondary Material Industries Inc.
    330 Madison Avenue
    New York, New York  10017

MILGRAM, Jack                                                      69
    Arthur D. Little, Inc.
    15 Acorn  Park
    Cambridge, Massachusetts 02140
                                    318

-------
                             AUTHOR INDEX
                               (Continued)
                                                                 Page No.
MURTHA, Joseph M.                                                 30
     President
     Sandgren, Murtha, Lubliner Inc.
     866 Third Avenue
     New York, New York  10022

RYDER, R. J.                                                       244
     Director of Research and Development
     Brockway Glass Company Inc.
     Brockway, Pennsylvania 15824

STORY, William S.                                                  263
     Executive  Vice President
     Institute of Scrap Iron and Steel, Inc.
     1729 H Street, N.W.
     Washington, D.C. 20006

TESTIN, R. F.                                                       295
     Director, Environmental Planning
     Reynolds Metals Company
     Richmond, Virginia 23218

VANASSE,  Norman A                                                49
     Manager of Corporate Packaging
     General Foods Corporation
     250 North Street
     White Plains,  New York 10602

WILLIAMS, Philip                                                   231
     Marketing Manager
     Glass Compsite Pack Operation
     Glass Container Division
     Owens-Illinois Inc
     333 East Front  Street
     Perrysburg, Ohio 43551
                                   319

-------

-------
                            LIST OF ATTENDEES
John H. Abrahams,  Jr.
Brockway Glass Co. Inc.
Brockway, Pennsylvania

N. P. Adriano
S. C. Johnson & Son, Inc.
1525 Howe Street
Racine, Wisconsin 53403

Judd H. Alexander
American Can Company
American Lane
Greenwich, Connecticut  06830

Robert M.  Alverson
New Holland Division
  Sperry Rand Corporation
New Holland,  Pennsylvania  17557

Carl A. Arenander
Malcolm Pirme, Inc.
18 Park PI. , P. O.  Box 36
Paramus, New Jersey 07652

Don Arnold
Chesebrough-Pond's Inc.
485 Lexington Avenue
New York, New York  10017

C, J. Arnsbarger
Anchor Hocking Corporation
109 N. Broad Street
Lancaster, Ohio  43130

Robert S.  Arvans
Union Carbide Corporation
One Cory Road
Mornstown, New  Jersey 07960

William H. Austin & Associates
186 South Main Street
Cheshire, Connecticut 06410

Thomas M.  Bacon
General Services Administration
FSS-FMSX
Washington,  D. C.  20406
Marilyn Barnes
Secretary
Battelle-Columbus

Ernest Barth
W.  Va.  Unv.
Box 20, 505 Burroughs Street
Morgantown, West Virginia  26505

Ernest A. Bortis
Battelle-Columbus

Donald Berman
Waste Systems Management-
 Allegheny County
404 Allegheny Bldg. -429 Forbes Avenue
Pittsburgh,  Pennsylvania  15219

Glen Bishop
Wisconsin-Dept,  of Natural Resources
1115 Rutledge Street
Madison,  Wisconsin  53706

P.  T. Bishop
S.  C.  Johnson &c Son, Inc.
1525 Howe Street
Racine, Wisconsin  53403

Jane Black
Secretary
Battelle-Columbus

Robert N. Black
URS Research Co.
155 Bovet Road
San Mateo, California

Kenneth A. Blaine
Chase Bag Company
Mill &  Cleveland Streets
Chagrin Falls,  Ohio  44022

James  R.  Bonnington
Chrysler Corporation
P. O. Box 2866
Detroit, Michigan 48231
                                      321

-------
A, "W".  Breidenbach
Division of Research & Development
Solid Waste Mgt. Office
Environmental Protection Agency
Rockville,  Maryland

W.  Keith Buechel
Weyerhaeuser Co,
Tacoma, Washington  98401

Dr.  K.  L.  Burgess
The  Dow Chemical Company
2040 Dow Center
Midland, Michigan  48640

