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Article history:
Received 5 October 2014
Received in revised form
15 February 2015
Accepted 13 March 2015
Available online 3 April 2015
Today's waste regulation in the EU comprises stringent material recovery targets and calls for comprehensive programs in order to achieve them. A similar movement is seen in the US where more and more
states and communities commit to high diversion rates from landlls. The present paper reviews scientic literature, case studies and results from pilot projects, on the topic of central sorting of recyclable
materials commonly found in waste from households. The study contributes, inter alia, with background
understanding on the development of materials recovery, both in a historical and geographical
perspective.
Physical processing and sorting technology has reached a high level of maturity, and many quality
issues linked to cross-contamination by commingling have been successfully addressed to date. New
sorting plants tend to benet from economies of scale, and innovations in automation and process
control, which are targeted at curtailing process inefciencies shown by operational practice. Technology
developed for the sorting of commingled recyclables from separate collection is also being successfully
used to upgrade residual MSW processing plants. The strongest motivation for central sorting of residual
MSW is found for areas where source separation and separate collection is difcult, such as urban agglomerations, and can in such areas contribute to increasing recycling rates, either complementary to- or
as a substitute for source separation of certain materials, such as plastics and metals.
2015 Elsevier Ltd. All rights reserved.
Keywords:
Central sorting
Single stream collection
Materials recovery facilities
Packaging waste sorting
Material recovery efciency
1. Introduction
Historically speaking, municipal solid waste (MSW) as we understand it today is a relatively new occurrence. In developed
countries, it can be traced back to the 1950se60s, when waste
amounts and its complexity were bolstered by post-war economic
prosperity, expansion of the petrochemical industry and sheer
diversication of both short- and long-lived consumer products.
Waste management came onto the political agenda only in the late
1960s, being driven mainly by emerging environmental protection
and understanding of societal impacts, and it has experienced
tremendous multilateral development, further evolving today under a new paradigm calling for sustainable resource management
* Corresponding author.
E-mail address: cic@kbm.sdu.dk (C. Cimpan).
http://dx.doi.org/10.1016/j.jenvman.2015.03.025
0301-4797/ 2015 Elsevier Ltd. All rights reserved.
182
strongly reected in the European waste legislation today. Similarly, in the early 1990s, many communities in the United States
(US) were developing mixed waste materials recovery facilities
(dirty MRFs). Nevertheless, these facilities achieved low materials
recovery rates and experienced operational and nancial challenges, which ultimately led to this approach being almost abandoned (Kessler Consulting Inc., 2009).
Pioneering separate collection programs in the 1980s focused on
few materials, such as paper and glass, which could be easily
collected kerbside or otherwise as mono-material streams. It is in
the 1990s that separate collection really picked up pace both in
North America and Europe and focused on an ever larger spectrum
of materials and products. The inherent limitations of source separation became apparent, especially public willingness to participate and the increasing complexity and costs of collecting
separately an increasing number of mono-material fractions. Material mixing followed by central sorting were, then, seen as a way
to reduce collection complexity and requirement for public
participation, and new collection and treatment approaches were
designed with this in mind. Source separation programmes, where
recyclables are partially of fully commingled, have expanded
rapidly ever since, especially in English speaking countries (USEPA,
2011; WRAP, 2011b), and the collection of mixed packaging waste
has become the norm in mainland Europe. Management systems
based on central sorting have, thus, targeted the relative simplicity
and savings on the front end (i.e. collection) at the cost of accepting
more comprehensive efforts and costs for material processing later
in the waste management chain. This has resulted, now, in more
than two decades of technological development in processing of
mixed material streams, leading today to sorting and separation
systems characterized by a high degree of technical complexity (e.g.
sensor-based sorting), increasingly standardized process ows and
high process efciency.
Increased pressure to divert biodegradable organic waste from
landlls in the 2000s resulted in renewed interest in mechanical
processing of residual MSW in Europe (Pretz, 2002; Thiel and
-Kozmiensky, 2010). As Mechanical-Biological Treatment
Thome
(MBT), it was seen as an alternative to more expensive and, in some
countries, politically ill-favoured combustion waste-to-energy
(WtE). In later years, a cross-over of advanced technology can be
seen, as more highly automated sorting systems are being included
in MBT design, promising again a total solution, i.e. residual waste
treatment and recovery of recyclable materials as a stand-alone or
complementary solution to source separation (Jansen et al., 2013;
Pretz et al., 2010). A similar trend is seen in the US where the
number of mixed municipal waste MRFs is growing again (USEPA,
2009; USEPA, 2011).
