MARS RECYCLING TECHNOLOGY

Mars Recycling Technology and its parent company Mars Flexible Packaging Europe Limited is the United Kingdom Registered Company and be a part of the oldest Prabha business Group India; having its diversified business areas of Agriculture, Construction, Manufacturing, Imports, Export and many more... 

The major share of the organisation’s revenue is earned from its Manufacturing arm from Packaging, that is into production of Flexible Packaging Laminates with the help of Flexo graphics Printing , Rotogravure Printing & LDPE, HDPE, Poly Propylene, 3 Layer Film, 3 Side Seal pouches, center & Bottom Seal Pouches, Zipper & Standy Pouches products.

Its core competence lays on the Industrial experiences it has acquired in the fields of flexible packaging of the various Polymers film. With the use of High Quality Ultra Modern Machinery in the state-of-the-art manufacturing unit, Prabha group has dominated in the Central India markets.

In Addition, the group engages a panel of the finest talented personnel present in the industry, just to boast the best R & D division in its sector. Their level of experience is of tremendous value to our customers and we take great pride in the quality of our service Supported by the strong infrastructure base, efforts are being directed to discover new products and to improve the existing ones to set up a new benchmark for International quality standards.

Team

Our manufacturing team consists of highly skilled employees who continually meet the high quality standards our company is committed to.

As for the company’s management policy, it is looking to grow together with its customers in a win-win relationship.

Strategic Partners and Implementation Control (SPIC)

The primary goal of SP is to translate corporate strategy into short term goals and work with team leaders to develop, set and monitor operational targets.
Production Efficiency Management (PEM)

Team members are primarily responsible for overall productivity of Mix Plastics Recycling processing plants. The PEM team is sub-divided into smaller teams: FSP, Renew, PET depending on specific areas.
Asset Performance Optimisation (APO)

The team works relentlessly to ensure all assets are maintained to deliver optimal performance. Team members constantly seek to improve performance and efficiencies while coming up with creative ways to lower operating cost and ensure 100% up time.
Capital Resource and Risk Management (CRRM)

The CRRM team is responsible for capital allocation, budgeting, risk identification and risk management.
Product Delivery and Customer Care (PDCC)The PDCC team is responsible for ensuring perfect order fulfillment (right quantity, right price, right time) while developing new markets.
Product Quality Assurance (PQA)Team members work with team leaders in quality benchmarking and monitoring to ensure perfect quality products.
Performance Enablement (PE)

The primary responsibility of team members, from recruitment to training, is to ensure that Mars Recycling is a happy, healthy and exciting place to work.

Supply Chain Optimisation (SCO)

The SCO team is focused on ensuring all material (feedstock, spares, consumables) availability at most competitive cost while ensuring smooth movement of finished products.

Materials Supply Optimisation (MSO)

MSO is focused on ensuring maintaining of minimum inventory of all feedstock, while ensuring 100% feedstock availability and converting our suppliers into partners.
Decision Support and Efficiency Enhancement (DSEE)

Team members are focused on improving internal processes to enhance efficiency. This involves working with team leaders, using the latest tools in information technology to achieve superior cycle times for transactions and supporting fact based decision making.
Facilitation and Internal Logistics (FIL)

The role of the FIL team is to ensure that all team members are supported for their travel and general administration needs.

PROCESS Sorting Washing decontamination Process.

The waste material is processed through a Mars recycling plant. Firstly the waste material is sort in state of art Plastics Bottle Sorting Plant

The input-bottles to feed the plant, comes from urban and industrial collection sites and are pre-sorted. At the first step of the system the packing ropes of the bottles bales are removed and they are then conveyed into a Sorting Plant.

Mixed Plastics Sorting Plant Description; Mixed Plastics means what it is a Post Consumer Plastics waste usually contains a very high proportion of recyclable materials such as Poly Ethylene PE LD or HD, Polypropylene PP, Polyethylene terephthalate PET, Polystyrene PS, Poly Vinyl Chloride PVC, Cardboard, Plastics films, Non Ferrous and Ferrous, which are separated by mechanical sorting. Polymers, paper or films are subsequently inspected at manual sorting stations for quality optimisation. The bottles are transported through a metals separator and then, to a belt conveyor for the visual control. From this point the bottles are conveyed into a screened cylinder where they are subjected to a water washing shower. the bottles are well separated from each other and the small parts are removed. At this step there is also the separation and elimination of the most part of the labels that are collected – with other impurities – and automatically conveyed to the containers for the dump. At the pre-washing outlet bottles fall onto a ballistic sieve which make them drip and separate from any possible labels.

The bottle stream is then stored in a “Constant Feeder» that ensures a continuous feeding to the following stages and allows short interruptions of the pre-installed machines. The “constant feeder” extraction belt is equipped with electronic loading cells and has the function to dose the bottles stream through a weighing system by adjusting the feeding capacity to the detection section.

From the constant feeder the bottles are continuously dosed to two NIR electronic control stations in series to sort out other contaminant polymers. A belt is foreseen for an eventually future installation of a colour detector. The detected and rejected bottles are collected on a belt and conveyed to the secondary NIR. The detected and sorted bottles are then manually controlled on a selection belt and conveyed to the wet grinders to be reduced into flakes.

The flakes are conveyed to the pre-floatation step to separate and to remove the most part of Polyolefin’s, the paper labels still present and the floating pollutants, before reaching the washing step. Through the pre-flotation it is partially avoided to dissolve in the water some substances such as inks etc., with the aim to keep the water cleaner in the next steps. The perfect cleaning of the flakes from the residual pollutants is therefore essentially concentrated on the removal of various impurities still stuck to the flakes. The system remove therefore the remaining labels, various impurities that are still stuck to the flakes and first of all detach and remove the glue and prevent its redistribution of flakes.

All these important functions are perfectly performed by a machine, the FRICTION WASHER. In the Friction Washer the heating is indirectly by steam, and the flakes are subjected, at very high temperatures, to a strong but non-destructive friction action, which causes the reduction to pulp of the labels and the hot removal of the glue.

A next floatation tank removes any impurity lighter than water, coming from the Friction Washer, such as the PE caps and labels.

The flakes are then conveyed to the centrifuge with fresh water rinsing system, which removes also the soda. A final hot air drier removes the humidity.

A sever selects the material at the required size. The oversize flakes are ground by a dry grinder. The flakes are then stored in two homogenising silos, A de-duster removes the fine particles, that are stored in the self cleaning filter, before the optical sorter.

The whole plant is put in operation and controlled from the control room by means of a computerised system interfaced with the PLC of the plant power cabinet.