RESIDENTIAL AND COMMERCIAL SINGLE STREAM SYSTEM AUSTIN, TEXAS

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1 RESIDENTIAL AND COMMERCIAL SINGLE STREAM SYSTEM AUSTIN, TEXAS 2013 RECYCLING SYSTEMS EXCELLENCE AWARD APPLICATION

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3 EXECUTIVE SUMMARY The City of Austin, a municipality focused on sustainability and committed to achieving Zero Waste by 2040, awarded Balcones Resources, Inc. (Balcones) a 20- year contract to process the majority of the city s residential recycling. Balcones has built a Materials Recycling Facility (MRF) that houses state-of-the-art recycling machinery and technology, and has the capacity to process more than 25 tons of residential and commercial single-stream recyclables per hour with recovery rates in excess of 95%. The MRF was designed to limit downtime, produce a superior end product and create an optimal working environment. The facility may also be easily expanded as Balcones' partnership with the City of Austin grows. Our partnership with Balcones Resources is something the city is very proud of. We are thrilled to see this project come online. The new MRF will not only help decrease the amount of waste we send to landfills but will also help the city achieve its Zero Waste goal much sooner. -Lee Leffingwell, City of Austin Mayor Balcones works collaboratively with the City of Austin to improve the efficiency of the City s recycling collection operations, increase the amount of material diverted from landfills, enhance the overall costeffectiveness of the City s recycling programs and promote the City s environmental goals RECYCLING SYSTEMS EXCELLENCE AWARD 2

4 1. Design of Recycling System The Balcones MRF was constructed on an existing acre site, which was a former Travis County facility. This $24 million venture represents the largest capital investment by a recycling company, public or private, in the state of Texas in The project consisted of a total of four buildings: two new buildings and two existing buildings. The MRF is housed in a new building and was built and planned with flexibility in mind. Two Existing Buildings were Remodeled Balcones utilized the newest methodology to design, build, and deliver the facility on-time and on-budget. The design/build delivery method gave the team the ability to fast-track the project; as the earthwork and underground utilities were underway as the building features were being designed and coordinated with the equipment vendors. The project was completed exactly 364 calendar days after breaking ground. Recycling System Design The Balcones MRF was designed to process residential and commercial single stream material and has the ability to capture over 95% of the available recycling stream. The principal system design parameters included: Maximum recovery of available commodities with minimal loss in residue Production of the highest quality, marketable end products Use of minimal labor to achieve the maximum recovery and highest quality end products listed above Safest possible working environment with full access platforms for sorters/ maintenance personnel System layout with ideal maintenance and rolling stock access to all pieces of equipment Durable and structurally superior equipment to ensure the longest possible lifespan and reliability Lowest possible operating cost per ton Complete systems control package with menu driven choices and diagnostics for maximum flexibility To achieve these design parameters, Bulk Handling Systems was selected as the equipment manufacturer. Based in Eugene, Oregon, this company provided equipment that was made in America and that offered the performance, safety and durability required by Balcones. Materials captured in this MRF include: PET HDPE-N HDPE-C Mixed Plastics OCC ONP Mixed Paper SOP Aluminum Ferrous Metals Mixed Metals Glass Mixed Rigid Plastics Film Plastics System Features include: Glass Clean-Up System Pre-Sort Area Conveyors Metering Bin OCC Separator Debris Roll Screens NewSorter Polishing Screen Fiber Post-Sort Area Container Post-Sort Area Residue Removal and Collection System Debris Roll Screens Polishing Screen Split Flow Chutes Conveyors Modifications to Post Sort Platforms Modifications to Controls Pneumatics (Aspirators/Dust Collector/Transfer Piping) 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 3

5 Merits Associated with this State of the Art System The Balcones system brings together the best in new technologies to produce the highest quality product in the most environmentally-friendly way. Already, the system has been proven to limit downtime, produce superior end products and create an optimal work environment for employees. The facility is clean and bright, with an extensive use of natural light and a comprehensive pneumatics system to capture dust. The equipment was strategically selected and optimally placed to specifically manage the unique blend of materials generated in the City of Austin and maintain the quality end-products expected by Balcones customers. In addition to system requirements including creation of an ideal work environment, production of superior end products, and limited downtime the length of the City of Austin contract necessitated the selection of a system that was both durable and flexible. Equipment chosen for this system had to be designed for longevity; it was imperative to install a state-of-the-art system with features that protected the life of each component. Additionally, Balcones anticipates changes to the City of Austin's recycling needs over the term of the 20-year contract and need options for modifying and/or expanding system capabilities. The selected system met the mark on all five requirements: reliability, capability, cleanliness/safety, durability and flexibility. A description of specific system components and their merits are listed below: Metering Bin System Infeed: The single stream material is fed to the pre-sort with a Metering Bin to provide a consistent feed rate for optimal operation of all downstream equipment. Commercial material is fed into a lower horizontal belt, ahead of the Metering Bin.

