E Executive Summary

Republic Services’ North Texas Recycling Complex 2014 Excellence Recycling Systems Award Entry

EXECUTIVE SUMMARY

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E Executive Summary

Located in the historic Garden of Eden community in Fort Worth, Texas, Republic Services’

North Texas Recycling Complex handles single-stream materials collected from more than

350,000 households in communities around the Dallas-Fort Worth area, including Tarrant,

Dallas, Collin, Denton, Parker and the surrounding counties. The MRF also processes

single-stream recyclables from commercial entities in the area.

Republic Services’ state-of-the-art MRF is LEED-certified and features a sorting system

designed and built with The CP Group. The system, which had its grand opening in Sep-

tember 2013, provides maximum flexibility to process a high volume of both residential

and commercial loads and is capable of processing at least 35 tons per hour of residential

single stream material, and 20 tons per hour of commercial and industrial recyclable

material. The plant was designed to recover 95% of the targeted recyclable materials

going through the sorting system, and it is achieving that goal.


Design of the Recycling System

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1 Design of the Recycling System

Republic Services’ North Texas Recycling Complex, a brand-new, 90,000-square-foot facility, handles

single-stream collected materials from residential and commercial entities in the Dallas-Fort Worth area.

Owned and operated by Republic Services, the MRF is capable of processing 35 tons per hour, or more

than 140,000 tons of material every year.

North Texas Recycling Complex was designed to process recyclable material including plastics marked 1 through

7, paper products, cardboard, glass, aluminum, and other materials. The material mix is approximately 60 percent

fiber and 30 percent containers, by weight. The system was custom-engineered, manufactured and installed by

the CP Group, based out of San Diego, California. Republic Services and CP worked together closely on this project

to transform this recycling system from concept to reality.

From its inception, this system was designed to be a future dual line system. As more capacity is required,

additional presort and disc screening can be added with minimal restructuring of the existing equipment, reducing

future system downtime and cost.

The flexibility and design innovation of this unique system include the following features and components:

The plant is equipped with two balers at opposite ends of the storage silos (for metal cans and plastic bottles) and bunkers (for paper). A reversing transfer conveyor fed by the can and bottle storage silos runs between the two baler feed conveyors, allowing the operator to bale cans and bottles with either baler. Reversible floor conveyors and doors at each end of the paper storage bunkers allow cardboard and paper to empty onto either baler feed conveyor.

A large screw auger on top of each storage silo continuously rotates, leveling the material as it drops into the silo. Shuttle conveyors above the paper storage bunkers serve the same function. This leveling action allows the silos and bunkers to be filled completely, greatly increasing plant storage capacity within the available silo/bunker volume. Photo eyes signal to the operator when each storage silo or bunker is 80% and 100% full and the status of silo/bunker doors.

The system includes three new CIRRUS™ optical sorting units. The first two Cirrus units recover HDPE and PETE plastics from the materials passing through them. The third CIRRUS™ unit, added in partnership with the Carton Council, recovers remaining #3-7 mixed plastics, cartons and aseptic containers, and performs a quality control check on the PETE sorted by the second unit for automated contamination removal. Steel and aluminum are removed before the plastics are conveyed to the optical sorters, thinning the material flow through them to allow greater sorting accuracy and recovery of the targeted plastics.

The facility houses a permanent Drum Magnet for steel can and other ferrous material recovery, vs. the “industry norm” suspended cross-belt electromagnet in most single stream plants. The Drum Magnet has lower maintenance requirements, is more reliable and uses less power than a cross-belt electromagnet.

There are multiple Film Vacuum hoods for collecting and transferring plastic film hand picked off the sorting

stations. The Film Vac is unique because it uses an internal ‘jetcone’ hood designed to re-use its own air as a

closed loop operation to minimize operational noise levels. The Film Vacuum transfers material to the patent-

pending Screw Compactor, a large auger that presses the plastic film into long tubes similar to the way a

sausage maker stuff sausages. These long tubes allow plastic film to be stored and handled much more

efficiently, with less mess, than loose collection and storage.



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STEP-BY-STEP LOOK AT EQUIPMENT USED AT THE FACILITY

As the mixed material arrives at the facility it is dumped from the trucks onto the tipping floor. From there,

state-of-the-art equipment conveys, processes, sorts, separates and bales the material so it can be resold and

given a new life in new products.

