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Plastic Recycling 1st Edition Sati Manrich Digital Instant
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Author(s): Sati Manrich; Amélia S. F. Santos
ISBN(s): 9781614705901, 1614705909
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Year: 2008
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Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 PLASTIC RECYCLING
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

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Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 PLASTIC RECYCLING

SATI MANRICH
AND
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

AMÉLIA S. F. SANTOS

Nova Science Publishers, Inc.

New York

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 Copyright © 2009 by Nova Science Publishers, Inc.

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Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 CONTENTS

Preface vii
Chapter 1 Introduction 1
Chapter 2 Waste Management of Plastics Residues 3
Chapter 3 First Steps of Plastic Material Recovery Process:
Sorting and Cleaning 7
Chapter 4 Mechanical Recycling 21
Chapter 5 Chemical Recycling 59
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

Chapter 6 Energy Recycling 63

Chapter 7 Remaining Challenges 69
Acknowledgments 73
References 75
Index 87

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 PREFACE

Since the discovery of plastics several decades ago, the widespread

consumption of plastic products and their subsequent inappropriate disposal and
accumulation have recently generated new societal concerns of waste
management due to their inherent slow degradability, high volume increase and
low recycling rates, which are negative on the basis of self-sustainability.
Regulations imposing waste reduction, reuse and recycling indices and
responsibilities, as well as effective collecting system and the development of
new, environmentally clean recycling technologies are some of the efforts to
achieve the self-sustainability goals. The efficiency of the collection and sorting
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

systems impacts directly on the amount of recycled plastics and on their cleanness
and quality, therefore, enlarging their market potential. The development of new
recycling technologies is diversified and can be classified into mechanical,
chemical and energetic recycling. In mechanical recycling, successful
technologies are achieved through the improvement of existing processes using
additives, blends with other plastics and alternative processing routes in order to
maintain the original properties of the virgin resin and even allowing them to
return to the same application as originally intended. Chemical recycling
processes to obtain intermediary products for new polymers become feasible due
to the cost reduction of the raw materials involved. Lastly, despite the under use
of the gross energy potential of the raw materials employed, energetic recycling
plants are gaining a proportion of residues whose technological solutions for
separation and/or reprocessing are deficient, but which, on the other hand, are
voluminous, consequently solving the problem of both residue accumulation in
densely populated regions and their respective insufficient energy supplies. In this
chapter, the authors proposed to present an overview of the current state of this
whole plastic recycling sector including their recent advances, and highlighting

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 viii Sati Manrich and Amélia S. F. Santos

new markets and recent trends on recycling technologies around the world.
However, mechanical recycling has been emphasized owing to the experimental
and published work of Manrich’s workgroup at the 3R Residues Recycling
Center, which has concentrated on studying all the steps in the process of
mechanical recycling.
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 Chapter 1

INTRODUCTION

For sustainable development and the limitation of environmental impacts to

become a realistic goal, reduction of the currently growing consumption of non-
renewable natural resources, reuse of products following consumption and
appropriate recycling of discarded residues are of paramount importance. The
effective practical application of the “3R” concept is especially important for the
burning of carbon-releasing energy sources to be minimized. Some studies have
indicated that, even if all emissions of CO2 and other greenhouse gases were
stopped immediately, the climate changes that have already occurred on the planet
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

would remain for some decades. Since from the stand-point of thermodynamics
and engineering practice, it is impossible to end such emissions altogether, efforts
have to be made to reduce the risks to the environment, whenever the opportunity
arises [1-3].
The reuse and various types of recycling of waste residues can lead to
reductions in the use of non-renewable material and energy resources, with the
energy savings generally ranked as follows: reuse > material recovery > energy
recovery (energy from waste). Conversely, burying the residues in landfills,
entailing as it does the total loss of material and energy, makes no such
contribution [2, 4]. In the case of plastics, whose main current source of raw
material is the petroleum, all recycling methods are technically viable and are
briefly described next [5,6].
Mechanical recycling consists of the reprocessing of plastic residues into new
products, different from or similar to the original products. The waste plastic used
may come from the manufacturing process or from post-consumer products. This
is the simplest way of recycling plastic waste, demanding the lowest initial
investments.