1.1. Competition-driven innovation
The premises and drivers for technological development in
sorting and separation systems can be underpinned to the much
broader eld of waste management development. Researchers
argue that waste management development has been governed by
the changing framework conditions in societal development and,
therefore, its drivers are always a complex set of interdependent
social, economic and environmental factors (Zaman, 2013). In the
US, the predominant driver for waste management appears to be
the free market, which has historically been dominated by large,
low-cost landlls (Kollikkathara et al., 2009; Wilson, 2007). With no
specic federal recycling legislation in place, the slowly increasing
material recovery and recycling rates can be linked to public
opinion, strongly favouring recycling and opposing waste-toenergy, which has even pushed for some recycling legislation at
state level. But the fast rise in, specically, commingled collection
183
Fig. 1. MSW collection and sorting systems for dry recyclables: (A) single-stream; (B) dual-stream; (C) mixed packaging waste; and (D) recovery from residual/mixed MSW. Dotted
lines and processes denote other collection and sorting systems that may or may not be present. Waste fractions in italic may or may not be included in the commingled stream.
184
Table 1
List of denitions.
Terminology
Denition
Municipal Solid
Waste (MSW)
Packaging and
packaging waste
Source separation
efciency
Separate collection
Kerbside collection
Materials Recovery
Facility (MRF)
a
Directive 1999/31/EC of the European Council of 26 April 1999 on the landll of
waste.
b
Directive 1994/62/EC of the European Parliament and Council of December 1994
on packaging and packaging waste.
c
Directive 2008/98/EC of the European Parliament and of the Council of 19
November 2008 on waste and repealing certain Directives.
185
Table 2
Examples of collected material mixtures with Single-stream collection (SS) in the US
and UK, in weight-percentage (wt.-%).
Material fraction
SS with
glassa
5.40
SS no
glassb
SS
(average)c
SS with
glassd
SS no
glassd
wt.-%
wt.-%
wt.-%
wt.-%
wt.-%
53.00
2.40
1.30
56.7
1.90
0.20
46.28e
10.33
25.33
81.9
0.27
0.13
40.17
8.43
16.58
65.2
2.10
0.21
40.73
13.94
11.23
65.9
0.97
28.47
33.52
4.37
66.4
2.41
1.28f
5.39
2.91
4.85
4.76
3.30
0.80
2.55
3.68
2.24
1.91h
4.80
6.60
4.54g
20.60
3.60
0.33
9.0
2
1.05
1.85
1.01
3.2
3.6
100
9.1
100
39.5
3.91h
3.90
2.93
5.39
0.64
17.55
4.38
30.5
22.4
6.93
3.48
1.09
10.15
9.2
100
3.5
100
11.2
100
3.27
0.98
25.7
2.24
a
R.W.Beck (2005), Input to Recycle America of York MRF, Pennsylvania (samples
taken in 2002 and 2004).
b
DEQ (2011), Average input, 5 SS MRFs in Oregon (study conducted 2009e2010).
c
Enviros Consulting (2009), Average input, 13 SS (both with glass and without)
MRFs in the UK (study conducted 2008e2009).
d
Eule (2013), the average of samples for input materials to 2 SS MRFs in England.
e
Newspaper (23%) magazines (8%) other compatible (15%).
f
Both ferrous and non-ferrous.
g
Bottles and tubs.
h
All non-ferrous and ferrous materials respectively.
186
Table 3
Household MSW collection systems e separate collection and materials in italic denote that these are not always present or included.
Collection systems
Form of collection
Predominant in
Glass collection
Biowaste collection
Single-stream commingled
Residual MSW
Glass collection
Biowaste collection
Dual-stream commingled
Residual MSW
Kerbside
Kerbside
Austria, Germany
Spain, Portugal
Belgium, Italy, Netherlands, Sweden,
and other European countries
Mostly Kerbside
Separate bins/bags or multi-compartment
bins for: metals, cardboard, glass (sometime
by colour), plastics, beverage cartons etc.