1. Drum Feeder: Material begins its journey through the facility by being loaded into a metering bin that consist

of a feed conveyor and drum feeder to load the system with material. The drum feeder features a heavy-duty

rotating drum with fixed paddles to tear open bags and provides a consistent flow of material to the system to

maximize efficiency and throughput.

The material then moves to the pre-sort conveyor, where large pieces of rigid plastics, metals and trash are pulled

out of the material stream to protect the system from damage and maximize the efficiency of processing and

sorting equipment.

2. Film Vac: Plastic films, such as grocery bags, are hand-picked and transported away by the Film Vacuum System

to the patent-pending Film Screw Compactor.

3. Film Screw Compactor: The Film Screw Compactor extrudes the plastic film into long tubes of plastic film, similar

to a sausage maker. The pre-compressed tubes of film can then be stored and baled at a later point in time.

4. OCC Disc Screen: Mechanical sorting plays an important role in the facility, starting with a series of patented

disc screens to separate material by size and shape. The first disc screen in the process is the OCC Screen, which

removes cardboard from the rest of the stream. The OCC Screen uses large serrated offset steel discs that rotate

and propel the cardboard forward. The elliptical disc pattern provides additional lateral agitation to liberate other

1. Drum Feeder

2. Film Vac

3. Film Screw Compactor

4. OCC Disc Screen

5. Glass Breaker Disc Screen (underneath OCC Disc Screen)

6. Zigzag

7. CP NEWScreen™ (2)

8. CPScreen

9. Drum Magnetic

10. Eddy Current Separator

11. CIRRUS Optical Sorters (3)

12. Two-Ram and Single-Ram Baler



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material, leaving the OCC end-product well sorted and highly marketable. All other materials such as smaller fiber

and containers fall through the openings and go on to the next screening step.

5. Glass Breaker Disc Screen: The second disc screening process removes all glass and small pieces of material,

known as “fines”. The Glass Breaker Disc Screen uses durable cast chromium elliptical discs that don’t wear out.

These heavy duty spinning discs break all glass and separate it from fiber and containers at maximum efficiency,

without losing any aluminum or other valuable commodities.

6. Zigzag Air Separator: The broken and screened out glass has one more processing step to go through before

becoming a saleable product. The Zigzag Air Separator is a fully adjustable cascade cleaning solution designed to

efficiently remove unwanted lightweight materials, such as small shreds of paper and plastics out of the heavier

glass. Differences in particle shape and weight allow the lighter material to be lifted up by an air stream and

transported off, leaving the heavier material, such as glass, to fall to the bottom, ensuring minimal loss of valuable

recyclable material.

7. CP NEWScreen: After the fines and glass are removed from the main stream, the remaining material, mainly

containers and fiber, are conveyed to the next disc screening process in the system: There are two NEWScreens

in this system due to the high throughput requirements. They are engineered to effectively separate larger fiber

from mixed paper and containers. The patented finger-disc technology pulls the large fiber over the top and

bounces containers and small fiber back off its bottom end.

8. CPScreen™: While the large fiber makes its way over to the inspection stations, the small fiber and containers

continue along to the CPScreen™, where mixed paper is sorted from containers. The long-lasting rubber cam-style

discs of the CPScreen™ feature small screen openings and are specially engineered to minimize loss of fiber to the

containers, recovering even the smallest pieces of paper.

To ensure that the containers are free of any small contaminants, they pass through one additional sorting step,

the Air Knife Separator. The Air Knife Separator eliminates light materials from the material stream, such as

shredded paper and foil.

Now that all of the paper has been captured and small debris have been eliminated, all that is left in the material

stream are mixed containers, such as single serve water bottles, tin and aluminum cans, milk jugs, detergent

bottles and various other types of plastics.

9. Drum Magnet: At this point it is time to separate the steel cans from the rest of the containers. The steel comes

into close contact with the Drum Magnet, a large rotating drum that magnetically attracts the steel to it, and pulls

it over the top. The rest of the material falls onto a conveyor that takes the remaining material to the Eddy Current

Separator.

10. Eddy Current Separator: As aluminum cans or other non-ferrous metals pass over the head pulley of the Eddy

Current Separator, an alternating electro-magnetic field creates eddy currents that repel the aluminum cans away

from the plastics, generating a clean aluminum fraction.

At this point in the process, cardboard, mixed paper, glass, aluminum, steel and small residue have been removed

and all that’s left are mixed plastics.



