Zero Liquid Discharge (ZLD) Waste Water Recycling System

How to wash recycled plastic without using any water ?

We know how...

The safe way to keep micro-plastics out of the environment

Zimmer America Recycling Solutions is proud to introduce the revolutionary BlueTreat Zero Liquid Discharge (ZLD) Waste Water Recycling System for plastics recycling wash lines, supplied by Germany based ACES GmbH. This innovative technology significantly reduces water consumption and eliminates waste water discharge, setting a new standard for environmentally responsible plastics recycling.

The ZLD system utilizes a closed-loop water circulation process. Two separate loops, one for bottle to flake grinding and initial flake washing and another for flake post-washing, ensure thorough cleaning of plastic flakes. Advanced microfiltration further purifies the water, ensuring optimal cleaning performance. A key component of the system is a two-phase decanter that efficiently separates solids from liquids, allowing the treated water to be reused in the flake washing process. This results in zero waste water discharge.

The ZLD system also results in a dramatic reduction in fresh water consumption. Compared to traditional (2.5 metric tons/hour) washing lines, the ZLD system saves an estimated 5.5 million gallons of fresh/waste water per year. This substantial water conservation not only benefits the environment but also reduces operational costs.

The ZLD system further addresses the challenge of managing the solid waste generated during the recycling process. The decanter removes microplastics, residual glue, label materials, and other contaminants, which then can be disposed of responsibly.

Water usage comparison without and with ZLD

Operation of 2.5 ton/hour wash line without ZLD

About 5.8 million gallons of fresh water and same amount of wastewater discharge in 1 year (that’s about 660 gal per hour fresh water converted to wastewater)
Operation of 2.5 ton/hour wash line WITH ZLD

Only 301,000 gallons of fresh makeup water needed per year to replace water loss in the wash line due to evaporation and flake adhesion. (That’s about 35 gal per hour).
No wastewater is generated or discharged.

Water Savings:

5,800,000 gallons per year water usage without ZLD, less 301,000 gallons per year ZLD make-up water = savings of 5,500,000 gallons of fresh/waste water per year

Depending on your local water and sewer rates, savings of $100,000.00 +/- per year can be achieved.

Furthermore, by eliminating wastewater discharge, the risk of costly municipal fines for insufficiently treated waste water can be significantly reduced.

process water before and after micro-filtration in loop #1 (grinding and initial washing)
process water before and after micro-filtration in loop #2 (post washing)