(broad denition)
Bin 1: dry MSW items
Bin 2: wet and soiled MSW items
Kerbside
187
188
Table 4
Typical required purity in the UK and results from three different characterization assessments in the US and the UK.
Product
Cardboard (OCC)
News & pams
Mixed paper
Al cans
Al foil
Steel cans
Metal mix
Glass
Beverage cartons
Natural HDPE bottles
Coloured HDPE bottles
Clear PET bottles
Coloured PET bottles
Plastic mix
Total sorting residues (wt.-%)
Plant input contamination (wt.-%)
Average (wt.-%)
Average (wt.-%)
Average (wt.-%)
Best (wt.-%)
Worst (wt.-%)
96
96
96
98
98
98
92.3
92.0
95.0
97.6
100.0
96.7
95.8
93.8
98.3
94.4
87.0
90.5
82.5
97.9
98.1
98.1
97.9
100.0
42.6
78.0
63.3
92.0
94.7
96.7
92.6
97.7
76.2
96
96
95
95
95
95
98.9
97.5
91.2
91.7
91.0
94.8
92.5
93.1
86.9
91.9
84.9
96.1
96.7
94.0
97.0
99.4
85.4
89.6
79.9
86.8
56.4
13.1
5.7
22.5
5.54
3.35
stream MRFs in North America and the UK. Table 4 shows product
purities measured in three studies, alongside typical quality requirements on the UK market.
R.W. Beck (2005) analysed collected streams, sorting residues
and recovered material streams arising in 9 MRFs (of which, 2
Single-stream and 4 Dual-stream). Sampling and characterization
took place between 2002 and 2004. Composition analyses, using up
to 36 fractions, were performed for paper and plastic products,
under the assumption that for other recovered materials (i.e. metals
and glass) the content of contaminants would be insignicant. In
this study, recovery efciencies were not measured and only simple
mass balances, based on plant yearly production, were presented.
Installation setups and technologies were not described in detail
due to condentiality issues. Enviros Consulting (2009) performed
a study for WRAP UK, in which the input waste, outputs and sorting
residues of a total of 18 MRFs, of which 13 single-stream, were
characterized in terms of composition to document both the quality
of commingled collection and MRF efciencies. This was done by
assessing a large number of samples over an extended sampling
period, however, material mass balances were not included in the
work. Moreover, all results were given as averages, with the
expressed aim of not disclosing or singling out any very well or
badly performing MRFs. A more comprehensive study was performed by the Oregon Department of Environmental Quality (DEQ),
where the authors had access and analysed all inputs and product
outputs of the ve largest single-stream facilities in the US state of
Oregon (DEQ, 2011). Complete mass balance and material specic
recovery rates were derived in this work, however, a word of
caution is appropriate in what regards possible bias, as these were
calculated and provided by the plant operators themselves. There is
no information concerning the level of technology or process ow
description. The analysis of outputs was made such that it cannot
be connected to a certain facility, due to condentiality agreements.
Lastly, Eule (2013) has assessed the performance of three singlestream MRFs in the UK over a period of several years. His doctoral
dissertation constitutes the most comprehensive study on MRFs to
date, offering insight from within the highly competitive industry,
into material mass balances, process design and performance of
such plants. The three evaluated plants were of large capacity,
75e100,000 tpa, but with relatively different process congurations and levels of automation. Eule (2013) uses a series of performance parameters to assess MRFs processing commingled dry
recyclables, such as total recovery rate of recyclable content, product
quality specications, plant availability and throughput rate. The rst
parameter, total recovery rate of recyclable content, is set by the UK
98.5
96.6
5.8
9.0
189
Table 5
Material specic recovery rates in all products, in compatible and in intended products, based on two studies. Total recovery rates are shown in bold.
