CP Group’s Balcones system revolutionizes recycling solutions

Efficiently Fractionating, Liberating, and Separating Recyclables in San Antonio. Discover how the Balcones system is setting new standards in the recycling industry and driving meaningful change.

September 3, 2024, 2 min read in News

Recycling Revolution Begins Here

Exterior of Balcones Recycling Facility building with a parking lot and three flag poles.

Balcones Recycling’s 50 TPH MRF in San Antonio, Texas, is a $68 million investment, processing approximately 240,000 TPY in a 145,000 square feet building.

Transforming Waste into Resources

A construction vehicle placing bales of recycling materials in a warehouse storage space.

The facility efficiently processes single-stream and commercial material using advanced equipment that improves material recovery and achieves higher purity levels.

Smooth Operational Launch

Two Recycling workers looking over a railing at the MRF tip floor.

The Balcones facility began operations on August 1, achieving a smooth startup, with CP Group onsite for several weeks to provide comprehensive training on operations.

Mastering Material Handling Excellence

The Drum Feeder enhances system throughput by consistently delivering material without placing a burden on the loader operator, enabling 10-minute intervals between loads for optimized time management.

Smart Input, Smart Recycling

An overhead shot of CP Group's Auger Screen, in teal green.

The system incorporates two infeeds and five CP Auger Screens™ for efficient material fractionization, eliminating the presort and enhancing system efficiency and worker safety.

Next-Level Separation Techniques

A view of the inside of a recycling facility overlooking conveyor belts, optics, and auger screens.

The Auger Screen series eliminates manual sorters, produces clean OCC, and enables parallel processing by splitting material flow by size without wrapping.

Glass Recycling Game Changer

A closeup view of the inside of a Glass Breaker machine with it's screens.

The facility’s robust glass breaker screen separates glass and fines from co-mingled recyclables, reducing contamination in other materials and facilitating efficient glass removal.

Maximum Separation Efficiency

A view of the LightsOut Air Drum Separator machine on a platform inside a MRF.

Balcones Recycling employs a durable LightsOut™ Air Drum Separator to effectively remove lightweight impurities from glass, improving glass product quality with very little maintenance.

2/d 3/d Material Liberation

Close up of a conveyor belt and an anti-wrap disc screen equipment.

The system employs advanced screen technology to optimize the liberation of 2D from 3D material, enhancing overall downstream sorting efficiency and improving material quality.

Fiber Recovery Made Efficient

Frontal view of four MSS Optical FiberMax sorting units in a recycling facility.

The five MSS FiberMax™ units fully automate fiber QC, efficiently recovering SOP, mixed paper, OCC, and 3D fiber for streamlined processing.

Flexible Film Recycling Innovation

Side angle of an MSS optical FilmMax sorter on a ramp in a recycling facility.

MSS FilmMax™ is a one-of-a-kind optical sorter that recovers challenging flexible film grades utilizing advanced air-assist system and a patented eject hood.

Container Processing Revolutionized

A view of the upper level of a MRF sorting line with a teal MSS PlasticMax and a Vivid Air AI unit.

This fully automated container line features five MSS PlasticMax™ and two Vivid AI™ units, efficiently recovering valuable plastic and metal containers with a last-chance line.

Intelligent Air Sorting

A side view of a MSS Vivid Air intelligent sorting machine in a MRF.

MSS VIVID Air™ leverages deep-learning AI for precise sorting and granular material classification, while air nozzle ejection enhances efficiency, enabling simultaneous extraction.

Efficient Material Handling

An overhead shot looking down into auger silos in a recycling facility.

The six auger silos, each assigned to specific material classifications, enable precise control over the optimal feeding of materials and eliminates half bales and reruns.

Bulk Storage Solutions

A view of automated bunkers for recycling materials in a MRF.

The facility features automated bunkers for SOP, mixed paper, and OCC, an oversized push-through bunker for excess OCC, and a dedicated bunker for rigid plastics.

Installation Success

Image of an equipment render poster listing various equipment highlights and callouts of the system.

CP Group employed over 110 trucks during construction, showcasing collaboration among contractors and clients, while establishing robust walkway infrastructure and dedicated MCC rooms.

Engaging the Community Together

A view of the inside of a recycling facility window overlooking workers moving around the floor of the MRF.

Balcones is planning an education center aimed at training employees and industry leaders on advanced recycling technologies and promoting community awareness about recycling practices.

Empowering Employee Well-Being

An exterior company yard with grass and dirt, showcasing wooden platform risers with plants.

This site promotes a positive work culture with amenities including a soccer field, walking trails, and a vegetable garden, enhancing employee wellness and engagement.

Commitment to San Antonio’s Future

The exterior of a recycling plant showcasing solar sculptors to promote sustainability.

The team actively engages with the local community through educational programs, promoting recycling awareness, and encouraging sustainable practices.

Innovative Practices Driving Change

A view of different material grade bales of mixed paper, plastic and cardboard in front of the recycling equipment.

Balcones Recycling exemplifies innovative recycling practices, enhancing operational efficiency and contributing significantly to sustainable waste management solutions.

This article was originally posted, September 1st, 2024: Recycling Today