James J, Burke
Drexel University
32nd & Chestnut
Philadelphia,  Pennsylvania  19104

M.  W. Burlis
Sherwood Medical Industries Inc.
183 1 Olive Street
St.  Louis,  Mis souri  63103

H, S. Caldwell
U. S. Bureau of Mines
College Park, Maryland

James V. Calhoun
Anchor  Hocking Corporation
109 N. Broad Street
Lancaster, Ohio  43130

George  Carlson
T, J. Lipton, Inc.
800 Sylvan Ave.
Englewood Cliffs, New Jersey 07632

C. W.  Castle
The  Procter  & Gamble Company
Spring Grove and June Streets
Cincinnati, Ohio  45217
Richard L, Cheney
Glass Container Manufacturers Inst.
330 Madison Avenue
New York, New York  10017

Michael J. Chun
Univ. of Hawaii
1890 E-W Rd. , Moore 402?
Honolulu,  Hawaii  96822

J. A. Ciszewski
Jos. Schlitz Brewing Company
235 West Galena Street
Milwaukee,  Wisconsin  53 21 2

Robert T. Clark
International Paper Co.
220 E. 42nd Street
New York, New York  10017

Clarence A. demons
Environmental Protection Agency
5555 Ridge Avenue
Cincinnati, Ohio 45213

Dr. R. Clendinmng
Union Carbide  Corporation
River Road
Bound Brook,  New Jersey  08805

Anthony R. Colella
Syracus University Research
  Corporation
1075 Comstock Avenue
Syracuse, New York  13210

Hugh H. Connolly
Solid Waste Management Office,  EPA
5600 Fishers Lane
Rockville,  Maryland  20852

Bill Coppins
Battelie-Columbus
Grant W.  Cheney
The Dow Chemical Company
2040 Dow Center
Midland, Michigan 48640
James M.  Costello
Monsanto
800 N. Lindburgh Blvd.
St.  Louis,  Mis souri  63166
                                     322

-------
Dr.  John P.  Cummings
Owens Illinois
1700 N.  Westwood
Toledo,  Ohio 43607

George Dankocsik
Saint-Glair Koppers  Co.
Frankfurt Rd.
Pittsburgh, Pennsylvania  15061

Robert G. Deitrich
Department of Public Works  ~
  City  of Baltimore
600 Municipal Office Building
Baltimore,  Maryland 21202

C. M.  Demse, Jr.
Bethlehem Steel Corporation
701 E. Third Street
Bethlehem, Pennsylvania  18016

Victor A. Denslow
Amoco Chemicals Corp.
130 E. Randolph
Chicago,  Illinois  60601

Ernest H. Duval
The  Gillette  Company,
Toiletries Division
Gillette Park
Boston,  Massachusetts  02106

Mr.  C. Soutt^r Edgar
International Paper Company
220 East 42nd Street
New York, New York 10017

E. Burley Edwards
Techs  Inc.
504 Third Ave. W.
Warren,  Pennsylvania 16365

M. D.  Eisele
Kaiser Aluminum  & Chemical Corp.
300 Lakeside Drive
Oakland,  California  94604
Dr. Michael J.  Eltel
Clemson University
Clemson, South Carolina  29631

Karl H. Emich
U. S. Industrial Chem,  Co.
101 S. Carico Street
Tuscola. Illinois  61953
Paul J. Emrick
Brockway Glass Company,  Inc.
McCullough Avenue
Brockway, Pennsylvania 15824

Richard Engdahl
BCL

Michael M.  Epstein
BCL

C. C.  Fain
Clemson University
Olin Hall
Clemson. South Carolina 29631

R. L  Feddersen
Hercules Inc.
900 Market Street
Wilmington,  Delaware   19803

Bruce  A.  Fletcher
V/est Virginia University
2876 University Avenue
Morgantown, West Virginia

William L  Fox
American Can Company
433 N. Northwest  Hwy
Barnngton,  Illinois 60010

Geoffrey Frohnsdorff
The  Gillette Company Research
 Institute
1413 Research Blvd.
K.ockville, Maryland  20850
                                      323