Input fractions (Eule, 2013) Total in products Total compatible Intended product Input fractions (DEQ, 2011) Total in products Total compatible Intended product
wt.-%
wt.-%
wt.-%
99.7
97.1
97.0
96.6
90.0
94.6
98.8
90.0
88.9
99.8
89.3
97.8
97.3
97.6
89.0
31.3
26.7
99.9
34.0
82.2
97.7
99.6
96.7
86.2
90.8
90.0
89.6
87.5
70.0
66.7
96.0
76.7
94.0
82.0
93.5
74.6
e
e
98.6
e
e
94.0
49.9
77.9
84.6
44.4
31.1
71.8
87.5
30.0
66.7
96.0
76.7
86.9
62.2
91.3
60.7
67.6
73.3
98.6
64.8
69.6
68.2
wt.-%
wt.-%
wt.-%
98.5
99.2
97.8
99.3
95.2
91.4
75.5
96.7
83.0
97.1
92.4
98.6
96.8
99.1
97.7
92.3
55.6
89.7
60.4
67.0
33.0
85.9
86.6
84.2
96.8
99.1
56.6
92.3
25.6
29.3
24.5
67.0
33.0
85.9
86.6
84.2
*Other plastics
*Plastic lm
*Glass
*Hazardous materials
*Other contamination
Weight % total output
69.2
24.1
1.4
54.1
16.5
94.2
68.0
75.9
98.6
45.9
83.5
88.9
30.8
75.9
98.6
45.9
83.5
85.8
*An asterisk in front of the material name means this material was not supposed to be included in the commingled collection.
Total in products e denotes all recovered material except the share in sorting residues.
Total compatible e denotes material recovered in the intended products compatible products.
190
Table 6
DKR product standards: material components and minimum purity (wt.-%).
Product
DKR-Nr.
Description
Purity (min)
Fe-metals (tinplate)
Aluminium
Beverage cartons
412
420
510
Paper-card packaging
Plastic foils
Mixed plastic bottles
550
310
320
323
325
328-1-2-3
90%
92%
94%
85%
98%
98% PET content
94%
90%
subject of debate for the last 20 years in the US and Canada. But
rather than the choice between mono-stream (e.g. kerbside sort)
and commingled collection systems, the focus of debate has been
commingled systems, i.e. single-stream vs. dual-stream systems.
On most points, the results of various studies are inconclusive (CRI,
2009; Lantz, 2008; Lantz and Morawski, 2013). In terms of economy, Lantz and Morawski (2013) reported results based on monitoring of the largest Ontario-based single-stream and dual-stream
programs between 2003 and 2011. Their analysis included kerbside
collection, processing (sorting) costs and subtracted revenues from
material sales. The results showed that single-stream programs had
in general been more expensive and that the gap in cost had
increased over this period. Nevertheless, some US-based studies
have shown that a switch from dual-stream to single-stream was
both economically and environmentally benecial (Chester et al.,
2008; Fitzgerald et al., 2012). In the US the cost of separate
collection programs is mostly supported by household fees for
waste management services.
The penetration of commingled collection is less prevalent in the
UK compared to the US. Here around 50% of local authorities employ
kerbside sort systems. A detailed analysis of costs and performance
comparing kerbside sort, dual-stream and single-stream systems in
the UK was published by WRAP (WRAP, 2008). The results of this
analysis indicated that kerbside sort systems incurred on average
lower costs compared to commingled systems, as a net of collection,
processing and revenue from sale of materials. Commingled systems
costs were highly dependent on MRF gate fees, while kerbside sort
costs depended on the income from direct material sales. However, a
more recent analysis performed on case local authorities indicated
the opposite, i.e. that assessed kerbside sort had higher costs
compared to commingled systems (Marques et al., 2014).
More broadly in Europe, where EPR-based legislation mandates
that the industry is responsible for their packaging end-of-life,
several questions have arisen: (1) whether the industry is actually covering the costs of collection and treatment, and (2) what is
Table 7
Material recovery in state-of-the-art LVP plants, adapted from Bnemann et al. (2011).
Product
Sorting technology
Reprocessing route
Manual
Magnetic separation
Eddy current
NIR
Air separation, NIR, foil grabber
NIR
NIR
e
e
>95%
60e90% (typically 80%)
90%
>70%
70e90%
>85%
e
Mechanical recycling
Steel industry
Pyrolysis and Al industry
Paper industry
Mechanical recycling,
Mechanical recycling,
Mechanical recycling or energy recovery
Energy recovery
191
192
Table 8
PPW recovery in the Netherlands based on recovery path (Van Velzen et al., 2013a).