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 2 Sati Manrich and Amélia S. F. Santos

Chemical or feedstock recycling consists of using heat or chemical treatment

to break down plastic residues into their basic chemical components, the
monomers or other products, which can then be recombined into polymers or used
for other applications. Typical examples of tertiary recycling processes are
hydrolysis and pyrolysis. Unfortunately, this kind of recycling demands huge
investments and is therefore viable only for large-scale operations where the
volumes processed are comparable to those in the petrochemical industry
(thousands of tons annually).
Quaternary or energy recycling is the recovery of the energy bound in the
plastic, by combustion, thus economizing on fossil fuels. However, the operation
of such processes must guarantee that the emission of volatiles is controlled, to
prevent the environment being contaminated by other paths [7, 8]. Recently, this
type of process has been excluded from the normal concept of recycling and
mentioned only as a form of energy recovery. In fact, this line of recycling is
often regarded as a wasteful underutilization of the gross energy stored in the
plastic.
Even though all the methods of material and energy recovery from plastic
waste are technically feasible, in practice they encounter economic, legislative,
market and other barriers. Published contributions in regulations, management
and recycling of plastic waste using all forms of media are numerous around the
world. Frequently, in books of edited contributions dedicated to plastic waste,
each chapter deals separately with one of the topics covered. In this chapter, we
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

present an overview of the current state of the whole plastics recycling sector, if
somewhat sketchily in some areas, including a brief review of the recent research
and development in the fields of mechanical, chemical / thermochemical and
energy recycling of plastic waste. However, there is an emphasis on mechanical
recycling, owing to the experimental and published work of Manrich’s workgroup
at the 3R Residues Recycling Center, which has concentrated on studying all the
steps in the process of mechanical recycling.

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 Chapter 2

WASTE MANAGEMENT
OF PLASTICS RESIDUES

Since the emergence of plastics in the 1940s, which was impelled by their
notable cost-benefit advantages over the traditional materials they replaced, the
concepts of security, comfort and hygiene have been improved. In addition, their
intrinsic characteristics of lightness, low processing temperatures, durability, low
thermal and electric conductivity, transparency and flexibility, among others, had
an immediate and growing impact on the correlated manufacturing sectors,
reducing consumption of both energy and natural resources. Furthermore, the
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

plastics industry was enormously successful in developing novel materials such as

plastic wood, synthetic leather and paper.
On the other hand, the mounting volume of plastic residues, coupled with
their extremely low biodegradability, generated a serious problem regarding the
amount of space they took up. In the developed countries, the large urban centers
have real difficulties in finding space for all the refuse, needing in some cases to
transport solid waste over long distances to its final destination [9].
This problem, along with those arising from poor disposal methods and the
associated environmental impact, the high added value of waste, the need to
promote sustainable development of the production chain and to educate people to
be more aware of the environment, has stimulated much research and practical
activity in the fields of the recycling, degradability, reuse and reduced generation
of plastic waste.
In view of the fact that plastic is said to compose between 5% and 10 % by
weight of municipal solid waste (MSW) [10-12] and yet is the material of which
the smallest fraction is recycled [13, 14], there is an ongoing discussion among
government, society and the manufacturing sector on the apportionment of

