Recycling Equipment Design

Understanding the Growing Demand for Recycling Equipment in Atlantic Canada

The recycling industry across Atlantic Canada is experiencing unprecedented growth, driven by increasingly stringent environmental regulations, rising landfill costs, and a collective commitment to sustainable resource management. For municipalities, waste management companies, and industrial facilities throughout Nova Scotia and the Maritime provinces, investing in properly designed recycling equipment has become not just an environmental imperative but an economic necessity.

Modern recycling equipment design requires a sophisticated understanding of material science, mechanical engineering principles, and the specific waste streams prevalent in our region. From the fish processing plants along the Bay of Fundy to the forestry operations in Cape Breton, each industry presents unique challenges that demand customised engineering solutions. The design of effective recycling equipment must account for throughput requirements, material characteristics, space constraints, and the harsh environmental conditions common to our Atlantic climate.

At its core, recycling equipment engineering involves creating systems that efficiently separate, process, and prepare materials for reintroduction into the manufacturing supply chain. This encompasses everything from simple sorting conveyors to complex integrated material recovery facilities (MRFs) capable of processing hundreds of tonnes of mixed waste daily.

Key Components of Modern Recycling Equipment Systems

Material Handling and Conveyance Systems

The foundation of any recycling operation lies in its material handling infrastructure. Conveyor systems designed for recycling applications must withstand abrasive materials, variable loads, and continuous operation cycles that often exceed 16 hours per day. Belt conveyors typically range from 600mm to 1,800mm in width, with speeds carefully calibrated between 0.3 and 1.5 metres per second depending on the sorting requirements and material density.

For Atlantic Canadian facilities dealing with wet or frozen materials during our extended winter months, conveyor design must incorporate features such as heated rollers, moisture-resistant bearings, and corrosion-resistant frame materials. Stainless steel or hot-dip galvanised components are essential for longevity in our maritime environment, where salt air can significantly accelerate equipment degradation.

Sorting and Separation Technologies

Effective material separation represents the most technically demanding aspect of recycling equipment design. Modern facilities employ multiple separation technologies in sequence:

• Trommel screens – Rotating cylindrical drums with varying aperture sizes (typically 50mm to 200mm) that separate materials by size, processing up to 100 tonnes per hour in larger installations

• Eddy current separators – Electromagnetic systems that eject non-ferrous metals such as aluminium and copper, achieving recovery rates exceeding 95% for properly prepared material streams

• Optical sorting systems – Near-infrared (NIR) sensors that identify and separate plastics by polymer type, operating at speeds up to 3 metres per second with accuracy rates above 90%

• Air classifiers – Pneumatic systems that use controlled airflow to separate light materials (paper, film plastics) from heavier fractions

• Magnetic separators – Both overhead and drum-style magnets for ferrous metal recovery, with field strengths ranging from 800 to 4,000 gauss depending on application requirements

Size Reduction Equipment

Shredders, granulators, and crushers form the backbone of material processing operations. Industrial shredders for municipal solid waste typically feature dual-shaft designs with hardened steel cutters, producing output sizes between 50mm and 300mm depending on downstream processing requirements. These machines must handle significant torque loads, with drive systems ranging from 75 kW for smaller units to over 500 kW for high-capacity installations.

Glass crushing equipment, particularly relevant for Nova Scotia's beverage container recycling programmes, requires specialised engineering to manage the abrasive nature of the material while producing consistently sized cullet suitable for manufacturing applications. Typical specifications call for output sizing of 10mm or less, with throughput capacities of 5 to 20 tonnes per hour for regional processing facilities.

Design Considerations for Maritime Climate Conditions

Engineering recycling equipment for Atlantic Canadian operations presents unique challenges that mainland designs often fail to address adequately. The combination of high humidity, salt air exposure, significant temperature variations (from -25°C to +35°C annually), and frequent freeze-thaw cycles demands robust design approaches.

Corrosion Protection Strategies

Equipment frameworks should specify minimum coating requirements of 85 microns for epoxy primers followed by 60-75 microns of polyurethane topcoat for outdoor installations. Critical components benefit from duplex coating systems combining hot-dip galvanising with paint systems, providing corrosion protection exceeding 25 years in coastal environments. Fasteners should be specified as A4 (316) stainless steel or hot-dip galvanised Grade 8 to prevent premature failure.

Cold Weather Operations

Hydraulic systems require careful specification for cold weather performance, with fluid selections rated for pour points below -40°C. Electric motor sizing must account for increased starting torque requirements when operating at low temperatures, typically requiring a 15-20% safety factor above calculated loads. Enclosed electrical panels should incorporate thermostatically controlled heaters to prevent condensation and maintain reliable control system operation.

Material handling systems processing organic waste or wet recyclables must incorporate design features that prevent freezing and material adhesion during winter months. This includes provisions for heated hoppers, steam cleaning connections, and polymer liners in areas prone to material buildup.

Regulatory Compliance and Safety Engineering

Recycling equipment operating in Nova Scotia must comply with multiple regulatory frameworks, including the Nova Scotia Environment Act, Canadian Standards Association (CSA) requirements, and Occupational Health and Safety regulations. Design engineers must integrate these requirements from the earliest project stages to avoid costly retrofits.

Environmental Compliance

Material recovery facilities require careful attention to dust control, with baghouse filtration systems typically specified for air-to-cloth ratios between 4:1 and 6:1 depending on dust characteristics. Leachate collection systems must be engineered to handle peak flow events while meeting discharge limits specified in facility permits, often requiring treatment capacities of 50 to 200 cubic metres per day for medium-sized operations.