-------
William Fulkerson
ORNL-NSF Environmental Program
Oak Ridge  National Laboratory
P. O.  Box X
Oak Ridge,  Tennessee  37830

FrankB. Glanotti, III
Allen & Hoshall
2430 Poplar
Memphis,  Tenneessee  38112

Dr. Hugh W. Gray
E. I.  du Pont de Nemours & Co.
1007 Market Street
Wilmington,  Delaware  19898

Philip J. Griffin
Corning Packaging Company
Riverside
Corning, New York  14830

Paul J. Gripshover
Battelle Memorial Institute
505 King Avenue
Columbus,  Ohio  43201

Robert E.  Grisemer
Continental Can Company, Inc.
150 So. Wacker Drive
Chicago, Illinois  60606

Morgan W.  Guenther
United States Brewers Assn. Inc.
1750 K Street,  N. W.
Washington,  D. C.  20006

Donald Haase
Mobil  Chemical Company
100 North Street
Canandaigua,  New York  14424

Dr. D. Joseph Hagerty
University  of Louisville
Belknap Campus
Louisville,  Kentucky 40208

John Hallowell
Battelle-C olumbu s
John P. Hansen
Ohio Wesleyan University
S. Sandusky Street
Delaware,  Ohio 43015

William M. Harrington, Jr.
Whitman,  Requardt and Associates
1304 St. Paul Street
Baltimore, Maryland  21202

H. M.  Hatmaker
Mead Packaging
1040 W. Marietta  Street NW
Atlanta, Georgia  30318

Walter Hedden
Battelle-Columbus

N. F. Henage
Diamond National  Corp.
3091 W. Galbraith Rd.
Cincinnati, Ohio 45239

A J. Herbet
Olinkraft Inc.
P. O.  Box 488
West Monroe,  Louisiana  71291

L. L.  Hinshaw
Battelle-Columbus

William J. Hogan
Stapling Machines Co.
21 Pine Street
Ilockaway, New Jersey  07866

Frank  L,  Holland
The Coca  Cola Export Corp.
Atlanta, Georgia  30301

George J.  Howick
Equity Research Associates,  Inc.
52 Wall Street
New York, New York  10005

Carroll T. Hughes,  Jr.
Waste  Combustion Corporation
P. O.  Box 6295
Richmond, Virginia 23230
                                      324

-------
Dr.  Samuel F. Hulbert
Clemson University
Clemson, South Carolina

David L. Hull
Ohio Wesleyan University
Delaware,  Ohio  43015

Mr,  Joseph W.  Hunt
Northwest  Georgia Regional Health
  Advisory Council, Inc.
1503 Turner McCall Blvd.
Rome, Georgia 30161

(Miss) Ruth Hupprich
Colgate-Palrnolive Company
300  Park Avenue
New York, New York  10022

Robert C.  Hurbanis
North American Van Lines
World Headquarters
Ft.  Wayne, Indiana 46805

David N. Immendorf,  P.  E.
Gilbert Associates Inc.
525  Lancaster Avenue
Reading, Pennsylvania 19603

Wafik H. Iskander
W. Va, University
W. Va. University —
Engineering Building
Morgantown, West Virginia 26506

Rose Jackson
Battelle-Columbus
T. Z.  Jenkins
Owens-Illinois
Toledo, Ohio  43601

James W.Jensen
U. S.  Bureau of Mines
P. O.  Box 280
Rolla,  Missouri  65401

Jean Johnson
Battelle -Columbus
Herb Johnston
Battelle-Columbus

Richard J. Karas
American Can Co.
433 N. Northwest Hwy.
Bar ring ton, Illinois  60010

Cameron Keim
Gerber Prod.  Co.
Fremont,  Michigan 49412

John R, Kettle
Adolph Coors Company
1280 W. 47th Avenue
Denver, Colorado  80211

Emory Kincaid
Aladdin Synergetics Inc.
703 Murfreesboro Road
Nashville,  Tennessee 37210