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 4 Sati Manrich and Amélia S. F. Santos

responsibility for the management of plastic residues in MSW [15]. The difficulty
in recycling plastics arises largely from the big fraction of plastic products
considered unsuitable for recycling from the outset and from the high operational
cost of plastic´s collection systems.
Several mechanisms have been employed to increase the viability of the
reversed logistics of returning the end-product packing material to the recycler:
taxation of the manufacturing sector about government regulations [16] the
establishment of taxes on non-recyclable packaging [17] the mandatory use of
recycled materials in some sectors [9] incentives on the use of articles made
entirely of such materials, with the removal of all licensing requirements on those
who wish to produce them [18] the opening of new markets for recycled plastic,
implementation of policies of exchanging post-used packages etc. for toys,
spendable vouchers, or sports material in needy communities [19, 20] and lastly
programs to inform, raise public awareness and provide opportunities for
consumers to play their part [21].
In parallel, initiatives used to improve the recyclability of packaging by
manufacturing plastics parts with fewer different resins and with easier separation
of components that contain distinct resins, and reduce the use of multilayered
material [13] adhesives, additives and labels on packs also play an important role
[9].
Thus, in various parts of the world regulations have been adopted in order to
achieve short and medium-term recycling targets [13]. In the European
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

Community (EC), which became the European Union (EU) in 1992, the goals for
rates of recovery and recycling in the packaging sector were set by the Directive
94/62/EC [22] to member countries, establishing June 2001 as the deadline by
which these goals had to be reached: recycling of at least 25% and at most 40% by
weight of all waste packaging and recovery of at least 50% and at most 65%. In
addition, for each specific type of material, the fraction recycled should be at least
15%.
The available data confirm that these projected rates have been achieved in
paper recycling in the EU [23]. Considering the plastic packaging sector, in
Germany, the country that recycles the highest fraction of its waste in Europe,
these targets have also been accomplished, or at least approximated, except in the
case of composites. New EU targets for individual types of plastic waste have
already been outlined for 2006, in which at least 20% of each type should be
recycled [23]. These targets are currently being revised by the EU, but national
governments, such as the UK, are also reconsidering their own packaging
recycling and recovery targets for 2008 [21].

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 Plastic Recycling 5

The particular concern over post-consumer plastic from the packaging sector
can be explained by its short useful life, which reflects in its fraction 75% of all
plastic waste [24]. In the EU, the recovery of plastic packaging residues was
boosted mainly by improvements in mechanical recycling that resulted from better
solid residue management practice [25]. The system of selective waste collection
used in Germany, organized by Dual System Deutschland (DSD), is a worldwide
reference [26].
In the EU countries in the decade from 1993 to 2003, generally speaking, the
mechanically recycled fraction of all discarded plastic rose from 5.6% to 14.9%.
Over the same period, largely because of the contribution made by energy
recycling indexes, the fraction of plastic in landfill fell from 75.7% to 61% [14,
25, 27]. In Japan, the equivalent fraction for solid residues in sanitary tips is
around 40% and much of this waste goes for energy recovery. The use of energy
recycling in those countries is justified by the reduced combustion of fuels to
produce energy, by the release of oil for the manufacture of virgin plastics and by
the provision of an alternative source of energy that reduces the problem of
energy shortage.
Similarly, in 2000, about 11% of all plastic produced in the USA was
recycled. This represents a great advance, since a mere 1% of plastic residues
were recycled in 1987 [9]. Nevertheless, this advance in recycling indexes has
been achieved by formal recycling regulations [28]. Relating to Poly(ethylene
terephthalate) (PET) recycling indexes, the USA is currently going through a
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

period of stagnation in the recycling of this resin, according to the annual reports
published by the American Plastics Council (APC), in spite of the very high
recycling levels of PET achieved in 1995. At most, the amount of recycled PET is
increasing in proportion to the growth in production of the resin [17, 29]. In 2001,
the fraction recycled did not actually fall, but only because the slack in the home
demand was absorbed by the export market [17, 30]. In 2004, the fraction of
recycled PET was of the order of 21.6%, according to the National Association
for PET Container Resources (NAPCOR) [31].
Turning to Brazil, in a national survey carried out by Plastivida, the plastics
division of the Association of the Brazilian Chemical Industry (ABIQUIM), the
proportion of plastic residues transformed by mechanical recycling is around
16.5%, higher than that in Europe [32]. Furthermore, Brazil is the third biggest
market in the world for bottle-grade PET [18, 32] and the amount of this resin sent
for recycling is of the order of 35% [20, 34, 35].
Given the precarious state of waste collection system in Brazil, such high
rates of recycling are achieved only with the spontaneous involvement of low-
income families whose earnings come largely from collecting plastic residues [20,