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11. CIRRUS Optical Sorters: The mixed plastics now travel to the most high-tech and fastest separation machines

in the plant: the 3 MSS CIRRUS optical sorters. These automated sorting units use advanced high-resolution, Near-

Infrared and color sensors for the ultimate separation performance for plastics. Advanced identification

algorithms and precise air jets separate the plastic by type and by color. The first CIRRUS unit ejects all HDPE, the

milk jugs and detergent bottles. The second CIRRUS sorts out all PET, the soda and water bottles. And finally, the

third CIRRUS automatically separates the beverage cartons as well as any mixed plastics. All of the plastics are

now separated by type and color.

12. Silos and Balers: After each material is separated throughout the process, they are conveyed to huge bunkers

where they are stored until baling. These bunkers have specially designed electronic eyes to tell the operator

when they are full and ready for baling. A large rotating screw augur across the top of the bunker evens material

out in the bunker to maximize storage space. When a bunker is full and a material is ready for baling, the operator

receives a signal, the respective bunker door is opened and the material falls onto the baler feed conveyor which

conveys it to the either the IPS Two-Ram baler or the Single-Ram baler for baling.


Regulatory Compliance

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2 Regulatory Compliance

Republic strongly supports and advocates the five R’s of Sustainability: Reduce, Reuse, Recycle,

Renew and Responsibility.

The five R’s of Sustainability are not mere slogans, but rather they reflect

Republic’s values and the continued commitment to sustainability and to

the communities it serves. Republic understands that the sustainability of

the environment depends on how well it protects and preserves natural

resources and educates current and future generations on environmental

compliance. In fact, Republic’s sustainability program centers on the

theme of “Protecting Today’s Environment for a Better Tomorrow.” This

message is important to the quality of life and regional prosperity in the

communities it serves and why compliance is so important.

Permit and Compliance

The North Texas Recycling Complex’s Municipal Solid Waste Permit

(Permit No. 2275) allows for Material Recovery, Transfer Station, and

Processing Facility operations. The facility is permitted to operate 24 hours

per day and 7 days per week. The facility is regulated by the Texas

Commission on Environmental Quality and has been issued a Texas

Pollutant Discharge Elimination System multi-sector storm water general

permit (Permit No. TXR05Z605). Inspections performed by the Commission

have never resulted in a notice of violation.

Environmental Stewardship

Evidence of this commitment to the environment and neighboring

communities can be seen throughout the facility and recycling system. This

focus on environmental stewardship throughout the planning process for

the North Texas Recycling Complex has resulted in numerous positive

outcomes for the surrounding cities including the achievement of LEED

Certification, the investment in energy-efficient equipment, and planting

an “urban forest” around the perimeter of the property.

Developing this MRF also reduces the local environmental impact of

recycling by enhancing the area’s recycling infrastructure. This means

collection and transportation trucks are driving fewer miles to facilitate

recycling, thus producing fewer emissions, causing less wear and tear on

roadways and having less of an impact on traffic. The communities

currently sending materials for processing at the North Texas Recycling

Complex are listed in the sidebar.

Duncanville • Star Harbor •

Corsicana • Gun Barrel City

•Dawson • Angus • Tool •

Blooming Grove • Mabank

•Wortham • Travis Ranch

•Malakoff • Lancaster • Rockwall

• Kerens • Cumby • Sunnyvale •

Caney City • Seagoville • Highland

Park • Desosto • Log Cabin •

Barry •Coolidge • Emhouse • Rice

•Ennis • Keene • Mesquite

•Mount Calm • Palmer • Mexia •

Mertens • Keene • West •

Malone • Whitney • Midlothian •

Mount Calm • Hillsboro • Bynam

• Parker • Hewitt • Alvarado •

Plano • Garland • The Colony •

Richardson • Van Alstyne • Oak

Point • Fairview • Aledo • Itasca

• St Paul • Sachse • Westlake •

Annnetta • Hudson Oaks •

Westover Hills • Benbrook •

Pelican Bay • Grapevine • Copper

Canyon • Sanctuary • The Resort

• Richland Hills • Roanoke •

Euless • Hurst • Newark • Argyle

• Haslet • Bedford • Blue Mound

• Trophy Club • North Richland

Hills • Pantego • Mansfield •

Arlington • Grand Prairie •

Southlake • Dalworthington

Gardens

COMMUNITIES SERVED


Planning

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3 Planning

The North Texas Recycling Complex planning process was multifaceted, addressing the current need for

recycling in Dallas-Fort Worth, while keeping an eye on the rapidly expanding population growth and

subsequent recycling infrastructure demand that will be placed on this metropolitan area.