6 Pre-Sort Line: The pre-sort platform is equipped with five bunkers for the storage of manually removed bulky items (wood, metals, mixed rigid plastics, plastic film, etc). The bunkers are designed with the capacity to have 40 yard Roll-Off Containers. OCC Separator : The input material has a percentage of OCC (9.19%), which is removed by an OCC Separator 98-9/8. This screen has been sized to ensure the mechanical removal of the majority of OCC, with minimal loss of other fiber such as ONP. Material falls through the OCC Separator to the #1 Debris Balcones Recycling System Roll Screen. This ensures the most effective means of removing glass from the input mix which results in higher quality finished materials and lower wear costs on downstream equipment. Debris Roll Screen (DRS ) #1 Model 84-9/9: A large two-deck DRS is positioned under the OCC Separator to remove the majority of the glass and fines prior to the NewSorter. The DRS is designed to remove glass and fines without losing valuable single serve containers. The 2- to 4-inch material from the second deck goes through an aspirator for fiber recovery before being sent to the second DRS NewSorter : The system is equipped with a NewSorter positioned in-line after the OCC Separator and before the Polishing Screen. The NewSorter separates newsprint from the material stream, sending the ONP over the screen while mixed paper and containers, the unders of the screen, continue to the Polishing Screen. The NewSorter and Polishing Screens have adjustable inclines, independent decks with variable speed drives, and separate tipple sections for fine tuning the angle adjustment to maximize product quality with changing material streams. DRS #2: The 2- to 4-inch material from the first DRS is sent to a single-deck DRS Glass Breaker where glass is broken into 2-inch minus pieces and sent to the Glass Clean-Up System. Containers are sent to the container line for further separation. Polishing Screen: The Polishing Screen is designed to separate remaining small fiber from containers. The most difficult screening in any system is the separation of small fiber from containers. Due to the in-line disc design, the length of the unit (26 shafts), angle placement, and field refined speed settings, the Polishing Screen is highly effective at this separation. Additionally, the 784 discs virtually eliminate the wrapping that is common with traditional disc screens. This means significantly less time cleaning screens and results in a safer workplace. The Polishing Screen is also equipped for three-sort unders removal, which enables removal of remaining 2 minus material ensuring the cleanest possible product to the container line. The disc design and 2 x 2 opening of the Polishing Screen keeps valuable single serve containers from falling through and maximizes recovery. A clean container stream is also critical for effective optical sorting and the Polishing Screen provides the ideal material distribution to optical units. Glass Removal and Cleaning: The unders from the first and second DRS s are sent to a Glass Clean-Up System. A vibratory screen removes the 3/8 minus fines, the overs are aspirated removing the lights (fiber and plastics) and sent to an expansion chamber, and the remaining air is directed to a filtration unit ensuring no dust is released into the surrounding atmosphere. The result is a clean three-color mix glass product with the highest market value. Container Sort Line: The container stream from the Polishing Screen is sent to a container line featuring a pre-sort for waste and three dimensional fiber, a total of six container bunkers for FM, AL, PET, HDPE-N and HDPE-C, and #3-#7 plastics. Ferrous is captured with a cross belt magnet. All plastics are air conveyed into the storage hoppers RECYCLING SYSTEMS EXCELLENCE AWARD 5

7 An Eddy Current Separator recovers the aluminum, which is also air conveyed to the hopper. Residue is conveyed directly into the waste packer. Fiber sorted at the container pre-sort is returned to the mixed paper line. Quality Control stations are provisioned for AL, PET, HDPE-N, HDPE-C, #3-7 Plastics, and Residue. Optical Sorters (2): The optical sorters separate the various plastics streams at very high efficiency rates requiring minimal manual post sorting. The NRT machine design ensures maximum recovery of valuable single serve containers. The MultiSort IR PET sorter uses transmitted versus reflected light which produces the most accurate reading of the unique polymer signature in the near infrared light spectra. The SpydIR sorting system uses infrared sensing technology to readily identify specific polymers from mixed materials. Storage Bunkers & Bins: All fiber and container storage bunkers and bins are designed to maximize the available space and promote baling efficiency. The fiber bunkers are equipped with fully automated walking floor storage and discharge systems to maximize efficiency and provide a metered feed to the baler. This reduces operational cost and increases baler throughput, through the virtual elimination of jams. One Touch Sorting Design for all Sorting Conveyors: Storage bunkers All sorting conveyors feature split chutes and underside with walking conveyors that enable sorters to pick two items and floor storage redirect materials to designated sorting areas. This design maximizes recovery and efficiency, while minimizing the need for 32-gallon containers on sort platforms. Third Sort Aspiration after Polishing Screen: All material that falls through the Polishing Screen are aspirated to collect any remaining fiber that gets through the Polishing Screen and pneumatically transferred to the Mixed Fiber line. Pre-Container Line Aspiration: All materials directed to the container line will be aspirated prior to the container line pre-sort stations to further ensure that the container stream is void of fibrous materials. Fiber Post Sort: The news and mixed paper post sort belts share a common platform area. A container return conveyor and a residue conveyor are provided to minimize double handling of these items. Three 240 cubic yard Walking Floor bunkers are provided to allow adequate storage of OCC, ONP, and Mixed paper, or SOP. All fiber products are walked onto the baler feed conveyor to either the MacPresse baler or to the Sierra twin ram baler. Baler & Baler Feed Conveyors: The system incorporates both a MacpPresse Single Ram and a Sierra Pacific Twin Ram Baler with in-feed conveyors. Designed into the system is the ability to feed either baler with fiber or containers, and both in feed conveyors allow for the material to be directly fed from the floor. Among fiber recyclers, the MacPresse is widely recognized as an extraordinarily efficient and dependable baling machine. The MacPresse is used as the primary fiber baler and the Sierra is used as the primary container baler. Dust Collection Filtration System for NewSorters and Polishing Screen: A custom dust hood system and ducting was mounted over the NewSorters and Polishing Screen to capture and filter most of the dust liberated during the screening process. The air is transferred back to a filter system, where the dust is discharged onto the residue conveyor. This system greatly improves atmospheric conditions within the facility, decreases general housekeeping requirements and improves the lifespan of downstream components by recovering a large portion of the dust off the NewSorters and Polishing Screen Controls Package: The selected control panel provides an easy to use but very sophisticated package to operate and maintain a complex system. With menu driven choices the system allows specific settings providing maximum flexibility as material composition and/or operating conditions change. The control panel enables both automatic 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 6