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 6 Sati Manrich and Amélia S. F. Santos

35]. This segment of the population currently represents about 500,000 informal
workers [32].
Finally, another type of residue demands our attention: the great volume of
rubber tires discarded annually in Brazil and accumulated annually around the
world [36, 37]. Since the beginning of the nineties, many Federal and State
Government ministries have been developing their own legal responsibility for
this residue. In Brazil, resolution 258, passed by CONAMA (National Council for
the Environment), obliges tire manufacturers and rebuilders (of retreads, remolds)
to provide an environmentally correct destination for an amount of used tires
proportional to their volume of production since 2002 and 2004, respectively [38].
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 Chapter 3

FIRST STEPS OF PLASTIC MATERIAL

RECOVERY PROCESS:
SORTING AND CLEANING

SORTING
One of the stages of plastic recycling that most threaten its feasibility as a
productive operation is the sorting of plastic material from mixed waste and,
especially, separation of the different types of plastic, which is hindered by the
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

fact that quite different plastics may be used for the same end. In other words, a
given product can be fabricated with very similar characteristics from distinct
plastics and these act, in mixed residues, as impurities of each other after
separation. This reduces the viability of the process and, in serious cases, can
cause a whole production line to be shut down [39, 40].
Related problems that must also be taken into account are those of
multicomponent items, good examples being car parts and plastic electric and
electronic devices with embedded metal inserts, and multilayered products such as
laminated, co-extruded or metalized flexible packaging [39-41].
The ideal practical solution to this problem would be to make suitable
alterations in the plastic residues at source; that is, to redesign the original plastic
product. At the design stage, then, priority should be given to reducing the
number and variety of components in one product and the variety of materials
employed as consumer goods with identical functions. Such ideas are exactly the
opposite of current design trends, particularly in the packaging and disposable
goods sectors. In most cases, the existence of multicomponent and multilayer
residues is justified primarily on technical grounds, while the reasons for

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 8 Sati Manrich and Amélia S. F. Santos

fabricating essentially the same product from diverse materials are based on
economics and marketing [41]. It is thus hard to imagine the above-mentioned
reversal in product design trends becoming a manufacturing priority on the
grounds of purely environmental gains.
Nevertheless, on the positive side, all over the world we see a lot of effort
being put into the research and development of appropriate technology that will
minimize the problems caused by mixed plastic waste and varying materials.
These studies concentrate on two fronts: the efficient separation of different
plastics and other components, and optimization of the composition of compatible
blends, or plastic composites of different materials, that combine, profitably, the
distinct properties of the component polymers [39-46]. The first of these research
areas will be discussed here and blends and composites in later sections.
The techniques used to separate mixed plastic residues can be classified in
several ways, but here they will be grouped as manual or automatic and each will
be approached in a specific way.

Manual Separation

The efficiency and productivity of this method depend entirely on the

experience of the workers responsible for identifying and sorting the plastic
residues. This is the method used in the vast majority of micro and mini-
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

enterprises in developing countries, where manual labor is cheap, and in Materials

Recovery Facilities (MRFs) worldwide, although it is still used even in some large
organizations that recycle electro-electronic residues in developed countries [39,
42]. When training technical personnel in the manual separation of plastics, basic
notions of how to distinguish between these materials have to be introduced. A
systematic procedure for the identification of components of municipal plastic
waste, especially the most prevalent plastics, which was proposed in an earlier
publication of the Manrich’s workgroup, has until now helped the Brazilian public
to achieve this aim [39].
This method consists of three steps: in the first, the identification is made
directly by codes; in the second, the identified product is correlated with the most
likely material, and in the third, certain properties specific to each material are
determined. The three steps are briefly described next.

