Lesson 1Baling and densification: balers, compactors, and bale quality considerationsThis section details balers and compactors used to densify sorted recyclables. It addresses bale formation, tying systems, bale quality criteria, and how feed consistency, moisture, and settings influence density, safety, and marketability.
Horizontal versus vertical balers in MRFsCompactors and pre-compaction strategiesBale density, dimensions, and weight targetsContamination limits and bale quality specsWire tying, safety, and bale handlingLesson 2Glass handling and cullet separation: breakers, screens, and glass-specific conveyorsThis section discusses glass handling from receipt to cullet separation. It explains breakers, screens, and glass-only conveyors, emphasising particle sizing, removal of fines and contaminants, and reducing wear, dust, and noise.
Glass breaker types and impact on fragment sizeScreens for cullet sizing and fines removalGlass-only conveyors and chute designManaging ceramics, stones, and residual metalsWear protection, dust, and noise controlLesson 3Primary feeding systems: hoppers, apron feeders, vibratory feedersThis section introduces primary feeding systems that transfer material from storage to the processing line. It compares hoppers, apron feeders, and vibratory feeders, highlighting flow control, bridging risks, wear, and integration with controls.
Hopper design, live capacity, and bridging risksApron feeders for heavy and abrasive loadsVibratory feeders for metering and spreadingLevel sensors and interlocks for safe feedingWear liners and maintenance access designLesson 4Ancillary systems: dust extraction, air knives, water sprays (if any), control panels and SCADA basicsThis section reviews ancillary systems that support safe and stable operation. It includes dust extraction, air knives, water sprays where used, and control panels with basic SCADA concepts for monitoring, alarms, and data logging.
Dust extraction hoods, ducts, and filtersAir knives for label and light fraction removalWater sprays for dust and fire risk controlLocal control panels and emergency stopsSCADA screens, alarms, and trend loggingLesson 5Conveying and material flow: conveyor types, transfer points, speed controlThis section examines conveyor types and material flow management in dry recycling plants. It covers belt, chain, and roller conveyors, transfer point design, speed control, spillage reduction, and how routing affects uptime and safety.
Belt, chain, and roller conveyor selectionTransfer chutes, skirting, and spillage controlSpeed control, VFDs, and throughput tuningInclines, declines, and material rollbackGuarding, walkways, and lockout pointsLesson 6Size reduction equipment: shredders, hammer mills, crushers, granulators — working principles and settingsThis section explains size reduction equipment used before sorting or baling. It compares shredders, hammer mills, crushers, and granulators, focusing on cutting mechanisms, screen selection, energy use, and controlling final particle size.
Single-shaft and twin-shaft shredder functionsHammer mill impact action and grate selectionCrushers for rigid containers and bulky itemsGranulators for plastics and uniform particlesEnergy, wear parts, and oversize controlLesson 7Truck unloading and tipping floor operationsThis section describes truck unloading and tipping floor operations at dry recycling facilities. It addresses traffic flow, safety zones, loader work patterns, contamination checks, and how storage and feeding impact downstream stability.
Traffic flow, signage, and safety proceduresTipping floor layout and storage strategiesLoader operation, stockpiling, and mixingIncoming load inspection and contaminationHousekeeping, fire risk, and incident responseLesson 8Magnetic and eddy-current separation: ferrous and non-ferrous removal principles and placementThis section explains how magnetic and eddy-current separators remove ferrous and non-ferrous metals. It covers operating principles, design options, placement in the line, and key parameters affecting recovery and purity.
Ferrous capture with overband and drum magnetsEddy-current rotor design and operating principleSeparator placement relative to shredders and screensKey settings: belt speed, splitter, and burden depthMaintenance, wear points, and safety precautionsLesson 9Optical sorting and near-infrared (NIR) systems: capabilities, limitations, and typical placementsThis section explores optical and NIR sorting systems for plastics, paper, and other recyclables. It covers detection principles, ejection hardware, calibration, limitations with dirt or moisture, and typical spots in the process line.
NIR detection of polymers and paper gradesColor cameras and combined sensor platformsAir jets, valves, and ejection timingEffects of moisture, dirt, and overlappingTypical placements after screening or sizingLesson 10Screening and classification: trommels, vibrating screens, ballistic separatorsThis section covers screening and classification equipment that sorts materials by size and shape. It explains trommels, vibrating screens, and ballistic separators, including operating parameters, typical cut sizes, and maintenance requirements.
Trommel design, speed, and aperture selectionVibrating screens and stroke adjustmentsBallistic separators for 2D and 3D splitsManaging fines, wrapping, and blindingInspection, cleaning, and wear monitoring