8 Control Panel and maintenance mode control of the equipment. The panel was constructed per the NEC code and fabricated in a UL Approved shop using best in class components that are locally available. All variable drives were fitted with input line reducers to minimize the amount of interference to each drive. The control panel was also equipped with an Ethernet port and modem so the panel can be remotely accessed by the manufacturer. Baler Redundancy: In a high-demand, high-production recycling operation, the baler is often referred to as the heart of the plant. If a plant is wholly dependent upon the service of a single baler for continuous production, it is likely that the plant will experience periodic unscheduled downtime due to the failure of the baler, the bale strapping system, or other baler related components. Because the Balcones MRF operates two high production balers, the plant is able to continue in full operation during any period in which one of the balers may be in need of repair. 2. Environmental Protection The Balcones MRF was designed to have a positive impact on human health, environmental quality and resource conservation. In an effort to utilize sustainable design solutions, Balcones chose materials that have high recycled content like the predominant exterior metal panels and new structural frames. The warehouse has a sky lighting grid that washes the interior with natural light throughout the day. All facilities are fitted with low energy consumption light fixtures and high efficiency HVAC systems. Balcones also installed a photo voltaic array to offset a portion of the on-site energy consumption. Additional water and energy efficient features include motion sensing office lighting, use of prevailing winds for open-air ventilation and a reflective roof. Optimal orientation of new buildings decreased direct sunlight. Other green principles included drought resistant native plants, minimal turf and crushed granite landscaping. Examples of green materials used are low/no VOC paints, glues and sealants, certified particle board, local reclaimed lumber, recycled content carpet, and locally-sourced construction materials such as the 100,000 square foot metal building for the warehouse. A notable aspect of the project is the reuse of the old City of Austin: Leadership in Zero Waste In 2011, the Austin City Council unanimously approved the adoption of the Austin Resource Recovery Master Plan. A culmination of two years of research, stakeholder engagement and community input, the Master Plan sets the stage for the City s programs and services for the next 30 years and beyond. The aim is to reach the goal of Zero Waste by 2040, which means keeping at least 90% of discarded materials out of the landfill. Photo voltaic array office structure. Instead of razing this building, contributing to landfill and using all new building materials, Balcones chose to renovate and improve this structure. Consistent with Balcones' commitment to recycling and the City of Austin s commitment to Zero Waste, a building that may have otherwise been seen as trash has been reused and given a new life. Over 3.9 million pounds of asphalt, 2.6 million pounds of brick, 81,900 pounds of metal, and 24,000 pounds of wood were reclaimed or recycled during this project. The MRF also helps reduce greenhouse gas emissions. The site of the new facility has access to a rail line that 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 7

9 runs from Austin throughout the country and internationally. Balcones contributes to a reduction in carbon emissions by using rail cars to ship a substantial portion of its products. Rail access allows for national and international shipping, and also reduces the number of miles traveled on roadways. Reduction in heavy vehicle trips is created by shipping outbound product via rail road, reducing three trucks for every rail car shipped. Reducing the carbon footprint associated with workforce commute was also a key component of the MRF design. Electric car charging stations are provided along with shower and changing room for bike commuting employees. In addition, many employees carpool or take mass transit to work. Overall Impact of the Recycling Program The facility began receiving Residential Single Stream (RSS) recyclables from third-party haulers in August 2012, and the City of Austin beginning in October In addition, Commercial Single Stream (CSS) accounts and Direct Feed Fiber accounts are also processed through the facility. Balcones is currently operating a single 8.5 hour shift Monday through Saturday. Between October 2012 and April 2013 Balcones achieved: 13% increase in Residential Single Stream inbound volumes 23% increase in Commercial Single Stream and Fiber accounts 24% increase in bale production Sorting equipment performance (RSS and CSS combined): o current average production percentage of 92% (90% is the targeted goal) o current average operational downtime of 4% (less than 25 minutes per day) o current average process downtime of 4% (less than 25 minutes per day) o glass throughput of 1,000 + tons per month Compatibility and Integration The recycling system is compatible with the local environment and integrated with and complementary to other local solid waste management systems. Balcones is a key stakeholder in the existing recycling infrastructure in Austin. The company recognizes the benefits of single stream recycling and the need for new facilities and we designed and built this MRF to provide highly integrated, cost effective and innovative services to residents and businesses for the next 50 years. Because the site is more centrally located to the City s entire collection service area, the City s operation is able to reduce route hours and gain in overall efficiency and productivity. There is a net reduction in the City s carbon emissions due to using this site, which is located eight miles from Austin City Hall. In addition, Balcones contributes to a reduction in the City s carbon emissions by using rail cars to ship a substantial portion of its products. The MRF has rail access that runs from Austin throughout the country and internationally. Reduction in heavy vehicle trips is created by shipping outbound product via rail road. Balcones supports the Capital Area Council of Governments (CAPCOG) recommendations for expanded Green Building initiatives, expanded reuse and recycling of construction and demolition debris, expanded organic waste diversion programs, and the development of resource recovery parks. All of these policies and programs are consistent with the company's long term vision of resource management and expanded and improved local and regional recycling infrastructure. Balcones has been a pioneer for Zero Waste initiatives in the recycling industry. The company displays their commitment to the City s sustainability and Zero Waste goals by providing waste minimization and recycling services to commercial, multi-family, and institutional entities throughout the City. Outside view of Balcones MRF 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 8

10 System Innovations Ventilation and Air Control Air emissions from this facility do not contribute to air pollution. A custom dust hood system and ducting was installed over the NewSorters and Polishing Screen to capture and filter most of the dust liberated during the screening process. The air is transferred back to a filter system, where the dust will be discharged onto the residue conveyor. Custom dust hood system and ducting Screens The screens are the heart of any MRF system. Effective material separation is the most important step in achieving high recovery rates of clean end products and lower operating costs. By effectively separating the material fractions at the screens all downstream sorters and optical units work far more efficiently. The unique screen discs provide excellent material agitation and separation. An added benefit is that disc changing does not require removal of individual shafts. Screen Wrapping and Cost of Down Time A hidden but significant cost of fiber screening results from screen wrapping. When screens wrap, the openings become blocked, material separation diminishes, and the screen, in essence becomes, a conveyor. In most systems, wrapped material is removed 1-2 hours per shift. This process is difficult and costly. The in-line disc design significantly reduces and, in the case of the Polishing Screen, virtually eliminates wrapping. Glass Screening A large two-deck Debris Roll Screen (DRS) is positioned under the OCC Separator to remove the majority of the glass and fines prior to the NewSorter. The DRS is designed to remove glass and fines without losing valuable single serve containers. Optical sorting technology Optical Sorting Optical technology has significantly improved the performance of single stream systems. To work effectively a clean stream of containers without fiber contamination must be provided to the system. The trishaped disc produces a very clean 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 9