E.  D.  Kttzke
S. C.  Johnson & Son,  Inc.
1525 Howe Street
Racine, Wisconsin  53403

Carol  E. Knapp (Miss)
Environmental Science &
  Technology Magazine
1155 16th Street, N. W.
Washington,  D. C.  20036

R.  C.  Koehn
General Mills } Inc. ,
James Ford Bell Technical Center
9000 Plymouth Avenue North
Minneapolis,  Minnesota   55427

Marcos S.  Kostolich
Gulf Environmental Systems Company
P. O.  Box 185
Chagrin. Falls, Ohio  44022

Kwoh H, Hu
U. S. Army Natick Laboratories
Natick, Massachusetts 01760
                                     325

-------
Donald Kyser
Minn. Pollution Control Agency
717 Delaware Street S. E.
Minneapolis,  Minnesota  55440

David P.  LaFave
Mead Packaging
1040 W.  Marietta
Atlanta,  Georgia  30302

Clyde Lamar
Excello Corp.
Detroit,  Michigan  48232

Rauno A.  Lampj  (Dr. )
U. S. Army Natick Laboratories
Kansas Street
Natick,  Massachusetts  01760

Edward P. Larizza
Pepsi-Cola Company
Anderson Hill Road
Building  6/Floor 1
Purchase, New York  10577

Ronald E.  Layne
Reynolds  Metals  Company
Grottoes, Virginia 24441

Louis W.  Lefke
Solid  Waste Management Office,  EPA
55^5 Ridge Avenue
Cincinnati, Ohio  45213

Dr. Bichard J. Lesher
National  Center for Resource
  Recovery, Inc.
1211 Connecticut Avenue - Suite 800
Washington, D. C. 20036

John H. Lindholm
Battelie-Columbus

Stephen A. Lingle
Office of Solid Waste Programs
P. O. Box 597
Cincinnati, Ohio  45201
Aileen Lubin
WTTG-TV Metromedia - Chanel 5
5151 Wisconsin Avenue N.W.
Washington, D.  C.  20016

C. J. Lyons
Battelle Columbus Laboratories
505 King Avenue
Columbus, Ohio  43201

Bruce  E.  MacNab
Jeffrey Gallon Inc.
100 East Broad Street
Columbus, Ohio  43215

Mr.  H. V. Makar
U  S. Bureau of Mines
College Park, Maryland

Walter R.  Malby
Aluminum Co. of America
1501 Alcoa Bldg
Pittsburgh, Pennsylvania  15219

Dr   Ward R. Malisch
University of Missouri — Rolla
Civil Engr. Bldg.
Rolla,  Missouri  65401

Duane  W. Marshall
Nat'l Council for Air & Stream
 Improvement
Western Michigan University
Kalamazoo, Michigan 49001

Chris Martelli
Trash, Inc.
Monterey, California

Lee  Martelli
Trash, Inc.
Monterey, California

Karl D. Matthews
Reading Company
12th & Market Streets
Philadelphia, Pennsylvania  19107
                                      326

-------
Roger May
O. S. U. / Franklin Inst.
Colunibus-Philadelphia

Tim McGee
Pa.  Department of environmental
  Resources
2102 Princeton Avenue
Camp Hill, Pennsylvania  17011

Saltord W. MeM-yler
Riverside  Paper Corp.
800 S. Lawe Street
Apple ton,  Wisconsin  549 11

Dr.  John G.  Meitner
Consultant, Jet Propulsion Laboratory
120 East Creek Drive
Menlo Park, California 94025

Roger L.  Merrill
Battelle's  Columbus Laboratories
505 King Avenue
Columbus, Ohio 43201

M.  J.  Mighdoll
National Association of Secondary-
  Material Industries, Inc.
330 Madison Avenue
New York, New York  10017

J. G. Miles
Procter k  GambJe Company
6300 Center Hill Road
Cincinnati, Ohio  45224

Dr. Jack Milgrom
Arthur D.  Little, Inc.
1  5 Acorn Park
Cambridge, Massachusetts  02140