− Step 1: Locate the identification code and note the number or

abbreviation found in the recyclable plastic symbol: 1 = PET, 2 = HDPE,
3 = PVC, 4 = LDPE/LLDPE, 5 = PP, 6 = PS and 7 = others, where

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 Plastic Recycling 9

HDPE, LDPE and LLDPE are high density, low-density and linear low
density polyethylene, respectively, PVC is poly(vinyl chloride), PP is
polypropylene, and PS is polystyrene. However, the residue from a
product, part or component does not always display a code, which may be
molded in relief or printed on the surface. If the code is missing or
identified as 7, the procedure has to move on to the following steps.
− Step 2: Consult a table of data, such as table 1, which helps the user to
identify the most likely material in a given product. It is found that,
contrary to what would be environmentally correct, the number of most
probable materials rises through the years, albeit rather slowly. Hence,
from time to time, these tables need revising.

Table 1. Polymers used most frequently in fabrication of packaging material

Type of packaging Typical use Most probable material*

Carbonated soft drinks PET
Cleaning materials and HDPE, PP, PVC
toiletries PET, PVC
Bottles Cooking oil PET, PP, PVC
Mineral water PP, PVC
Vinegar HDPE, HIPS, PP
Yoghurt drinks
Margarine HIPS, PP
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

Yoghurt HDPE, HIPS, PP

Pots, containers and
Sweets and chocolates PET, PP, PS, PVC
trays
Disposable plastic cups HIPS, PP
Prepacked fruit & vegetables PS, PVC
Soft drinks PP
Cleaning materials and HDPE, PP
toiletries HDPE, PP
Cooking oil LDPE
Lids Vinegar HIPS, PP
Yoghurt HIPS, PP
Margarine LDPE, HDPE, PP
Mineral water HDPE, HIPS, PP, PS
Sweets and chocolates
Plastic bags Supermarket bags HDPE, PP
Fruit and vegetable bags LDPE, LDPE/LLDPE,
Films† HDPE, PP
Biscuits and snacks bags LDPE, LDPE/LLDPE, PP
*
While these materials are the most likely ones, the packaging can be made from others.
†
Film is a term used for plastic sheets 254 μm or less thick, normally used in shopping
bags.

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
 10 Sati Manrich and Amélia S. F. Santos

− Step 3: Given the list of most likely plastics, determine some specific
distinguishing properties that are simple to compare; these are indicated
below, for the case of post-consumer plastic packaging. Here we will
omit the techniques of differential scanning calorimetry and infrared
spectroscopy. Depending on the plastics in question, identification may
be achieved by testing only one of these properties, or a sequence of tests
may be required. This sequence varies from case to case and an example
will be given later, for the case of plastic bottles.
− Transparency: transparent ⇒ PET, PP, PVC, PS; translucent or
opaque ⇒ HDPE, PP, high-impact polystyrene (HIPS),
LDPE/LLDPE, PET.
− Whitening: exhibit whitening when folded ⇒ PP, HIPS, PS, PVC.
− Hinge: PP is the only plastic that withstands the repeated force used
to open and close the pack with a one-part device, the hinge.
− Density: the polyolefins, (HDPE, LDPE, LLDPE, PP) and expanded
polystyrene (EPS) float on water, being less dense (ρ < 1.0 g.cm-3).
− Combustion: the flames and smoke given off by burning plastic are
characteristic of each type. Table 2 describes these features of several
plastics.
− Solubility: ability to dissolve in various liquids or solvents is specific
to each plastic. Table 3 shows some examples.
Copyright © 2008. Nova Science Publishers, Incorporated. All rights reserved.