11 container stream and ensures optimal optical performance. 3. Regulatory Compliance Environmental Compliance Balcones MRF has met or exceeded all state and local compliance requirements. Examples of this environmental compliance includes the following: Texas Commission for Environmental Quality Storm Water Protection Texas Commission for Environmental Quality Petroleum Storage Texas Commission for Environmental Quality Material Recovery Facility Permitting Texas Department of Agriculture Scale Certification United States Department of Transportation Registrations Texas Department of Transportation Registrations Travis County Fire Marshall City of Austin Environmental Compliance Supporting Documentation Supporting documentation including a letter from the Texas Commission for Environmental Quality and multiple news articles are included in the supplemental materials section. Regulatory Citations As of May 24, 2013, no regulatory citations have been issued to the Balcones MRF. 4. Planning Design and Effectiveness of the Facility s Planning Process The City of Austin s aggressive Zero Waste plan calls for a 90% reduction in landfilled resources by To get there, the city set a stringent goal of diverting half its waste from landfills by 2015, compared with less than 40% diversion in The team at Balcones recognized that in order to achieve the City s goals, they would need an effective design to achieve the requirements of reliability, performance, cleanliness/safety, durability and flexibility. The quick turnaround time of 364 days from groundbreaking to move-in required a meticulous and thorough planning process. Not only was the MRF constructed on time, but it was also delivered on budget which is a testament to the planning executed by the equipment suppliers, the architects, the contractors and Balcones project manager. Planning Process in Action Austin s residential stream is rather unique. Some 25 to 30% of the city s recyclables are glass, which is almost twice the national average. Efficiently removing all that glass from the paper and containers was paramount to ensure that Balcones maintained its characteristically high level of quality. This requirement was carefully factored into the planning process. The planning team selected screening technology to remove glass on the front end in what is a very efficient, clean process. As a result, the glass products are of superior quality while the purity of the paper and container stream is preserved. Plans to Address System Downtime When Balcones was awarded the contract to process the City of Austin s residential single stream (RSS) material it was an enhancement to the company's on-going business of commercial recycling of office buildings, manufacturers, retail and printing customers. The planning and design of the facility was focused on utilizing the equipment to accommodate these two material streams RECYCLING SYSTEMS EXCELLENCE AWARD 10

12 Per the City of Austin contract, a five-day storage capacity for the RSS material is required. Additionally, it was necessary to layout the tipping floor to accommodate both Commercial Single Stream (CSS) business, high grade paper accounts, and any direct feed material from third party recycling customers. The equipment design and layout incorporated both a MacPresse and Sierra baler to act as backups to one another to ensure uninterrupted baling. The walking floor bunkers under the processing platform are reversible and can feed either baler resulting in an equalized distribution of daily baling activity. With the MacPresse acting as the primary fiber baler, its location proximate to the direct feed fiber tipping floor allows for efficient tipping and baling of the clean OCC accounts and high grade fiber that does not require extensive sorting across the equipment. The Sierra two-ram baler also has a direct feed capability and allows for the efficient processing of high volume industrial plastics and if needed, can serve as a backup to the fiber direct feed tipping activities. The system controls notify plant management when walking floor bunkers are at 75% capacity. This allows for the planned transition from direct feed activities on the balers to a seamless emptying of the walking floors to ensure that there is no downtime associated with emptying these bunkers. During the commissioning of the plant, material streams were analyzed and settings were programmed to control metering bin throughput and system conveyor speeds for four material characteristics; RSS dry, RSS wet, CSS dry, and CSS wet. These baseline settings allow plant management to establish the day s operations and modify the settings as necessary to ensure quality control and optimized processing. 5. Performance, Economics & Cost-Effectiveness Measuring Success Balcones is the largest independent paper recycler in the Southwest. The company does not own or have an interest in a landfill. Balcones' definition of success is to create the highest value from discarded materials by cleaning and processing them for maximum end user yield and diverting as much waste as possible from the landfill. From the time when operations commenced, Balcones has seen increased RSS inbound volumes, increased CSS and Fiber accounts, and a 24% increase in bale production. The facility also processes a glass throughput of 1,000 plus tons per month. Sorting equipment performance has exceeded the goal of 90% average production percentage with the current average production percentage of 92%. The current average operational downtime is 4% and the current average process downtime is 4%. Additionally, the system has been shown to successfully reduce process residue as compared to other City of Austin processors. The Balcones MRF has an average production time of 92% of daily shift operating hours. Balcones processes RSS at a rate of tons per hour with a 22 person sorting team and CSS at tons per hour with a 19 member team. The quality of the end product has been excellent on all grades of material including fiber, plastic, metals, and glass. Waste Screening Procedure When a truck deposits material on the tipping floor the traffic controller assesses the load for contamination. He or she then works with the loader operator to extract any trash or non-recyclable materials. Pictures are taken and relayed to Balcones' collection partners to identify the potential source of the contamination on their route RECYCLING SYSTEMS EXCELLENCE AWARD 11