Miss Sheila Minnitt
Glass Container  Council of Canada
67 Yonge St. , Ste. 501
Toronto 215 Ontario,  Canada

J. A. Minns
Owens-Illinois
Toledo, Ohio 43601
Mrs. Rodger MitcheJl
League of Women Voters of Ohio

HarJan L  Moore
City oi Indpls.
2422 City-County Bldg.
Indianapolis, Indiana

Reuben T  Morgan
Standards fk  Quality Control,
Federal Supply Service, GSA
CrystdJ Mall Bldg 4
Washington,  D.  C.  2040o

Dr.  D. L.  Morrison
Battelle Columbus Laboratories
505 King Avenue
Columbus, Ohio  43201

Joseph M.  Murtha
Sandgren &  Murtha, Inc.
86b  Third Avenue
New York, New York  10022

"W.  E.  Nelson
Career Research Foundation
Tuskcgee Institute
Alabama  36088

Willard L. Newman
Genera]  Electric Company
Bldg   69 ~ Room 151, 1 River RoAd
Schnectady, New York   12305

Lou Nowacki
Battelle- Columbus

Ralph Oakley
Lewis-Howe
3 19 S.  4th Street
St.  Louis,  Missouri  63102

Anthony O'Donohue
City of Toronto
100 Queen St. W. , City  Hall
Toronto, Ontario,  Canada

Donald Q. O'Brien
Warner-Lambert Company
201 Tabor Road
Morrib Flams, New Jersey  07950
                                      327

-------
James B. Ogden
US Army Material Command
Installations & Services Agency
  AMCIS-RI-IC
Rock Island, Illinois  61301

Edward J.  Ostrowski
National Steel Corporation
Research Center
Weirton, West Virginia 26062

W. A.  Patterson
Converted  Plastics Group,
  W.  R.  Grace &c Company
P. O.  Box 464
Duncan,  South Carolina 29334

R. O.  Peterson
S. C. Johnson & Son, Inc.
1525 Howe Street
Racine,  Wisconsin 53403

William  H.  Pfeifer
Battelle  Memorial Institute
505 King Avenue
Columbus, Ohio  43201

Harold A.  Pilar
W, Va. University
Engineering Building
Morgantown,  West Virginia  26506

Mort Present
Sanitas Services of Indiana, Inc.
3200 W.  Bertha Street
Indianapolis,  Indiana 46222

Bill  Pope
Battelle-Columbus

Thomas  G.  Prioleau, Jr.
Lever  Brothers Company
390 Park Avenue
New  York, New York  10022

J. B. Rasmus sen
S. C. Johnson & Son, Inc.
1525 Howe Street
Racine,  Wisconsin 53403
George S. Rennie
Continental Can of Canada
475 Commissioners Street
Toronto, Ontario, Canada

Richard Reynolds
CIBA-GEIGY Corporation
Ardsley, New York 10502

Marvin T.  Rhodes
West Virginia University
1 10 Ellen Lane
Morgantown, West  Virginia  26505

Arthur H. Richardson
E. S. &A, Robinson  (Canada)  Ltd
69 Laird Drive
Toronto 17, Canada

Linda Ross
Battelle-Columbus

R. J. Ryder
Brockway Glass Company, Inc.
Brockway, Pennsylvania 1 5824

George F.  Sachsel
Battelle Columbus Laboratories
505 King Avenue
Columbus, Ohio  43201

Julian Scheer
National  Center for  Resource
 Recovery, Inc.
1211 Conn Avenue,  N. W.
Washington, D.  C.   20036

S.  A. Schilling
Battelle-Columbus

Chas. W  Schneiderhan
Mobil Oil Corp.
150 E. 42nd Street
New York, New York  10017

Frank J. Sellinger
Anheuser-Busch, Inc.
721 Pestalozzi Street
St.  Louis,  Missouri 63118
                                      328

-------
S. R. Shrivastava
W.  C. Larsen,  P.E.
Consulting Engineers
44 Saginaw Drive
Rochester, New York  14623