− Halogen or Beilstein test: if a copper wire is heated to redness, rested

on the plastic and then returned to the flame, and the flame turns
green, the residue is a halogenated plastic, such as PVC, which
contains chlorine.
− Hardness and malleability: it is very hard to distinguish polyolefins
from each other by means of simple tests alone. Experienced
technicians differentiate the polyethylenes, LDPE and HDPE, from
other plastics, including PP, as they are readily scratched with the
fingernail, whereas the rest are too hard. Since LDPE is more
malleable than HDPE and PP, it can be distinguished by bending or
pressing the article.

Plastic Recycling, edited by Sati Manrich, and Amélia S. F. Santos, Nova Science Publishers, Incorporated, 2008. ProQuest
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 It was known, of course, that a band saw under stress would be
inclined to gravitate to the rear. In this mill the attempt is made to
prevent this and compel the saw to follow its proper path around the
wheels by raising or depressing the tail end of the top wheel shaft;
and in order to do this automatically a steel trolley was applied to
the rear edge of the saw, closely following it, whatever its position
might be; but any movement of the trolley towards the front or rear
was followed by a corresponding adjustment of the tail box of the
top shaft. The effect of the trolley on the edge of the saw was bad;
and besides that there really was no special need of any device of
the kind.
In connection with this mill there are also three other interesting
features worthy of mention, as one of them in particular illustrates
the method then prevailing of preventing a log from rubbing or
dragging against the saw when the carriage was run back or being
gigged for the next cut. At the present time an off-setting
mechanism is applied to the carriage trucks, but previously a
depressor, so-called, was applied to all mills substantially as shown
in the Wilkin mill and others illustrated herein. That is to say, both
the upper and lower saw guides were movable transversely, and the
off-bearer by means of a hand lever, forced the guides back from the
saw line, carrying the saw sideways away from the log, and in this
manner contact with the face of the log was prevented; but it was
hard on the saw.
In this mill, however, there is a new departure as shown by the
application of two small friction rolls or pulleys behind the saw, in
place of the usual saw guides; the idea being to force the saw out to
the saw line by means of the rolls, and then when the carriage was
gigged the rolls were moved back and the saw permitted to fall away
from the face of the log; this feature being an imitation of the same
thing embodied in the Allington mill previously built at Saginaw, but
not shown herein. This arrangement, however, proved to be severe
on the saws, because such short bends will crack them in a short
time, and besides this the rolls made such a roar in a mill that not
much else could be heard.
 Next in this mill a spring was employed to maintain a sensitive
automatic strain on the saw; and this, like the other special features
of the mill, proved worthless, and the mill, like the Allington, went
out of use and is unknown to the art now.
Now in all the preceding it is shown that Saw Mill Machinery
Builders were studiously striving during all the years between 1880
and 1887, and some of them to a much later date, to produce a
Band Mill for sawing logs that would do good work and as much of it
as lumbermen would be satisfied with, and that, too, without so
much cracking and breaking of saws. The simple fact that they were
continually devising new constructions with a statement each time
that now they had struck it, and the further fact that without an
exception all of these were entirely abandoned and fundamentally
new machines brought out at a later date, prove indubitably that all
of their former efforts had failed to meet the full requirements which
lumbermen expected and demanded.
The question then naturally arises, how did it come about that
successful cutting band mills of a wholly different type are now
universally in use? Who is the man who originated the strictly
modern band mill that served as a pattern for all to follow? The
following will explain it:
Aug. 23 and Sept. 13, 1887, patents were issued to D. C.
Prescott, then of Marinette, Wis., for improvements in Band Saw
Mills, and other patents followed shortly thereafter on further
improvements.
 D. C. Prescott in 1887