13 Operational Performance The plant is performing on par with Balcones' original expectation. Technical support and quick response time from the equipment vendor Bulk Handling Systems has allowed the company to troubleshoot and resolve issues before they become major impediments to the processing schedule. Operationally: Balcones operates a single shift Monday Saturday Total inbound tons of all RSS, CSS, direct feed fiber and plastics averages 7,200 tons per month of which 4,000 tons are RSS Residential Single Stream is being processed at 25 (+/-) tons per hour Commercial Single Stream is being processed at (+/-) tons per hour Bale production is averaging 6,000 bales per month Average shift time is 8.6 hours with the average hours of at 8.0, resulting in an average production time of 92% of daily shift operating hours System Downtime and Resolution Downtime averages 8% and is categorized as either Operational or Process, each of which accounts for half the overall percentage. Operational related downtime is primarily due to system clean out, material jams and nonequipment issues. Process related downtime involves mechanical and equipment component issues. The Supervisory Control and Data Acquisition (SCADA) computerized management system monitors all facets of the plant s operations producing management reports that enable the Plant Management Team to analyze Operational and Process related downtime and effectively manage their impact. Well trained and highly skilled Plant Mangers, Supervisors, Maintenance Personnel, along with preventive maintenance, good housekeeping practices and vendor support all lead to an environment where the inevitable downtime situations are handled efficiently and effectively with minimal disruption. Customer Service Throughout Balcones' history, customer education has played a vital role in controlling the waste coming into the plant. Customer education and the working relationships that have been established with the City and 3 rd party recyclers along with the effectiveness of the processing equipment have allowed Balcones to experience approximately 10% residual on RSS and 2-3% residual on CSS. Longstanding relationships with recycling partners have led to very effective communication channels that have allowed Balcones to historically keep contamination to a minimum. In addition, the company's commercial recycling education program works with property managers, janitorial companies and tenants to ensure that the proper materials are collected within the office environment and placed in the appropriate collection containers at each facility. The City of Austin also has an effective curbside recycling collection program along with extensive education campaigns which have gone a long way in communicating to the citizens of Austin the effects of contamination on the community's recycling success. Balcones is currently working towards a partnership with the City of Austin to help meet the Zero Waste Initiative goals as established by the City Council. The company participated in the Master Plan meetings that the City held in July 2009, and actively participate in the monthly City of Austin Zero Waste Advisory Commission meetings (ZWAC), Resource Management Commission and Environmental Board. Currently, Balcones serves on the City of Austin Recycling Ordinance Task Force. System Costs and Operating Budget The system successfully performs as projected. Balcones is able to maintain premium standards for material quality without having to add any supplemental labor beyond what was designed for system usage. Electrical expense per kilowatt hour and maintenance expense per ton are both under budget. Reliable, precise financial 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 12

14 modeling is absolutely critical when considering a project of this magnitude, and the company has been pleased that the system has been able to perform as promised. Recouping Facility Costs Due to the effective planning process, the limited system downtime, the higher than expected production time, and the quality of the materials produced by the system, Balcones is on pace to recoup this investment within the timeframe projected. The importance of the planning process cannot be understated, as this allowed for optimal performance of a system that was built in an extremely tight timeframe. While the investment was significant, it was critical to incorporate each component of the system to facilitate an optimal process and produce a superior product. This investment is not only generating immediate results, but will also provide the long-term outcomes necessary to serve the City of Austin for many years to come. 6. Use of Equipment/Systems & Technologies Equipment Used at the Facility Metering Bin: The Metering Bin is a highly effective method of feeding materials into a processing system. With a variable speed chain belt and a variable speed drum at the discharge end, material flow to the system can be precisely regulated. This is key for maintaining a consistent flow of materials into and throughout the processing system. The bin is complete with a rear door for removal of any bulky items that may inadvertently get loaded into the bin and a side access door for easy cleaning. Metering Bin Metering Bin Benefits: Increases throughput and system capacity up to 20% Provides a consistent material feed into the system Maximizes system sorting and screen efficiency Frees up loader operator to perform other tasks Heavy duty construction maximizes durability and uptime OCC Separator : The OCC Separator automatically separates old corrugated containers (OCC) from mixed recyclables. The uniquely designed and patented OCC Separator provides unmatched separation efficiencies. The in-line, tri-shaped discs impart a bouncing, wavelike action on the material stream, liberating other types of fiber and contaminants from the OCC product. Smaller material falls through the Inter-Face Opening (IFO) between the discs, while the OCC travels up and over the screen deck creating a clean cardboard product. OCC Separator Benefits: Effectively removes OCC from mixed recyclables Increases system throughput in fiber and commingled processing systems In-line discs provide accurate sizing of material, increasing the percentage of OCC recovered and reducing the amount to be manually sorted 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 13

15 Disc design reduces potential for material wrap, reducing downtime Heavy-duty discs ensure long disc life and reduced maintenance NewSorter : The NewSorter screen automatically OCC Separator separates old newsprint (ONP) from mixed paper and rigid containers by using in-line discs. The tri-shaped rubber discs impart a wavelike action into the material stream, liberating containers and smaller fiber from the ONP product. The ONP is conveyed forward while the other objects fall through the screen opening. The unique disc design provides variable Inter Face Opening (sizes), allowing you to fine tune the screen to keep up with changing material streams. The end result: a virtually contaminant-free ONP product ready to meet or exceed paper mill requirements with minimal post sorting. Newsorter NewSorter Benefits: Removes ONP from mixed paper and rigid containers In-line discs provide accurate and adjustable sizing of material, reducing product loss Disc design reduces material wrap, reducing downtime Heavy-duty discs ensure long disc life and reduced maintenance High product throughput Variable speed drives and hydraulically adjustable deck Polishing Screen: This unique polishing screen creates three material fractions: Mixed Fiber, Containers and Fines by using the 2-D and 3-D characteristics of these materials. Paper is conveyed over the screening surface, while containers and other three-dimensional objects roll off the back of the screen and are consolidated for sorting. The fine materials, consisting of bottle caps, dirt, grit and small fiber, fall through the screening surface and are removed from the material stream in order to limit product contamination. The three-sort unit provides an extremely clean container stream, resulting in improved recovery of valuable containers and virtually no loss of fiber to residue. Polishing Screen Benefits: Single piece of equipment to separate paper from containers no air drum separator is necessary with a Polishing Screen In-line discs virtually eliminate material wrapping, resulting in reduced downtime, enhanced safety and extended screening efficiency Longest disc wear in the industry Polishing Screen NRT MultiSort IR: This advanced plastic bottle sorting system is designed to separate specific polymers from a mixed stream of material. The separation is independent of color and depends only upon polymer type. This rugged piece of equipment is designed for 24/7 plastic bottle sorting. The MultiSort IR offers a proven, efficient and extremely precise solution for distinguishing and ejecting one type of material. NRT MultiSort IR Technology NIR identification of specific polymer type In-Flight Sorting enables use of transmissive detection for robust signal Proprietary infrared sensing technology and algorithms for rapid detection 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 14

