The CESPA-managed plant operates two 8-hour shifts from Monday to Saturday.

During 2019, the ECOPARC IV light packaging plant, located in Hostalets de Pierola, in Catalonia, processed nearly 18,000 tons. During this period, the treatment line worked at maximum capacity, achieving good performance, both in terms of recovery and purity of materials. It was found that if the line worked above this capacity its performance dropped substantially.

Due to the increase in expected inputs and in order to maintain working shifts, it was necessary to increase the tons per hour treated by the line.

Therefore, an expansion of the treatment line was proposed in order to increase its hourly capacity, maintaining the same product recovery and purity ratios as at present.

For this production increase, the following requirements were requested to PICVISA:

On the one hand, the incorporation of a new optical sorter, ECOPACK 2000, with the objective of decongesting the current ballistic separator, the main “bottleneck” of the facility.

This new equipment was installed at the discharge of the belt that collected the 50-200mm fraction from the sorting trommel. The equipment now positively separates all recoverable 3D material and sends it to the next optical separator, also an ECOPACK 2000.

To ensure that the material collected in the 50-200mm trommel plunge arrives spread across the width of the first optical acceleration belt, a material spreader, specifically a DS-01 disc spreader, was installed.

On the other hand, the incorporation of this second new optical sorter, with the objective of decongesting the current cascade of optical sorters of the 3D fraction of the ballistic separator.

The new equipment now also positively blows the majority fraction, in this case PET (with a proportion of between 10% and 20% by weight of the input) and sends it, by means of different conveyor belts, to a manual quality control in the existing cabin.

The material not blown in the first optical sorter is sent to the ballistic separator, while the material not blown by the second sorter is sent to the rolling line of the same ballistic separator.

Both sorters can work beyond the plant’s capacity, thus leaving room for future expansions. In addition, the two ECOPACK 2000s more than meet the customer’s performance requirements, with recovery and purity levels of 90%-95%.

Thanks to the flexibility of the multispectral vision, the ECOPACK optical sorters can be configured for quick changes in the classification of new materials to be separated that may arise in the incoming flow to be treated. In addition, ECOPACK equipment can automatically sort and separate various types of materials by composition (NIR), color (VIS) and/or shape (deep learning).