Separation of Laminated Glass into Glass and Interlayer for Recycling
- Advanced Technologies to Recycle Laminated Glass -
Laminated glass is found in automobile windshields and building and house windows. When it is no longer in use, most of it end up in landfills or incinerated because recycling laminated glass is challenging. Typical crushing machines would crush laminated glass without separating its attached interlayer so that the glass cannot be reused. To recycle laminated glass cullet and interlayer, Donico Inter Co., Ltd. had developed a unique, unprecedented crusher (FDS1250) and an exfoliator (NDF1000S). With these machines, laminated glass can be crushed without ruining the attached interlayer. The glass and interlayer can be reused in different products, and landfills can be reduced at the same time.
Major Features and Advantages
I. Crushing Laminated Glass
Used laminated glass is first crushed in the special crusher, FDS1250. The crushing process is also called “dry process.” During this process, laminated glass is crushed until it is in the granular state. Unlike conventional glass crushers that can ruin attached interlayer, FDS1250 crushes and removes 50 to 70% glass cullet of laminated glass without damaging the interlayer so that the glass does not contain other materials and can be reused in different products.
II. Separation of Glass and Interlayer
The crushed laminated glass undergoes separation or “wet process,” using the exfoliator, NDF1000S. The separation process involves chemical stripping and shear force to wash off glass fragments. A specially developed solution kept at the best temperature is used to separate the glass fragments from the interlayer. The glass fragments are washed off in a rotary drum (water treatment tank). With this technique, neither glass nor interlayer gets damaged or changes its quality. The NDF1000S removes over 99.96% of glass fragments and allows the interlayer to be recycled.
III. 3R Promotion
Recycling laminated glass represents 3R (Reduce, Reuse, Recycle) promotion. FDS1250 and NDF1000S do not only reduce landfills but also allow both glass and interlayer to be reused. The machines directly contribute to saving the environment.
To date, there is no other commercial record of machines like FDS1250 and NDF1000S in the world. Donico Inter Co., Ltd. has sold two units of these machines last year in Japan and received orders from overseas as well. The demand for these machines is expected to rise as the number of automobile recycling operation is increasing both in developed and emerging nations. The company desires to expand their business especially in Asian countries that are currently undergoing rapid growth.
Our equipment consisting of crushing equipment (FDS1250) and exfoliation equipment (NDF1000S) can efficiently separate laminated glass into glass and interlayer for recycling.
Laminated glass is used in various products and machines such as automotive, buildings and houses. Most of the cases, used laminated glasses are either discarded or incinerated for waste disposal. Recycling of laminated glass is challenging because crushing equipment available today can only crush the laminated glass and cannot separate impurities mixed in the crushed glass.
We believe our technology can directly contribute to the recycling of used laminated glass for reuse in various products and machines as mentioned above. We also believe that because our equipment can efficiently recycle used laminated glass, we can save energy and used glass as valuable resource for reuse. Finally, our proposed equipment should be a promising solution for overcoming glass disposal issues in final landfill site.
The uniqueness of our equipment is the combination of dry process by FDS1250 (crushing laminated glass) and wet process by NDF1000S (separation of glass and interlayer). This combination can contribute to the recycling of laminated glass for reuse and at the same time can contribute to reduction of energy consumption (i.e. 3R promotion).
We believe our technology is unique and one of state-of-art technologies in the world because so far there is no other commercial record of equipment like ours.
The glass-interlayer separation efficiency rate of our equipment is more than 99.96%.
As our equipment can separate laminated glass into glass and interlayer, the separated interlayer can be reused as recycled interlayer for glass production.
The exfoliation technique of our equipment is associated with dissociation solution developed by NSG group, which enables washing process for interlayer keep at a most suitable temperature in a rotary drum for eliminating glass fragment stuck on glass interlayer.
Specifications of crushing equipment (FDS1250) and exfoliation equipment (NDF1000S) are as follows.
Crushing equipment: FDS1250
|Width of crushed glass||50~1250mm|
|Thickness of crushed glass||3~12mm|
|Average speed of delivery of crushed glass||1200mm/min|
|Adjustable range of roll gap||-2~+18mm|
|Main motor||Tsubaki Gear Motor
GMTA075-50L450ZW, 0.75kw 4P AC200V 3 phase 50/60 Hz
|Main power||AC200V 3 phase and/or AC100V single phase|
|Solar panel||3.5 W (7V 0.5 A)|
|Option||Dust collector (made by Sintokogio Co.,Ltd.), conveyor, glass
interlayer shooter, glass interlayer dish, tank for cullet, and water spray equipment for glass interlayer.
Exfoliation equipment: NDF1000S
|Barrel rotation motor||Tsubaki Gear Motor
GMTA150-50L165ZW, 1.5kw 4P AC200V Inverter
3 phase 50/60 Hz
|Magnet pump for ejector||Inverter, MX-402 1.5Kw|
|Hopper for cullet collection||LPF200M1.0VL DC24V|
|Plate flange heaters||PL5-3550-510 6Kw AC200V
(2 plate flange heaters are required)
|Main power||AC200V 3 phase and/or DC24V|
|Standard accessories||Tank for cullet collection, hook for interlayer extraction, special
liquid stripper (can be diluted 100-fold), water treatment
tank for glass interlayer.
|Option||Heating equipment for drying glass interlayer.|
Technical maturity / Past record of introduction
Development of our equipment and the dissociation solution has completed in 2008. So far we have successfully installed 10 crushing equipment (FDS1250) and we have been improving our sales records since 2008. We are now positively considering to expand our business outside Japan.
Although dissociation solution is available at reasonable price, our company licenses the dissociation solution from a Japanese manufacturer so the license fee applies on top of the product price. Therefore, our local partner company also has to license this product from that Japanese manufacturer in order to access the dissociation solution for our system.
Information on patent related to this technology
|Name||Donico Inter Co.,Ltd.|
|Address||6F-A Optex Nionohama Bld. 4-7-5 Nionohana, Ohtsu, Shiga, 520-0801, Japan|
|Capital||2.1 million yen|
|Contact person||Kaneyuki Inoko
Chief Executive Officer
|Number of employees||2 (2 for international operation)|
|Date of company foundation||18th of April 2013|
|The type of business||Glass recycling business|
Modality of business transaction
We are looking for business partner(s) willing to import our system to locally operate decomposition of glass from discarded automobile, crushing of glass and separation of interlayer.
Image of FDS1250
Stripping Method of FDS1250
Image of NDF1000S
Stripping method of NDF1000S
Contact Person(s) *Please mention that you saw UNIDO's website when making the first contact with the company.
- Waste treatment & management : ELV (end-of-life vehicles)