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The correct recycling  #5 (39), 2006

Recycling Correctly

Olefin interregional polymer group is one of the few successful domestic polymer waste recycling projects. General manager Stanislav Viktorovich Dyachuk tells us how the company has achieved these impressive results.



- Stanislav Viktorovich, how has your company been growing?

- In 1998 the government of Moscow and the Moscow region issued a regulation concerning organizing polymer waste recycling plants resulting from the situation with waste amount at the dumps becoming critical. That was the moment when we decided to develop this new business sphere in Russia.

Stanislav Viktorovich Dyachuk, general director of Olefin

Olefin was founded in August, 2000 and from the very beginning was focused on creating its own polymer recycling complexes producing secondary polyethylene. No recycling equipment was produced in the country at that time and we started with finding experienced designers, studying patents concerning recycling and buying separate lines’ components. In 2001 we designed and manufactured our first recycling complex with 60 kg/h productive capacity. In the next 18 months we were involved in certifying procedure and testing but the project was not a success: all the units run well separately but the line altogether did not work. Then we realized it was no use to re-invent the wheel and bought an imported recycling line with 250 kg/h output. Only then we began to understand that recycling is made of thousands of little things we hadn’t any idea about before. We needed two more years to penetrate into the essence of this business; it was not at once that we realized what polymer recycling market demanded.

Today, when 6 six years have passed, we know the principles this business is based on: first – production quality; second – technological process optimized to the best extent; third – raw materials; fourth – focus on ecological safety. Business lives if it doesn’t contradict other social needs, it should, besides profit, be turned to the society. That’s what I mean saying “The correct recycling”.

- What are the components of "correct recycling"?

- Materials, right sorting, quality equipment. Materials are the basis for success here. What is taken at dumps is only partially recyclable. We prefer collecting waste where it is produced – that is, at the Cherkizovsky market in Moscow you can find our presses and polymer waste sorting stations.

Recycling Correctly

Much attention is paid to selection. We sort the materials by color and type; teach our clients how to do it; stimulate dump management to sort the waste by rising purchasing price. In the course of time we have repudiated all equipment suppliers except Erema (Austria) and Neue Herbold Maschinen (Germany). They offer machinery that allows optimizing the production process and minimizing human participation in manufacture.

- Could you tell us about the company structure?

- We have four offices: one in Moscow (the head one), one in Tver (manufacture and transport) and also offices in Ekaterinburg and Novosibirsk. Materials storehouses are located in Krasnoyarsk, Novosibirsk, Chelyabinsk, Ekaterinburg, offering production that we make as well as production of the leading domestic and foreign producers of plastics.

The system of polymer waste collection and sorting in the Ural and Siberian regions has been organized and is developing now due to our local affiliates – Olefin-Ural and Olefin-Sibir. We are going to organize similar productions in every city with population of million and over. We are ready to negotiate with the cities’ administrations and other organizations and private individuals about creating unitary enterprises in the regions.

Olefin owns production sites in Tver. By now we have already launched the first line – for regranulated LDPE production – that is supposed to give 3.5 thousand tons of output a year. Today we manufacture two brands LDPE153P, MFI 0.2-0.5 and LDPE158P, MFI 0.6-2.5. We are going to start making composites based on LDPE 153P for cables and pipes isolation. LDPE 158P is used by us for film production and we also sell it. I’m proud to say that we ensure stable MFI and homogeneous regranulate structure.

With financial support from Sberbank and Smart leasing (Moscow) we are going to launch another line for making regranulated HDPE and PP with 3.5 thousand tons annual productive capacity. By the end of 2007 we expect the complex’s total output to achieve 7 thousand tons of regranulate a year.

Recycling Correctly

Our transport department is also located in Tver. We organize picking up waste from plants and markets and delivering the finished product to the client. We possess huge articulated lorries, Renault Magnum, that carry up to 25 tons load.

- The new line has been just recently launched in Tver. Have any results been achieved yet?

- The promotion that we organized – distributing “test” LDPE regranulate lots – has lead us to interesting conclusions. It turns out that our main clients are not molded goods, film or sheet producers, but pipe and cable isolation manufacturers. So we had an idea to organize joint manufactures with our clients on the basis of our production. This kind of integration will bring down production prime cost and optimize manufacturing process. That’s why we think of buying two twin-screw extruders to exercise manufacture integration. Another similar project involves using self-produced regranulated HDPE for making automobile lockers.

Manufacture integration attracts us. We are ready to suggest cooperating with other companies and to manufacture production under their brands. We are ready to provide equipment and materials. So we’ll be glad to contact organizations and private individuals in this sphere. We are also interested in contacts with specialists and science institutions ready to offer technologies for processing PE and PP regranulate into composites and filled plastics.

— - What problems do you face today working in polymer recycling?

- The major one is the lack of legal regulations for waste collecting and sorting. It’s no use counting on moral motivation, people need legal and material stimulation. However, we don’t wait for wonders that could make legislators, we just try to develop our business. Olefin is open for collaboration with companies, private individuals and local administrations in collecting, sorting and recycling polymers: we offer consultations, help in forming the enterprise’s funds and engineering, we provide the necessary technical information, transport, materials and equipment. Turn-key recycling complexes are also available. Whenever there’s a wish to start recycling, we are ready to help.

Our main aim is to give a second life to used thrown away polymers. We don’t just make another polyethylene bag of a used one to destine it for the same fate. It’s not the correct recycling. We change materials’ sphere of application and recycle them into materials and goods that will serve for long time, lingering materials life mostly without time limits. This is what I call “correct recycling”.

 

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