16 Self-cleaning infrared sensing system Easy-to-use color touch screen graphic control panel NRT In-Flight Sorting: NRT s unique In- Flight Sorting technology separates NRT from the rest. While other companies detect material over the belt and eject some time later, NRT offers In-Flight Sorting, which detects and ejects material in flight. This greatly reduces error caused by material moving on the conveyor belt between detection and ejection, and also eliminates interference. By detecting in flight, the detection units do not get confused by the conveyor belt, or labels that may be sticking to it. This results in the industry s leading purity and hit rates among optical sorters. NRT In-Flight Sorting NRT SpydIR : This advanced infrared sorting system separates numerous selected polymers from a mixed stream. It uses proprietary technology and fast, highly sensitive algorithms to rapidly identify unique polymer signatures from their infrared spectra. NRT SpydIR Technology NRT SpydIR Technology: NIR identification of multiple polymer types In-Flight Sorting enables use of transmissive detection for robust signal Proprietary infrared sensing technology and algorithms for rapid detection Self-cleaning infrared sensing system Easy-to-use color touch screen graphic control panel Glass Cleanup System: This system is designed to remove shredded fiber, dirt and debris from a 2-1/2" (-) broken glass product. The system consists of a vibratory screen, aspirator, combi-separator and dust filter. The precise air separation delivers a marketable glass product and in most cases, the shredded fiber can be reclaimed with the combi-separator and added to a mixed paper product. Efficiency and Effectiveness of Equipment The City of Austin residential single stream material composition represents a unique blend among municipal collection programs due to the high volume of glass that is generated. The Glass Cleanup System has proven itself to be highly effective in removing this abrasive and abundant material. The Eddy Current Separator, NRT Multisort IR and NRT SpydIR optical sorters have proven to be so efficient and effective that when the Commercial Single Stream blend is run, it is not necessary to man these QC Glass Cleanup System 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 15

17 stations, and staff may be assigned to other processing activities. Staffing for the Residential Single Stream processing consists of 22 sorters stationed as follows: Pre-Sort Stations 6 HDPE (N & C) hand sort 2 NEWS Sort Line 6 Aluminum CQ 1 MXP Sort Line 4 PET QC 1 Container Line Pre-Sort 1 #3-7 QC 1 The January 26 th, 2013 composition study for the COA was as follows: ONP 25.01% HDPE - Color 0.91% MXP 13.13% Tin/Bi-metal 2.17% OCC 12.80% UBC 0.98% PET 3.05% Scrap Metal 0.43% Plastics # % Glass 27.66% HDPE - Natural 1.08% Residual 10.76% Total 100% 7. Worker Health & Safety Employee Training Frequency and Topics Balcones is committed to creating a safe working environment. The company has a full-time safety manager and actively participates in a voluntary compliance program managed by the State of Texas in coordination with OSHA. Balcones has been repeatedly recognized in the OSHA Safety and Health Achievement Recognition Program (SHARP) as an exemplary facility and is working to achieve this status at the Balcones MRF in Austin in 2014, which is the first year of eligibility for this new facility. Balcones created an in-house safety training program resulting in dramatic reduction in on-the-job injuries. Company-wide safety meetings are conducted on a monthly basis, along with facility inspections. The safety team is comprised of a team of managers who complete meetings and inspections as a group. This team meets weekly to discuss outstanding issues and concerns, and empower all employees to be responsible for a safe working environment. The company is committed to maintaining a safe work environment for all employees. Balcones has developed and implemented safety-training programs with adherence to OSHA standards and procedures for employees including, but not limited to an Injury, Illness, and Prevention Program (IIPP), Emergency Response Program, Hazardous Communication Program, first-aid instruction for all managers and supervisors, proper signage of safety hazards, blood borne pathogens, confined spaces, asbestos, respirator protection, hearing protection, personal protective equipment, radiation, fire prevention, vehicle and equipment operations, welding and machine guarding, and fall protection. All safety trainings and meetings are conducted with Spanish language translators and English and Spanish handouts are provided. At Balcones, all employees are empowered to create and maintain the safest work environment possible RECYCLING SYSTEMS EXCELLENCE AWARD 16