Even as the demand for recycling infrastructure has grown due to effective municipal recycling education

programs and the increased participation among area residents and businesses, Republic Services knows that this

is just the tip of the iceberg. According to the U.S. Census Bureau 2012 numbers, the Dallas-Fort Worth

metropolitan area recorded the largest population increase in the nation, adding more than 130,000 people.

This growth exceeds that all other metropolitan areas including Houston, Los Angeles, New York, Washington D.C.,

Atlanta, Phoenix, Miami, San Francisco, and Seattle.

In anticipation of this continued growth, and in support of the municipalities in the Dallas-Fort Worth area,

Republic emphasized the need for flexibility and future expansion throughout the planning process. The unique

system designed by Republic and The CP Group reflects the innovative and forward-thinking approach that was

necessary to develop a fully functional MRF that can, with little downtime or construction, accommodate a second

line to meet the ongoing, growing need for the processing of both residential and commercial materials in the

Dallas-Fort Worth area.

Currently, the system is designed to support both residential and commercial single stream processing on a single

line. Residential single stream is processed during the first shift, and commercial single stream loads are processed

during the second shift. The planning process addressed the expected need for additional capacity and a dual line

system and the facility was designed to accommodate a second sort line.

There are several practical aspects of the forward thinking used throughout the planning process. For example,

the system is designed with extra space besides the screens and infeed conveyor for the future placement of a

dual line, which will increase the system’s capacity from 35 tons per hour to 55 tons per hour. In addition, the

CIRRUS Optical Separator is oversized to

accommodate the future increase.

The proactive planning not only resulted

in a system that meets processing needs

by providing the flexibility necessary to

effectively process residential and

commercial single stream tonnage on a

single line with a focus on safety,

efficiency, limited downtime and

minimized environmental impacts - it also

provides a launching pad for expansion as

the needs of the surrounding

municipalities continue to grow. CIRRUS Optical Separator


Performance, Economics & Cost Effectiveness

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4 Performance, Economics & Cost Effectiveness

The North Texas Recycling Complex system has proven capable of operating at its anticipated

production rate of 35 tons per hour for residential materials and 20 tons per hour for commercial

materials. The plant was designed to recover 95% of the targeted recyclable materials going through

the sorting system, and it is achieving that goal.

In addition to the numerous performance capabilities and operational goals achieved by the system, the versatility

of the line and ability to accommodate future expansion while minimizing the corresponding cost and downtime

was a critical deliverable realized as a result of the planning, construction and operation of the North Texas

Recycling Complex facility. The system has been performance-tested by a third party expert and has met and

exceeded the high Republic Services standards.

Additionally, the system has achieved economic milestones:

The initial investment in the facility was as planned and construction was completed within budget.

The facility reached profitability sooner than expected.

While these are welcome achievements, the anticipated payoff in forward thinking design will be even stronger.

Republic Services is committed to providing the recycling infrastructure needed to support the growing demand

for recycling services among the municipalities in the Dallas-Fort Worth area. The time and resources invested in

this project will continue to pay off as the facility is able to quickly and cost-effectively adapt to meet these

expanding needs. Through this system, North Texas Recycling Complex is poised and ready to offer the

surrounding cities and communities the capacity and diversion results they seek.


Use of Equipment/Systems and Technologies

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5 Use of Equipment/Systems and Technologies

Republic Services partnered with CP Group to design, manufacture and install the processing system at

North Texas Recycling Complex, with a focus on versatility, functionality, safety and the environment.

The following describes the operational features to manage the

residential and commercial single-stream materials processed at

the North Texas Recycling Complex:

Drum Feeder: The drum is configured with bolt-on cast-

chromium alloy paddles, which helps break and fluff up the

material without shredding or tearing and is very effective for

commercial material, bagged material and broken bales. This

horizontal drum feeder discharges onto a separate incline

conveyor which feeds onto the pre-sort line.

Impact Air Film Vacuum: The film vacuum system offers the

ultimate flexible solution for collecting and conveying handpicked

material during the manual sorting process. The system consists

of a series of specially designed material collection hoods, which

are typically mounted in the ceiling of the sorting cabin, above the

waste belts. The unique internal ‘Jetcone’ hood design minimizes

operational noise levels and the amount of air withdrawn from the sorting cabin, by utilizing a closed loop system.

