Lesson 1Glass handling and cullet separation: breakers, screens, and glass-specific conveyorsThis lesson covers handling glass from arrival to separating cullet. It explains breakers, screens, and special glass conveyors, with focus on sizing particles, removing fines and dirt, and cutting down 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 2Screening and classification: trommels, vibrating screens, ballistic separatorsThis lesson looks at screening and classification gear that sorts materials by size and shape. It covers trommels, vibrating screens, and ballistic separators, including settings, usual cut sizes, and upkeep needs.
Trommel design, speed, and aperture selectionVibrating screens and stroke adjustmentsBallistic separators for 2D and 3D splitsManaging fines, wrapping, and blindingInspection, cleaning, and wear monitoringLesson 3Optical sorting and near-infrared (NIR) systems: capabilities, limitations, and typical placementsThis lesson explores optical and NIR sorting for plastics, paper, and other recyclables. It covers how detection works, ejection gear, calibration, issues with dirt or wet materials, and where they fit in the 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 4Magnetic and eddy-current separation: ferrous and non-ferrous removal principles and placementThis lesson explains magnetic and eddy-current separators for removing iron and non-iron metals. It covers how they work, design choices, where to place them, and key settings for better 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 5Truck unloading and tipping floor operationsThis lesson describes unloading trucks and tipping floor work at dry recycling sites. It covers traffic flow, safety areas, loader patterns, contamination checks, and how storage and feeding keep downstream steady.
Traffic flow, signage, and safety proceduresTipping floor layout and storage strategiesLoader operation, stockpiling, and mixingIncoming load inspection and contaminationHousekeeping, fire risk, and incident responseLesson 6Size reduction equipment: shredders, hammer mills, crushers, granulators — working principles and settingsThis lesson explains size reduction gear used before sorting or baling. It compares shredders, hammer mills, crushers, and granulators, focusing on cutting methods, screen choices, power 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 7Conveying and material flow: conveyor types, transfer points, speed controlThis lesson examines conveyor types and material flow in dry recycling plants. It covers belt, chain, and roller conveyors, transfer designs, speed control, spillage cuts, and how paths affect 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 8Ancillary systems: dust extraction, air knives, water sprays (if any), control panels and SCADA basicsThis lesson reviews support systems for safe, steady running. It includes dust extraction, air knives, water sprays if used, and control panels with basic SCADA for monitoring, alarms, and logging data.
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 9Primary feeding systems: hoppers, apron feeders, vibratory feedersThis lesson introduces main feeding systems moving material from storage to processing. It compares hoppers, apron feeders, and vibratory feeders, noting flow control, bridging risks, wear, and control links.
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 10Baling and densification: balers, compactors, and bale quality considerationsThis lesson details balers and compactors for densifying sorted recyclables. It covers bale making, tying, quality standards, and how steady feed, moisture, and settings affect density, safety, and market value.
Horizontal versus vertical balers in MRFsCompactors and pre-compaction strategiesBale density, dimensions, and weight targetsContamination limits and bale quality specsWire tying, safety, and bale handling