Noise emissions represent another critical design consideration, particularly for facilities near residential areas. Equipment specifications should target sound power levels below 85 dBA at one metre, with acoustic enclosures or barriers engineered to achieve property line levels compliant with municipal noise bylaws, typically 55 dBA during daytime hours and 45 dBA at night.

Worker Safety Systems

Modern recycling equipment design places worker safety at the forefront. Essential safety features include:

• Emergency stop systems – Hard-wired circuits providing response times under 500 milliseconds, with clearly marked pull cords along conveyor lengths at maximum 30-metre intervals

• Machine guarding – Fixed and interlocked guards meeting CSA Z432 requirements, with proper clearances for all pinch points and rotating equipment

• Lockout/tagout provisions – Standardised isolation points for all energy sources, with clear identification and adequate working space for maintenance procedures

• Ergonomic design – Sorting station heights between 850mm and 1,050mm, conveyor speeds limited to 0.3 metres per second for manual picking operations, and adequate lighting levels of 500 lux minimum at work surfaces

Integration with Existing Infrastructure

Many recycling equipment projects in Atlantic Canada involve upgrading or expanding existing facilities rather than greenfield construction. This requires careful engineering assessment of existing infrastructure capacity, including structural loading, electrical supply, and site constraints.

Structural Considerations

Existing building floors must be analysed for their ability to support new equipment loads. Trommel screens, for example, may impose dynamic loads of 50 to 150 kN depending on size and operating speed. Concrete slab thickness of 200mm minimum with appropriate reinforcement is typically required for heavy processing equipment, and existing floors often require strengthening or the installation of independent foundations.

Electrical Infrastructure

Modern recycling facilities demand significant electrical capacity. A medium-sized MRF processing 100-150 tonnes per day typically requires 500-750 kVA of connected load, with motor control centres designed for variable frequency drive (VFD) operation to optimise energy consumption. Power factor correction equipment should target values above 0.95 to minimise utility demand charges, which represent a significant operational cost for Maritime facilities.

Control system architecture should employ programmable logic controllers (PLCs) with network connectivity for remote monitoring and diagnostics. This capability proves particularly valuable for facilities in rural Nova Scotia communities, enabling rapid troubleshooting support without requiring immediate on-site presence.

Emerging Technologies and Future-Ready Design

The recycling industry continues to evolve rapidly, and equipment designs must accommodate future technology integration to protect capital investments. Several emerging technologies warrant consideration in current design projects.

Artificial Intelligence and Machine Learning

AI-powered sorting systems using machine vision and robotic picking arms are becoming increasingly cost-effective for medium-scale operations. These systems can achieve picking rates of 60-80 items per minute with contamination rates below 5%, representing significant improvements over manual sorting. Design provisions should include adequate floor space, structural capacity, and utility connections for future robotic installation.

Advanced Sensor Technologies

Hyperspectral imaging and X-ray fluorescence systems enable sorting capabilities impossible with conventional optical systems, including identification of black plastics, multi-layer packaging, and specific metal alloys. While current capital costs limit adoption, prices continue to decline, making design provisions for future sensor integration a prudent investment.

Digital Twin Technology

Creating digital representations of recycling equipment systems enables predictive maintenance, performance optimisation, and operator training without disrupting production. Modern equipment designs should incorporate adequate sensor provisions and data connectivity to support digital twin development as this technology matures.

Economic Considerations and Return on Investment

Recycling equipment represents a significant capital investment, with complete material recovery facilities ranging from $2 million for smaller regional operations to $20 million or more for large-scale provincial facilities. Engineering design decisions directly impact both capital costs and long-term operational economics.

Key factors affecting project economics include:

• Throughput capacity – Proper sizing prevents both underutilisation of capital investment and capacity constraints that limit revenue potential

• Material recovery rates – Each percentage point improvement in recovery directly impacts revenue, with typical commodity values ranging from $100/tonne for mixed paper to $2,000/tonne for sorted aluminium

• Energy efficiency – Variable frequency drives, regenerative braking, and optimised motor sizing can reduce energy consumption by 20-30% compared to conventional designs

• Maintenance requirements – Design for maintainability reduces downtime and labour costs while extending equipment service life beyond the typical 15-20 year planning horizon

• Labour optimisation – Automation of hazardous or repetitive tasks improves worker safety while reducing operating costs

For Nova Scotia facilities, additional economic factors include transportation costs to end markets (often located in central Canada or export destinations), seasonal volume variations, and the availability of qualified maintenance personnel. These regional factors must inform design decisions to ensure economically sustainable operations.

Partner with Experienced Engineering Professionals

Successful recycling equipment projects require engineering expertise that spans mechanical design, electrical systems, process engineering, and regulatory compliance. The unique challenges of Atlantic Canadian operations demand familiarity with our regional climate conditions, regulatory environment, and industry landscape.

Sangster Engineering Ltd. brings decades of professional engineering experience to recycling equipment projects throughout Nova Scotia and the Maritime provinces. Our team understands the technical requirements of modern material recovery systems and the practical realities of operating in our Atlantic Canadian environment. From initial feasibility studies through detailed design, construction support, and commissioning, we provide comprehensive engineering services that deliver reliable, efficient, and compliant recycling equipment installations.

Whether you're planning a new material recovery facility, upgrading existing equipment, or seeking to improve the performance of your current operations, contact Sangster Engineering Ltd. to discuss how our expertise can support your recycling infrastructure objectives. Our Amherst office is conveniently located to serve clients throughout Nova Scotia, New Brunswick, and Prince Edward Island with responsive, professional engineering services.

Partner with Sangster Engineering

At Sangster Engineering Ltd. in Amherst, Nova Scotia, we bring decades of engineering experience to every project. Serving clients across Atlantic Canada and beyond.

Contact us today to discuss your engineering needs.