Conveying air used to transport the material is recycled back through a return air system to significantly reduce

the cabin make up air requirements.

Impact Air Film Screw Compactor: The screw compactor’s main function is to

compress waste materials collected by the filmvac system into manageable

plastic bags. The unit comprises a single screw auger within trough, which

compacts the material into a circular outlet spigot. The unit achieves its

compaction by means of combination of the length of the outlet spigot and the

rubber tension clamping ring, which retains the expanding spool of plastic waste

bag to provide a variable length “Sausage-Like” bale for ease of handling. During

operation, as material is fed into the unit, the rubber clamping ring allows the

bag or tube to be extruded whilst maintaining compaction density.

Impact Air Dust Control System: Processing material in a MRF generates dust

which can create an unpleasant working environment for employees,

housekeeping issues and significant fire risks as airborne dust particles that come to rest on plant equipment. The

air control system used at North Texas Recycling Complex provides a highly effective dust capturing at the source,

at conveyor discharge and transfer points.

Impact Air Film Vacuum

Safety Fence

Impact Air Film Screw Compactor

Safety Fence



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CP OCC Disc Screen: The CP OCC Disc Screen automatically separates large cardboard from other fibers, containers

and debris. It consists of durable 1/2” thick steel discs, with an offset elliptical pattern that provides lateral

agitation to remove contaminates, containers, and mixed paper, leaving the OCC end-product highly marketable.

Glass Breaker Disc Screen: The Glass Breaker Screen increases system throughput, maximizes glass breakage, and

improves end-product marketability by providing an industry-proven way to simplify glass processing. Non-wear

steel alloy elliptical discs provide maximum glass breakage while decreasing jams and downtime. Heavy-duty and

low-maintenance, this multi-level screen is field-proven to break and separate broken glass and fines from fiber

and containers at optimum efficiency, without losing any aluminum.

Zigzag Air Separator: The Zigzag material separation system is a fully adjustable cascade cleaning solution suitable

for most recycling facilities. It is designed to efficiently remove unwanted lightweight material (ideally 0-50mm in

size) from the higher density materials. Differences in particle shape and density cause the lighter material to be

lifted by the air stream, leaving the heavier density material to discharge from the bottom under the action of

gravity, providing excellent rates of separation. Variable air velocities and material feed rates ensure minimal loss

of valuable recyclable material providing maximum flexibility and highly efficient cleaning of the material. Ideal

for shredded or granulated plastics, rubber, WEEE material, C&D waste, and plasterboard.

CP NEWScreen™: The CP NEWScreen™ provides efficient separation of paper from containers, and automatically

separates large fiber from mixed paper, containers, dirt, and debris. Large flat fiber materials are sent upstream

while various types of rigid containers such as cartons, bottles, cans and small fiber fall out of the stream to be

processed on additional screens. The patented long-lasting finger disc technology ensures efficient separation and

higher throughput paired with the lowest maintenance in the industry.

CP NEWScreen™



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Air Knife Separator: The Air Knife system’s main function is to remove low value ‘light’ fractions, such as un-

pickable paper, plastic and foil, from the material stream. The input air creates a high velocity air stream through

which the falling material has to travel. The lighter material fractions are blown or separated from the falling

material and are captured by the extraction hood and conveyed away. The heavier material is unaffected by the

incoming air stream and falls through the air stream onto the conveyor below.

CPScreen™: The CPScreen™ automatically separates small fibers from containers, and 2D from 3D material. Small

screen openings decrease loss of fiber to container line, recovering even the smallest pieces of fiber. It’s long-

lasting, patented rubber cam-style

discs are specially engineered to

have consistent spacing at all points

at all times to make discs highly

resistant to both jamming and

wrapping. Cam discs also have low

amplitude that avoids aggressive

separation to keep fiber clean of

small containers and other

contaminates. The screen ensures

that material is sized properly for the

most efficient sort possible.

Magnetic Drum Separator: Republic has installed Magnetic Drum Separator, a permanent self-cleaning separator

designed for heavy-duty, high-volume ferrous recovery. It is

a heavy duty drum magnet for high volume ferrous

separation and recovery. It has a tough and rugged design

that performs even under the harshest conditions. This large,

powerful magnetic drum has a non-magnetic exterior shell

that is driven around a fixed magnet center. Ferrous metals

are drawn out of the material stream by the powerful

magnetic center and held against the revolving shell; the

steel is released when it reaches a discharge point beyond

the magnetic field. The magnet placement is customizable

and can be fed in any position; the drum can drop the ferrous

material off over the drum, under the drum, or down from the drum if fed from the top.