Recovery path
Separate collection
Post-separation
2010 data
55%
11 kg (with miss-sorting)
9 kg (plastic content)
19.5 kg (with miss-sorting)
12 kg (plastic content)
n.a.
n (Spain);
Ecoparc 4, Larnaca, Castilla y Leo
Barcelona Cyprusa 8 plants (Montejo et al., 2013)
(wt.-%)
(wt.-%)
Average
(wt.-%)
Min
(wt.-%)
Max
(wt.-%)
13
72
29
3
39
67
73
88
10
45
70
70
45
45
45
45
e
e
12
61
62
13
20
29
14
56
e
0.2
35
33
5
0.4
5
1
10
e
39
84
95
49
60
48
36
71
e
10.5
2.5
13
193
Table 10
Composition of certain material products from Ecoparc 4 during performance testing.
Material
PET
HDPE
Paper/card
Beverage cartons
Aluminium
Fe metals
wt.-%
wt.-%
wt.-%
wt.-%
wt.-%
wt.-%
wt.-%
98
94
90
90
90
82
e
e
e
e
e
e
e
e
98.70
0.36
0.10
0.00
0.00
0.00
0.04
0.00
0.35
0.19
0.00
0.00
0.26
100
0.24
98.31
0.02
0.02
0.00
0.00
0.02
0.38
0.45
0.46
0.00
0.00
0.10
100
0.00
0.00
98.58
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.04
1.38
100
0.50
0.25
1.21
96.28
0.04
0.14
0.00
0.08
0.00
0.42
0.00
0.00
1.09
100
0.00
0.00
0.07
0.11
93.72
0.00
0.22
0.00
0.00
3.12
0.00
0.00
2.76
100
0.00
0.00
0.00
0.00
0.01
98.57
0.00
0.00
0.00
0.23
0.00
0.00
1.19
100
194
Table 11
Efciency overview of MSW recovery (in cited literature).
Total input waste
recovered as output
products
Quality of output
products (purity)
wt.-%
wt.-%
wt.-%
Reference
Installation type
MT before WtE
Wijster (Netherlands),
1 plant (250.000 tpa)
Netherlands, 3 plants
(about 500.000 tpa)
4%: 3% polyolen
concentrate; 1% foil
plastics
2.8% plastic products
,a
MBT and MT
before WtE
MBT
Trier (Germany),
experimental setup
MBT
Barcelona (Spain); 1
plant (250.000 tpa)
MBT
Larnaka (Cyprus); 1
plant (200.000 tpa)
MBT
Barcelona (Spain); 1
plant (300.000 tpa)
MBT
n (Spain); 8
Castilla y Leo
plants (approx. 800.000 tpa)
SWANA (2013)
Dirty MRF
Dirty MRF
Dirty MRF
20% recyclables;
20% compost like output;
15% RDF
10% recyclables;
11% compost like output;
7% RDF
2.5e13% recyclables;
around 25% compost like
output
22% recyclables;
48% organics before
composting
25e75% total diversion
from landll
3e73% total diversion
from landll
High (Table 10 in
this article)
Not given
Not given
Not given
Mentioned as lower
compared to separate
collection
Not given
Not given
Not given
a
The plants described in the rst 4 entries recover in addition to plastics also other materials (e.g. ferrous and non-ferrous metals, other recyclables, RDF), however, the cited
studies only analysed the recovery of plastics.
b
To calculate the diversion from landll rate in the US, the organics stream is counted before biological degradation losses (explaining the higher values of up to 70e75%).
Table 12
Cost parameters, in Euro per tonne of input at respective activity (from Van Velzen
et al., 2013a).
Activity
Source separation
Post-separation
Residual MSW
PPW
Mixed waste
Collection
72
56e82
Transport
n.a.
Separation (MBT
plant)
Transfer stations
Transport to plastic
sorting
Plastic sorting plants
Transport to recycling
Recycling
Incineration tariff
n.a.
181e580 (kerbside)
184e185 (bring
schemes)
7 (kerbside)
4 (bring schemes)
n.a.
220
n.a.
n.a.
25
11e17
n.a.
41e47
n.a.
n.a.
n.a.
88
125
18e19
90e230
88
145
10e12
100e250
88
5e12
from mixed collection were estimated at 47 V, with the construction of a new MBT plant, and at 40 V, with the modication of an
existing MBT plant.
