Abstract: A method for reformulating reclaimed, contaminated mixed waste plastics into useful articles wherein a plurality of batches of the mixed waste plastics are preprocessed to produce substantially homogeneous mixtures of a desired particle size range that are characterized according to their respective apparent densities, and are thereafter blended to produce a mixed plastic feed material having a plastic content predetermined to be desirable for reprocessing into at least one of such useful articles.

Abstract: A method for reformulating reclaimed, contaminated mixed waste plastics into useful articles wherein a plurality of batches of the mixed waste plastics are preprocessed to produce substantially homogeneous mixtures of a desired particle size range that are characterized according to their respective apparent densities, and are thereafter blended to produce a mixed plastic feed material having a color predetermined to be desirable for reprocessing into at least one of such useful articles.

Abstract: A method for reformulating reclaimed, contaminated mixed waste plastics into useful articles wherein a plurality of batches of the mixed waste plastics are preprocessed to produce substantially homogeneous mixtures of a desired particle size range that are characterized according to their respective apparent densities, and are thereafter blended to produce a mixed plastic feed material having a target density predetermined to be desirable for reprocessing into at least one of such useful articles.

Abstract: A method for reformulating reclaimed, contaminated mixed waste plastics into useful articles wherein a plurality of batches of the mixed waste plastics are preprocessed to produce substantially homogeneous mixtures of a desired particle size range that are characterized according to at least one of their respective plastic content, densities, color and degree of contamination, and are thereafter blended to produce a mixed plastic feed material having properties predetermined to be desirable for reprocessing into at least one of such useful articles.

Abstract: A method for reformulating reclaimed, contaminated mixed waste plastics into useful articles wherein a plurality of batches of the mixed waste plastics are preprocessed to produce substantially homogeneous mixtures of a desired particle size range that are characterized according to their respective apparent densities, and are thereafter blended to produce a mixed plastic feed material having a rheology predetermined to be desirable for reprocessing into at least one of such useful articles.

Abstract: An extruded composite material comprising a discontinuous phase of cellulosic fiber encapsulated in and bonded to a continuous phase of a polymeric component preferably comprising a major portion of recycled polyethylene.

Abstract: A system and method for removing fine cellulosic contaminants from plastic film utilizing a plurality of tanks, means for moving the plastic film sequentially through the tanks, means for recirculating an aqueous solution through each of the tanks, means for filtering the recirculating aqueous solution, and means for injecting flocculant into the recirculating solution. The subject system preferably includes at least two independent circulation modules, each having means for recirculating and filtering an aqueous solution and for minimizing liquid carry-over from one module to another. The system also preferably includes means for monitoring the turbidity of the recirculating aqueous solution and for injecting flocculant into the recirculating solution whenever the turbidity exceeds a predetermined maximum value.

Abstract: A method for recycling waste plastic material, from polymeric film or hydropulper waste, including plastic and cellulosic fiber or organic contaminants. The method includes the steps of introducing the waste plastic material into a size reduction unit, and reducing the size of the waste plastic material to particles having a maximum dimension ranging between about 1 inch and about 8 inches; mechanically hammering and rubbing the plastic material for separating a portion of the cellulosic fiber from the plastic; separating another portion of the cellulosic fiber from the plastic by flotation with agitation; further reducing the particle size of the plastic to a maximum dimension of about 1/2inch; dewatering the plastic; drying the plastic to a moisture content of less than about 10 weight percent; and rolling the plastic into pellets.

Abstract: A shredder including a shredder housing having an inside, an outside, side walls, end walls, such that the end walls and side walls are engineered and joined together to maintain tight tolerance within the shredder. The end walls and side walls define a top inlet opening and a bottom outlet opening. Two parallel spaced apart shafts are horizontally aligned with each other and rotationally mounted through the end walls for receiving rotational power. Adjustable speed rotational motors engage each of the shafts for rotating them in counter-rotational directions. A plurality of uniform thickness disk-shaped blades are alternatingly positioned with interposed disk-shaped spacers placed therebetween. The spacers have a thickness slightly thicker than the blades.