18 Safety is an essential aspect of all Balcones operations. Each employee in the MRF undergoes both initial and ongoing extensive safety training. Topics such as hazardous waste identification, traffic control, appropriate customer conduct, clear understanding of operational flow on the site and in the MRF, and other related and required safety topics is provided. Initial training is conducted using classroom, video, and job shadowing strategies before an employee is allowed to work in the MRF or scale house. Regular ongoing training is also conducted including monthly safety meetings, regular tailgate meetings to address specific topics, and other topics as necessary. All employees are provided with and required to wear high-visibility protective safety equipment. Injury Rates The current experience modifier is.85 company-wide. Safety Policy and Enforcement Balcones is committed to the consistent implementation and enforcement of the safety policy. The safety policy includes procedures regarding the stacking, handling, processing, and storage of material. These rules are enforced by the Team Leaders, Shift Supervisors, Operations Manager and General Managers of Balcones. Penalties for deviation from these procedures result in a disciplinary action and up to and including termination of employment. Operation of Balers/Compactors: Only trained employees are allowed to use baling/compacting equipment. Team Leaders train all new employees on safe procedures. Under no circumstances and at no time should any employee place any body part inside the baler/compactor when equipment is operating or energized. Lock Out/Tag Out (LOTO) procedures must be observed if it becomes necessary to access the equipment. This includes cleaning the equipment. Safety devices installed on the January February March April May June July August September October November December Balcones Safety Training Calendar LOTO Program Review & Inspection Record Hazard Communications Policy Emergency Response Plan Tornado Safety Training Bale Stacking Policy Compresses Air Cleaning Policy Electrical Safety & Awareness Fire Prevention Plan Fire Evacuation Plan Fire Drill & Documentation Heat Stress Proper Hydration Heat Index Poster Welding Training & Hot Work Permit Review Compressed Gas Cylinder Training Confined Space Entry Hearing Protection Review, Training & Testing PPE Training & Review Proper Handling of LP Gas Tanks Safety Policy Review Forklift Training Forklift Driver Safety Policy Review Fire Drill & Documentation Safe Lifting Techniques Slips, Trips & Falls Empty Skids & Pallets equipment may not be altered in any way. Any alteration is considered a blatant disregard for the safety policy and immediate termination will result. Lock Out/Tag Out Procedures: If it becomes necessary for a qualified employee to enter equipment, the LOTO procedures must be followed. Employees are instructed to refer to the Balcones Safety Manual for a complete description of these procedures. Any equipment with an electrical source must be cut off at the disconnect box and lock/tag must be placed on the disconnect. This lock must be locked and the key placed inside the pocket of the individual entering the equipment. When the individual completes the maintenance and returns to the area of the disconnect box, he or she may check the equipment first and then remove the lock and turn the power back to the on position. If the maintenance require two or more persons to enter the equipment, one lock per person should be placed on the disconnect box. For instance, if four people enter the compactor hopper, four locks must be placed at the disconnect when it is in the OFF position. The key should remain with each individual while they 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 17

19 are inside the equipment. If no locks and/or keys are available in an area, employees are directed to ask a Team Leader or Shift Supervisor for a lock before entering the equipment. Forklift Operations: Only licensed forklift operators operate forklifts. At no time may anyone without a license operate a forklift, even if for a short distance. All Balcones forklift drivers attend training and wear the forklift badge/certificate at all times. Balcones forklift drivers operate forklifts according guidelines set forth in the training. Bale Stacking, Handling, and Storage: Bales are inspected by the baler operator and by forklift drivers as bales exit the baler. Bales are checked for proper number of wire ties and bales not meeting standards are repaired or reprocessed immediately. Bales are inspected by the baler operator/forklift driver for density. An acceptable bale is shaped in a rectangular form with uniform edges and feels solid to the touch. Any bale known or suspected to not meet standards are rejected and reprocessed immediately. Bales are stacked in a safe manner. Bales are not stacked more than three high. No exceptions may be made. Bales not meeting above standards may not be placed in the stacks for any reason and are immediately placed back for reprocessing. Personal Protection Equipment (PPE): Depending upon the job description, supervisors instruct employees on their required PPE. This is required to begin work and must be worn at all times during the shift. An employee is not be allowed to work until PPE is in place. Repeated violators are subject to termination. Injury Reporting Policy: Any injury that occurs at work must be reported to the Operations Manager before the end of shift. Even if an injury does not seem significant, it must be reported so that the necessary care can be given. It is clearly communicated to employees that it is very important that all injuries are reported immediately and that on-the-job injuries are not a reason for termination. However, failure to disclose complete details regarding an injury may be reason for discipline or termination. Violations of Safety Policy: A violation of the safety policy results in one written warning. Subsequent violations by the same individual result in immediate termination. Any violations that are an attempt to bypass safe-guards or safety switches result in immediate termination without warning. 8. Public Acceptance, Appearance & Aesthetics Maintenance Program Balcones is known for its high level of attention to maintaining a clean operating environment in order to produce the highest quality material for end users and to provide an optimal work environment for employees. A key component of the maintenance program is the innovative dust collection system that prevents accumulation on outbound materials. Balcones also implements a consistent cleaning process as part of normal operations. At the end of each shift, each member of the warehouse team has an assigned area both on the equipment platform and the floor area that they are responsible for sweeping and policing to prepare for the next day. The shafts of the OCC, NEWS and Polishing screens are cleaned at the end of each shift along with the metering drum. This prevents the build-up of material that reduces the effectiveness of the screening equipment. A deep-clean is completed on a quarterly basis where the entire plant is shut down and cleaned thoroughly. The company has an in-house maintenance team that performs all maintenance activities associated with the equipment at pre-planned intervals. Everything from daily oiling of the machinery to periodic disc replacement to unplanned mechanical issues are integrated into the maintenance planning schedule to keep the equipment operating at peak performance. Balcones takes great pride in the company's corporate image and this is exemplified through the staff s commitment to the maintenance and cleanliness of facilities, equipment and vehicles RECYCLING SYSTEMS EXCELLENCE AWARD 18