Lawrence H. Skromme
Sperry Rand
New Holland,  Pennsylvania

George M. Smart
Central States Can Co.
700 16th Street, S.E.
Massillon, Ohio 44646

H. C.  Bowen Smith
Goldman, Sachs &  Co.
55 Broad Street
New York, New York  10004

Joe Smith
Corco Inc.
6950 Worthington-Galena Rd.
Columbus, Ohio  43085

G. Ray Smiths on, Jr.
Battelle-Columbus

Dr. Curtis M.  Snow
Monsanto Enviro-Chem System, Inc.
800 N. Lindbergh Boulevard
St.  Louis,  Missouri  63166

M.  Jack Snyder
Battelle  Columbus  Laboratories

John L.  Splendore
Metcalf &i Eddy  Engineers, Inc.
Statler Office  Building
Boston,  Massachusetts  02116

R. Lee Steiner
Drexel University
32nd & Chestnut Street
Philadelphia,  Pennsylvania  19104

George F.  Stewart
University of California
Food  Science &  Technology
Davis, California  95616
H. Stewart
Cumberland Engineering Co.
P. O.  Box 6065
Providence, Rhode Island 02904

P. B   Stickney
Battelle-Columbus

E. Joseph Stillwell
Battelle -Columbus

William S. Story
Institute of Scrap Iron & Steel
1729 H. Street N. W.
Washington, D.  C.  20006

Dick Stitt
National Solid Waste Mgt. Assoc.
1145 19th Street N. W.
Washington, D.  C.  20036

Mrs.  John B.  Swern
League of Women  Voters of Ohio
3440 Olentangy River Road
Columbus, Ohio

Masaru Tanaka
Dept. of Civil Eng., Wayne State U.
667 Merrick
Detroit, Michigan  48202

Ann Tasseff
Environment Reporter
1231 25th St. N. W.
Washington, D.  C.  20007

Bert Taylor
DairyPak,
5971 Olentangy River Road
Worthington, Ohio  43085

Dr. Robert F.  Testm
Reynolds Metals Company
6601 West Broad Street
Richmond, Virginia 23261

Narayan Thadam
Westinghouse  Electric Corporation
7670 Old Springhouse Road
McLean, Virginia  22101
                                     329

-------
David L.  Thar
Container Corp.  of America
1204 E   12th Street
Wilmington,  Delaware  I9&02

L. M.  Tupman
General  Electric Company
Appliance Park,  Pildg. 35, Room 133
Louisville, Kentuck/  40225

Norman  A. Vanasse
General  Foods Corporation
250 North Street
White Plains, New York  10625

Ted Venti
Amway Corporation
7575 E.  Fulton Road
Ada, Michigan  49301

Roberto  Tong Villaneuva
Westresco, Inc.
809 Collins Avenue
Marysville, Ohio  43030

Gordon Von Doersteri
Boise Cascade Composite Can Division
13300 Interstate Drive
Hazelwoocl, Missouri b3042
William K  Wilson
National Bureau of Standards
Washington, D. C.  20234

David H.  Wiitsee
Atlanta Region Metropolitan
  Planning Commission
900 Glenn Building
Atlanta,  Georgia  30303

Mr  John C. Wirth, Jr
Avon Products, Inc.
30 Rockefeller Plaza
New York,  New York  10020

Charles M  Woodcock
General Foods Corp.
275 Cliff Street
Battle  Creek, Michigan 49016

Joe W.  Ray
Battelle- Columbus

Duane  Yother s
Battelle-Columbus
James A. Waters
Vistron/Standard Oil (Ohio1)
1608 Midland Bldg
Cleveland, Ohio  44145

Mr.  Gerry R.  Wehrmann
The Coca-Cola Export Corporation
Coral Gables,  Florida

Jarnes A.Weissburg
Advisor-Group for Recycling in Pa,
4835 Girard  Road
Pittsburgh, Pennsylvania  15227

Philip Williams
Owens-Illinois, Inc
P. O,  Box 1035
Toledo, Ohio  43601

-------