Eddy Current Separator: Aluminum is passed over the rotor which contains a rotating series of powerful rare

earth magnets causing an Eddy Current Separator reaction to the aluminum. The eddy current separator ejects

the aluminum with the same force as a magnet pulls steel. As aluminum cans or other non-ferrous metals pass

over the drum, the alternating magnetic field creates eddy currents that repel the material away from the

CPScreen™

Magnetic Drum Separator



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conveyor. While other materials drop off at the end of the conveyor, the non-ferrous metals are propelled over

a splitter for separation.

CIRRUS™: The CIRRUS™ combines high-resolution near-infrared, color, and metal sorting. It sorts a wide variety

of mixed materials, using advanced digital signal processing and software algorithms. The detection in mid-air

provides higher signal levels for transparent items (PET color sorting) and allows sorting of black items.

IPS TR 1388BT 200 Two-Ram Baler: This system uses a High Efficiency Two-Ram Baler. Utilizing a pre-compression

lid, this baler has a high density and high capacity for baling. The pre-compression lid also means that no baler

operator is required, and allows for up to twice the thru-put on materials such as PET, HDPE, aluminum, and steel

cans. This multi-material baler produces export bales, allowing North Texas Recycling Complex to take full

advantage of the international markets.

Advanced MRF Office Interface System: A SCADA system oversees the operation at the North Texas Recycling

Complex and help the plant manager to diagnose and pinpoint areas where modifications need to be done so the

system can reach maximum efficiency. The SCADA system includes touch screen controls, operational statistics, a

wireless touchscreen, and a video monitoring system.


Worker Health & Safety

Page 13

6 Worker Health & Safety

Safety is Republic’s highest priority and therefore, a strict policy of safety protocols has been created

with supporting infrastructure, where employees are trained to think, choose, and work within a

training framework designed for safety.

Safety is Republic’s portal for the achievement of exceptional customer experience, and is viewed as the

responsibility of all Republic employees. Every step is taken to ensure safety in its administrative offices, in its

operations yards, on its collection routes, and at its transfer/recycling

facilities. Republic’s excellent safety record is achieved by the clear system

of safety checks and balances it employs, its safety policies and procedures,

and sound decision-making used when hiring, combined with the active

retention of the very best employees.

Safety Training

Employees are trained on the first day of employment on key safety topics

(listed in sidebar). Employees then receive refresher training on these

topics during monthly safety meetings.

Employees also participate in Republic Services’ Focus 6 program which

trains employees on the skills to avoid the six most serious types of losses

in the industry.

Safety Design Elements

Numerous design elements were included in the system to facilitate and

enhance operational safety. The system uses Miller Temporary Anchorage

Connectors, which wrap around l-beams and other structures for

supporting workers. Crossbars above the rotors are dimensioned to hold

one person each and provide valid anchor points for lanyards.

All disc drives on each screen have brake motors with locking hand release

levers. Brakes are activated when the power goes off, locking rotors. Rotors

cannot turn when maintenance personnel is walking or standing on them.

The system is also designed to minimize the walkable area between work

stations. Because of this attention to accessibility, maintenance issues can

be spotted and addressed quickly with minimal risk. In addition, the

employee entrance to the facility is on the second floor. This design feature

significantly reduces MRF employee presence on ground level, where

vehicles and equipment are operated.

Personal Protective

Equipment

Lock Out Tag Out

Confined Space

Hazardous

Communications

Blood Borne

Pathogens

Emergency

Evacuation

Hearing

Conservation

Fire Extinguishers

Heat Stress

Electrical Safety

Fall Protection

Machine Guarding

Drug & Alcohol

Awareness

SAFETY TRAINING TOPICS


Worker Health & Safety

Page 14

6 Worker Health & Safety

A safety fence surrounds the

ground level of the plant and is

locked during operation. Access to

the ground floor beneath the

sorting equipment is limited to

authorized employees with keys

during operation, which

significantly reduces associated

safety hazards.