20 Public Relations Measures and Public Education Information Public Education and Outreach Balcones believes that public involvement is key to reducing the City s waste. The MRF is a state-of-the-art, recycling facility that diverts and processes valuable resources for their highest and best use. Through consistent training of customers and a highly efficient sorting/processing technology and equipment, Balcones is able to maximize the recovery of recyclables and provide a consistent product to end market consumers. The MRF site was purposefully planned in a way that would contribute to the City of Austin s Zero Waste goal to educate, promote and advocate recycling and reuse. The site was built to include classrooms for use by Balcones, the City of Austin, and the general public for educational presentations and seminars. In addition, Balcones has partnered with EcoRise to develop and deliver educational materials and workshops designed to connect and inform communities about waste, recycling and environmental stewardship. With a customized program centered on 21st century skill development, EcoRise works with school teachers to introduce youth to sustainable living practices and engage students in solving real-world problems affecting their schools and communities. This proven educational tool is offered for use in the public and private schools in Austin. The lesson plans are designed to be compatible with the State education curriculum requirements. Raise Awareness The EcoRise educational program informs and engages residents of new waste and recycling initiatives adopted by the city, building a common understanding of how it works and appropriate recycling practices. Impact: 75% of students shared information with their friends & family - creating a trickle-down effect Change Behavior EcoRise educational materials emphasis real-world application of knowledge, challenging students to conduct waste audits and develop solutions to improve their recycling practices at home and at school. Impact: 97% of EcoRise participants adopt sustainable living practices Train Young Leaders The EcoRise program delivers both short-term and long-term impacts by cultivating a generation of young adults who understand the value of environmental stewardship and the importance of individual behavior change. By placing students at the center of waste management, they share this knowledge with friends and family and champion the city's new recycling initiatives on campus and at home. Impact: 81% of the students feel empowered to lead change in their community Balcones MRF: A Good Neighbor Living Wage Jobs The Balcones MRF is located in Travis County in a Census Tract that is an SBA Designated HUB Zone where 30.3% of households in the surrounding community live below the poverty line. The median family income in the surrounding community ($33,750) is 29% lower than the statewide median family income. More than 80 employees currently employed at the MRF and approximately new living wage jobs were created after this project was brought online in the summer of With addition of 2nd shift, 15 additional jobs will be created. Proven History Balcones understands the importance of local companies partnering with the City and others to preserve precious resources and to improve the quality of life for all Austin residents. The company has a proven history of investing in the Austin community. In 1996, Balcones built a recycling facility at 2416 E. 6 th Street. Many of the 31 jobs created were filled by low income residents that lived in East Austin neighborhoods RECYCLING SYSTEMS EXCELLENCE AWARD 19

21 Community Involvement Balcones believes that public involvement is key to reducing the City s waste and is actively involved in the Austin community. Balcones and its Principals have helped raise funds and provided sponsorships to the numerous organizations. Balcones staff are members of The Lady Bird Johnson Wildflower Center, the Hillcountry Conservancy, Keep Austin Beautiful, National Recycling Coalition, Institute of Scrap Recycling Industries (ISRI), and Capital Area Corporate Recycling Council. Kerry Getter, Balcones CEO, was a founding member of the Corporate Recycling Council of Texas. Balcones has sponsored recycling programs for non-profit organizations like Keep Austin Beautiful and schools in the Austin Independent School District. Balcones provided free consulting services to the Wildflower Center for their work in achieving Gold Status in the LEED Certification. The company is an active member in the Greater Area Chamber of Commerce and the Real Estate Council of Austin. Art in Public Places As a locally-owned company, Balcones understands the importance of Austin s Art in Public Places program and its enhancement to the community. The company supports the City s integration of public displays of art into community landmarks and architecture. As the City's processing provider, Balcones committed to allocating 2% of the MRF construction budget to the program and developed the Balcones Burner Bash, a graffiti art competition to benefit the Lady Bird Johnson Wildflower Center. Balcones Burner Bash graffiti art Awards and Recognition Balcones is very proud of having been recognized for the following awards and accomplishments: 2013 Austin Business Journal Commercial Real Estate Awards "Industrial Development" Winner 2012 Waste Age Equipment Color and Design Award Finalist for the 2012 UIL Development of Distinction Awards Ernst & Young Entrepreneur of the Year, (twice a finalist) Named as one of Top 100 Recyclers in the U.S. and Canada by Waste News National Recycling Coalition Award for Outstanding Environmental and Community Leadership Named by Austin Business Journal as one of 25 Faster Growing Businesses in Austin Supplemental Materials The following links may be used to view videos of the Balcones MRF and the Balcones Burner Bash. Balcones MRF Video: Balcones Resources in Austin - YouTube Balcones Burner Bash Video: Balcones Burner Bash YouTube 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 20

22 Supplemental Materials 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 21

23 Supplemental Materials 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 22

24 Supplemental Materials 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 23

25 Supplemental Materials 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 24

26 Supplemental Materials BALCONES RESOURCES INC.'S MATERIAL RECOVERY FACILITY WAS BUILT ON AN EXISTING ACRE SITE, WHICH WAS A FORMER TRAVIS COUNTY PRECINCT MAINTENANCE FACILITY. IN APRIL 2011, THE CITY OF AUSTIN AWARDED BALCONES RESOURCES A 20-YEAR CONTRACT TO PROCESS 60 PERCENT OF RESIDENTIAL CURBSIDE RECYCLING MATERIAL. THE ROUGHLY $25 MILLION PROJECT CONSISTED OF FOUR BUILDINGS, TWO OF WHICH ARE NEW. THE TWO EXISTING BUILDINGS WERE RENOVATED AS A 6,489- SQUARE-FOOT CORPORATE OFFICE BUILDING AND A 4,200-SQUARE-FOOT MAINTENANCE BUILDING WITH AN EMPLOYEE BREAK ROOM. THE NEW CONSTRUCTION INCLUDED A 97,505-SQUARE-FOOT PROCESSING BUILDING AND A 4,572-SQUARE-FOOT OPERATIONS OFFICE. PROJECT TEAM: ARCHITECT: ARCON ARCHITECTS, BUYER BROKER: STREAM REALTY, CIVIL ENGINEER: BURY+PARTNERS, FINANCIER: PLAINSCAPITAL BANK, GENERAL CONTRACTOR: KINGHAM DALTON WILSON, LTD. (KDW) - DESIGN/BUILD, LAW FIRM: SMITH+ROBERTSON, LEAD DEVELOPER: BALCONES RESOURCES, INC., SELLER BROKER: NAI COMMERCIAL INDUSTRIAL PROPERTIES, TITLE COMPANY: STEWART TITLE 2013 RECYCLING SYSTEMS EXCELLENCE AWARD 25