OMNOVA Solutions significantly improved recycling capabilities at its plant in Auburn, Pennsylvania by investing in rotary batch mixers from Munson Machinery Co. Inc., NY.

OMNOVA supplies printed flexible and rigid films to commercial and residential product makers for flat and three-dimensional (3D) lamination to wood, metal, particle board and substrates used in high-end and commodity products. Applications include cabinets for kitchens, bath and healthcare; home and office hospitality furniture; retail displays; wall and floor coverings; and interiors of recreational vehicles.

The plant compounds, calenders, prints, embosses, and coats primarily PVC films. Despite significant reductions in waste through LEAN SixSigma and other continuous improvement programs, OMNOVA's calendering process still generated process waste material that could be recycled. In an effort to effectively re-utilize this material and improve the plant's environmental footprint, OMNOVA invested in its recycling program.

OMNOVA's options to recycle material were initially limited. To improve the recycling process, OMNOVA invested in a Munson 700-TSC-300 rotary batch mixer with capacity of 18,000 lb. (8,165 kg) and 300 cu ft (8.5 cu m). The company granulated its start-up and process waste material, reducing its particle size and then blended it in the mixer. Plant process engineer Steve Reed says, "The homogeneous mixing action of the Munson machine produced high-quality recycled blends that could be added back into compound formulations in-house or sold outside to brokers." One benefit of the machine's mixing efficiency was to reduce variations in particle size distribution. This prevents particle segregation and problems arising from different melt temperatures during re-processing.

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