Abstract: A method for recycling waste plastic material, from polymeric film or hydropulper waste, including plastic and cellulosic fiber or organic contaminants. The method includes the steps of introducing the waste plastic material into a size reduction unit, and reducing the size of the waste plastic material to particles having a maximum dimension ranging between about 1 inch and about 8 inches; mechanically hammering and rubbing the plastic material for separating a portion of the cellulosic fiber from the plastic; separating another portion of the cellulosic fiber from the plastic by flotation with agitation; further reducing the particle size of the plastic to a maximum dimension of about 1/2 inch; dewatering the plastic; drying the plastic to a moisture content of less than about 10 weight percent; and rolling the plastic into pellets.

Abstract: A method for producing rolled plastic pellets comprising from about 5 to about 10 weight percent cellulosic fiber and less than about 10 weight percent water from mixed plastic waste comprising polymeric film.

Abstract: A flying cutoff blade assembly for cutting a hot pliable extruded plastic and wood fiber composition product including product entry and exit trays, a housing having a knife with upwardly and downwardly facing edges to cut the product in alternating upward and downward cutting directions, a support plate and upper product stop block each having a slot for passage of the knife for non-deforming non-stick contact support of the product during cutting wherein the housing is moved back and forth of the product at a speed sufficient to permit cutting of the product without the product ramming into the knife during cutting.

Abstract: A separation tank adapted for use in washing and separating recycled polymeric material from contaminants, the separation tank comprising a centrally disposed baffle and being adapted to receive and circulate an aqueous medium around the baffle; transversely mounted, rotatable members adapted to submerge floating material within the aqueous medium; transversely mounted, rotatable members adapted to aggressively agitate the surface of the aqueous medium; and longitudinally spaced sumps disposed in the floor of the tank on the side of the baffle opposite the agitation members to collect contaminants settling out of the aqueous medium; and members adapted to divide the aqueous medium into surface and subsurface portions for the respective recovery of the polymeric material and recirculation of the aqueous medium.

Abstract: An extruder assembly for composite materials, the extruder assembly having a barrrel with feed and compression sections, a rotatable screw adapted to convey a composite material through the barrel, at least one fiber alignment means, and a die. The screw diameter in the feed section is approximately twice the screw diameter in the compression section, and the flight spacing in the feed section is approximately twice the flight spacing in the compression section.

Abstract: A process for making synthetic wood products from waste wood fiber and recycled plastic material by mixing waste wood fiber having a moisture content of less than about 15% with dry waste plastic material, including low density and/or high density polyethylene; heating and kneading the mixture to form a homogeneous mass; sizing the mass into discrete chunks suitable for use as an extruder feed material; extruding the material to form products having predetermined cross sections; and rolling and cooling the product to prevent deformation of the product shape.

Abstract: A system for making synthetic wood products from waste wood fiber and recycled plastic material by mixing waste wood fiber having a moisture content of less than about 15% with dry waste plastic material, including low density and/or high density polyethylene; heating and kneading the mixture to form a homogeneous mass; sizing the mass into discrete chunks suitable for use as an extruder feed material; extruding the material to form products having predetermined cross sections; and rolling and cooling the product to prevent deformation of the product shape.

Abstract: A method for reclaiming plastic and cellulosic fiber from plastic coated waste. The method includes the steps of introducing previously hydropulped plastic coated waste into a size reduction unit to reduce the plastic coated waste to a maximum dimension of about 1-4 inches. The plastic coated waste is then subject to flotation with agitation to separate the plastic from the cellulosic fiber. The cellulosic fiber is then screened, dried, and baled. The plastic is further reduced to a maximum dimension of about 1/2 inches and dewatered. The dewatered plastic is dried to a moisture content of less than 10% and rolled into plastic pellets. This method produces plastic pellets comprising from about 5 to about 10 weight percent cellulosic fiber and less than about 10 weight percent water from hydropulper plastic coating waste.

Abstract: A method for making a composite material including a discontinuous phase of cellulosic fiber encapsulated in and bonded to a continuous phase of a polymeric component containing a major portion of polyethylene by mixing the cellulosic fiber and polymeric component while raising the temperature of the mixture to the encapsulation point, maintaining the encapsulated material within the encapsulation range while reducing the particle size, and thereafter extruding the material while controlling its temperature within the encapsulation range and substantially aligning the fibers in the flow direction until the material contacts a heated die.