Maximizing Plastic Recovery: Strategies for MRFs to Turn Waste into Valuable Resources

From Waste to Resource: How Material Recovery Facilities Can Maximize Plastic Recovery

In today’s sustainability-driven economy, Material Recovery Facilities (MRFs) play a pivotal role in the circular economy by turning post-consumer plastics into valuable resources. However, with fluctuating market prices, rising transportation costs, and increasing scrutiny on contamination, many MRFs face challenges in maximizing the value of their recovered plastics.

This article explores actionable strategies for MRFs to increase plastic recovery rates, reduce contamination, and build stronger relationships with buyers and processors.

1. Improve Sorting Processes with Advanced Technology

One of the most significant ways MRFs can enhance the value of recovered plastics is by investing in advanced sorting technologies. Optical sorters, AI-driven recognition systems, and robotic arms are revolutionizing plastic sorting by identifying and separating materials more accurately and efficiently than traditional methods.

MRFs that utilize advanced optical sorters have reported a 20-30% increase in sorting accuracy, resulting in cleaner bales and higher payouts from buyers (source: Recycling Today).

Tip: Ensure your sorting line is calibrated to identify and separate valuable resins such as PET (#1) and HDPE (#2) while diverting contamination like PVC or food-soiled plastics.

2. Focus on Reducing Contamination

Contamination remains one of the biggest obstacles for MRFs trying to sell their recovered plastics at a premium. Contaminants such as glass, metal, and food residue lower the quality of bales, forcing buyers to offer lower prices or reject shipments altogether.

The U.S. average contamination rate in recycling streams is around 25%, meaning one out of every four items in the bin does not belong (source: EPA).

Strategies to Reduce Contamination:

• Education Campaigns: Partner with municipalities to educate residents and businesses on proper recycling practices. Clear signage and public outreach can significantly reduce contamination at the source.

• Pre-Sort Inspections: Implementing a manual pre-sort step to remove large contaminants can prevent equipment jams and reduce contamination downstream.

3. Optimize Bale Composition for High-Value Markets

Different types of plastic fetch different prices in the market. For example, clear PET bottles and natural HDPE containers have much higher demand compared to colored plastics or mixed rigid plastics. MRFs can increase profitability by optimizing their bale composition to focus on high-value materials.

As of Q4 2024, clear PET bales were averaging $0.19 per pound, while mixed plastic bales averaged just $0.03 per pound (source: Recycling Markets Index).

Tip: Create separate streams for high-value materials like natural HDPE and ensure bales meet buyer specifications, such as maximum allowable moisture levels and consistent density.

4. Strengthen Relationships with Buyers and Processors

Building trust and maintaining transparency with end-market buyers is key to ensuring steady demand for recovered plastics. MRFs that consistently provide clean, high-quality bales are more likely to secure long-term contracts and avoid price volatility.

Ways to Strengthen Buyer Relationships:

• Regular Communication: Provide buyers with detailed bale reports, including material composition and contamination rates.

• Transparency on Issues: If there’s a contamination issue or delay, notify buyers early and offer solutions.

5. Invest in Preventive Maintenance and Upkeep

Equipment malfunctions can lead to downtime, lower sorting efficiency, and missed shipments—all of which impact an MRF’s bottom line. A well-maintained sorting line and baler ensure consistent output and higher-quality bales.

Facilities that implement regular maintenance schedules experience 15-20% fewer unplanned breakdowns and achieve higher throughput rates (source: Waste360).

Tip: Schedule regular inspections and replace wear parts before they become a bottleneck. Preventive maintenance is often more cost-effective than emergency repairs and downtime.

6. Explore Partnerships for Hard-to-Recycle Plastics

Certain plastics, such as multi-layer films and mixed rigid plastics, are difficult to process and often end up in landfills. However, partnerships with specialized recyclers and chemical recycling facilities can open up new revenue streams for MRFs.

Opportunities for Hard-to-Recycle Plastics:

• Chemical Recycling: This process breaks plastics down to their molecular building blocks, enabling the recycling of materials that would otherwise be discarded.

• Film Take-Back Programs: Partner with film recyclers that can handle post-consumer LDPE films, such as grocery bags and shrink wrap.

7. Leverage Data to Improve Operations

Data-driven decision-making can significantly improve an MRF’s efficiency and profitability. By tracking key performance indicators such as contamination rates, bale weights, and material recovery rates, MRFs can identify bottlenecks and optimize their processes.

Key Metrics to Track:

• Material recovery rate (%)

• Average bale purity (%)

• Downtime due to equipment failures (hours per month)

• Contamination rate (%)

Tip: Invest in recycling software that provides real-time insights into your operations and automates reporting for regulatory compliance.

Conclusion: Turning Waste into Value

Plastic recycling isn’t just about diverting waste—it’s about capturing value. By implementing advanced sorting technologies, reducing contamination, optimizing bale composition, and fostering strong partnerships with buyers, MRFs can transform their operations and maximize the value of their recovered plastics.

At Midas Peak, we’re committed to helping MRFs and processors close the loop by connecting them with the right buyers and optimizing logistics for efficient, sustainable recycling. Contact us today to learn how we can help you increase your recovery rates and profitability.

Ready to take your plastic recovery to the next level? Contact us today to explore how Midas Peak can support your recycling goals.