The facility also features trapped key interlocking, which utilizes locks and keys for sequential control of

equipment and machinery to ensure safe operation. Trapped key interlocks are used to ensure safe access to

potentially live equipment in the plant. A safe sequence of operations is enabled through transfer of keys that are

either trapped or released in a predetermined order. For example, a key is used to isolate a power source (circuit

breaker or supply valve), this key is then released

and can then be used to gain access through a gate

or door to a high risk area by inserting it into an

access lock. The key will then remain trapped until

the gate or door is closed, ensuring that the gate or

door cannot be closed and the initial key released

until this personnel or safety key is returned. Access

doors contain a keylock system. The power is shut

off when the access doors are opened. With the

double key system, the machine cannot be started

while the doors are unlocked.

The area behind the access doors of the CPScreen and NEWScreen gets closed by a fold-down service platform,

from where the rotors are accessible. The floor is moved by hydraulic cylinders, and can only be unfolded when

the screen is in its lowest position. This system

eliminates the risk of falling during maintenance

and cleaning, and in so doing, provides built-in fall

protection so that harnesses are not required.

In addition to implementing Republic Services’

extensive safety programs and integrating

numerous safety elements in the design of the

system and equipment selection, the North Texas

Recycling Complex team contracted Susan Eppes,

President of EST Solutions, to ensure compliance with OSHA regulations and overall safety. Following a

comprehensive review of the site plan and programs, recommendations were reviewed and incorporated into the

safety program.

Keylock System

Fold-Down Service Platform

Safety Fence

http://en.wikipedia.org/wiki/Lock_(device)

http://en.wikipedia.org/wiki/Key_(lock)

2014 Excellence Recycling Systems Award Entry Republic Services’ North Texas Recycling Complex

Public Acceptance, Appearance & Aesthetics

Page 15

7 Public Acceptance, Appearance & Aesthetics

Republic Services is a proud partner of the Garden of Eden neighborhood in Fort Worth, Texas. Earning

community support during the permitting and approval process was a pivotal component of the

planning process. Republic was honored to have the Garden of Eden Neighborhood Association’s vocal

endorsement of the North Texas Recycling Complex throughout the process.

Garden of Eden is a historically Black community in Fort Worth, Texas, that was settled by freed slaves from

Kentucky and Tennessee around 1860. There were 54 households along the Trinity River. Today, the community’s

population includes 20 descendants of the original settlers. The Garden of Eden had fallen on hard times until the

Neighborhood Association was developed in 2004. Since then the area has been designated a historic

neighborhood. Garden of Eden received the 2004 Neighborhood of the Year Award.

As a partner of the Garden of Eden community, Republic Services

makes being a good neighbor a daily priority. Community

members were engaged in the planning process and the

Neighborhood Association spoke in support of the project at

Planning Commission and City Council meetings. The Association

members joined civic leaders from cities throughout the

Metroplex for the Grand Opening Celebration.

A Learning Center was included in the complex to aid in

the safe and effective offering of tours and educational

presentations. Surrounding municipalities benefit from

the opportunity to bring community leaders, municipal

staff, and all types of groups to tour the facility. The

Learning Center can accommodate groups of up to 70

and offers 180⁰ views of the sortline.

Community beautification was carefully considered throughout the “urban

forestry” component. Three dozen trees were added to the property along with

their environmental and aesthetic benefits.

To enhance the look of the neighborhood, the facility is well-maintained, with an

updated façade. In addition, Republic Services achieved LEED Certification for the

North Texas Recycling Complex and the facility was built with numerous

sustainable features. The Complex is bright and clean, with energy-saving lighting

systems such as the use of outdoor LEDs, motion sensors, daylight sensors. In

addition, heat pumps are used for heating and cooling and they are managed with programmable thermostats.

The facility is also a welcomed source of local employment, bringing new, green jobs to residents in the

surrounding cities. The North Texas Recycling Complex runs two shifts, five days a week, employing 75 people,

including sorters, equipment operators, scale attendants, drivers and administrative and supervisory staff.

Urban Forestry Site Diagram

Community Guests at Grand Opening

State and Local Leaders at the Grand Opening Ribbon Cutting


Supplemental Materials

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S Supplemental Materials



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Please find an article regarding the North Texas Recycling Complex from Recycling Today.

http://www.recyclingtoday.com/republic-mrf-texas.aspx



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The poster shown above is on display in the Learning Center at the North Texas Recycling Complex and

used during tours while visitors observe operations from their panoramic view of the facility.

Documents

E Executive Summary