In the Dutch TIFN project, a full system economic assessment for
the considered scenarios was attempted (Bing et al., 2013; Van
Velzen et al., 2013a). The main cost parameters which were
determined for the two recovery paths, i.e. separate collection and
post-sorting, are presented in Table 12. Considering all operations
from collection to recycling of plastics and transportation needs,
full system costs per tonne of recycled PPW ranged from 660 V to
870 V for source separation systems and from 870 V to 920 V for
the post-separation system. The results of this study thus indicated
that slightly higher overall costs were incurred by the postseparation system. Nevertheless, this has to be measured against
post-separation systems yielding larger amounts of PPW and
plastic recyclates compared to source separation.
6. Discussion
6.1. Product quality and implications for the recycling industry
6.1.1. Commingled separate collection and sorting of dry recyclables
Both in some European countries and North America, increasing
pressure to extend separate collection systems and increase national recycling rates, has resulted in implementation of fully or
partially commingled collection systems. On one side, some of the
reported advantages to these systems are high public participation
due to convenience, a simpler collection system (automatic or
semiautomatic pickup, less vehicles and people) entailing lower
costs compared to other approaches and better working
195
mills, in general, did not accept recovered paper from MRFs which
process glass, due to risks of machine damage.
Between 2000 and 2005, as it became the world's biggest
market for recovered paper, China began tightening quality requirements for imports. Marley (2007b), explains that US operators, beneting from considerable experience (3rde4th generation
MRFs), complied instantly with the new market requirements,
while the UK operators were confronted with difculties. In the
same time period, WRAP UK dedicated several studies to MRFs in
the UK, and also developed a costing model which indicated that
50.000 to 80.000 tpa was the threshold for plant economies of
scale, which would permit investment in better technology and
subsequent improvements in product qualities (Graham, 2006;
WRAP, 2011b). WRAP found in 2005, that 81% of England's MRFs
were below this threshold (WRAP, 2006). This, however, has
changed signicantly until today, as the UK waste sector matured,
new investments favoured larger installations, using advanced
processing techniques, and which can ultimately take better
advantage of economies of scale (Eule, 2013).
In a recent research paper, Miranda et al. (2013) reported results
from two studies (between 2007 and 2009), where the quality of
incoming (imported) recovered paper to a large paper mill in Spain,
from commingled collection systems in the UK, was extensively
monitored. The rst study analysed typical qualities coming from a
variety of MRFs in the UK, while the second reects qualities after
the supplier commissioned a high-tech plant based on the US
design (using star and disk screens as primary separation and glass
breaker screens to remove glass). The results on typical imports
from the UK displayed large variability in unusable material content, from 1% to 29%, with the average value at 11.9% (standard
deviation of 6.5%), which was to be expected. However, with
shipments from the new MRF, unusable material decreased to between <1% and 16.6%, with an average value of 8.1% (75% of samples
displayed values between 5% and 10%). These numbers were then
compared to other surveys on shipments received by mills in
mainland Europe from separate collection systems (typically
mono-material or commingled paper and cardboard collection),
where unusable material content varied from 1% to 7%.
The results of Miranda et al. (2013) are in agreement with efciencies presented in Section 4.1.2., and conrm that plant technology level can have a great inuence on product quality. State-ofthe-art facilities can separate paper products with purities on the
same levels as that of streams coming from separate collection.
6.1.1.2. An additional perspective on material quality. Miranda et al.
(2011) demonstrated a clear statistical connection between paper
quality loss and increase in separate collection rates in Spain over
time, explained mainly by collection tapping into lower quality
sources (e.g. households). The authors monitored the quality of
different sources of recovered paper used as raw material by a
Spanish paper mill, during a 4 year period (2005e08), period
during which separate collection of paper increased in Spain from
58.5% to 68.6%. Overall results showed an increase in unusable
material content (as annual average) from 5.5 % to 8.7% over the
period. The change in quality was explained in the study by the
extension of separate collection systems, as early on households
represented only a minor part of the recovered paper supply which
was rmly tapping high quality sources such as service, commerce
and industry.
In this sense, Miranda et al. (2011) suggests that waste paper
from households inherently has a lower quality compared with
other sources. Of course, miss-sorting by households can be corrected though information campaigns and similar approaches, and
quality typically should improve as collection systems mature.
Possible improvements, however, may be overturned by the
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