The creation of these mills was purely upon the principle

previously described by Mr. Esplin who so signally failed in its
application. Plainly it was evident that to secure a nervous, sensitive
and constant strain on a band saw, it was imperative to reduce the
weight upon the straining levers to the least possible quantity
consistent with strength, and to make all the pivotal points as near
frictionless as possible by the intervention of knife edges or ball
bearings; and while it was impossible to reduce the weight to a point
so as to accomplish an automatic adjustment as quick as a flash, it is
a fact, nevertheless, that in the Prescott mills of that date a strain
was automatically maintained sufficient to successfully accomplish
the work of sawing lumber accurately and in acceptable quantities.
And these were the mills that set the pace for all other builders and
revolutionized saw mill constructions.
 PRESCOTT BAND SAW MILL
Patented September 13, 1887; over 150 built and most of them
are
in service at the present time, 1910
 PRESCOTT BAND SAW MILL
Patented November 26, 1889, with set-off for increased space
from saw line to column. 8 foot wheels, 12 inch saws

The light metallic top wheel with its shaft, runs in boxes
mounted on plungers, and from them stems lead down to the
straining levers, and all were made as light as possible.
Characteristically about all band mills now employ this system, and
whether they have a single column or a double column, the
arrangement is substantially the same.
We often read of big day’s work performed by some make of
band mill, but it is proper to say that the day’s work performed in
the saw mill of the North Wisconsin Lumber Co. at Hayward, Wis.,
has never been equaled. This was done by two of Prescott’s No. 3
mills, being the second one illustrated, as follows:

NORTH WISCONSIN LUMBER COMPANY

Hayward, Wis., Aug. 23, 1893.

D. CLINT PRESCOTT.
Dear Sir:—The North Wisconsin Lumber Company made
the following cut: August 22, 1893, with two Prescott Band
Mills only, 609 selected logs, scaled full. Average 1.97 to
1,000 feet, 309,400 feet.
Lumber scale, 1 inch, 45,236
1¼ and 2 inch, 294,077
339,313 feet
The cut of August 22nd shows what can be done with
large logs, and the cutting was as perfectly done as any day’s
cut we ever made. W. H. Elliott, Superintendent of Valley
Lumber Co., Eau Claire, and A. L. Ulrich, of Rice Lake Lumber
Co., will vouch for the cut of August 22nd, as well as Captain
Rogers, our Superintendent, and myself.
Yours truly,
R. L. McCORMICK,
Secretary N. W. L. Co.

It is of interest to note the gain of about 30,000 feet by sawing

the logs with a Band Mill instead of a Circular Mill.
This record, widely published at the time, coupled with the fact
that nearly three hundred Prescott mills were then in successful
service, is evidence enough to show that all other Band Mills as
herein shown had become obsolete and were back numbers, and
were abandoned for the later constructions all are now familiar with.
 But before any of them, or any of the others that have appeared
on the market since then, can boast of big cuts or a superior grade
of mills, it is up to them to show a better record than the one above
given; a record that will be vouched for by Mr. McCormick who is still
alive.

R. L. McCormick in 1893

There are also two of this same type of Band Mills now running
in the saw mill of the Fosburgh Lumber Co. at Norfolk, Va., and
notwithstanding they are nearly twenty years old, there are no
Bands on the Atlantic seaboard anywhere that equal them today,
either in the quality or extent of daily output.
The short, compact mill with the base above the overlays of the
saw floor, originated with Prescott. Wood rims with rubber faces on
the wheels were speedily abandoned by him, and wheels all of metal
were brought into use, so that a filer in rolling tension into the saw
had a clean wheel free from bunches of pitch and sawdust which
stuck to the rubber faces and produced unbalanced wheels; but then
everybody supposed that rubber faces were a necessity. Mr. Prescott
demonstrated that the mill was vastly better without them.
The late improvements made in frame constructions merely add
stability without increasing the quality or extent of the output, this
being entirely dependent upon a light weight of the top wheel with
its shaft and boxing in combination with a straining lever system
made as frictionless and sensitive as possible; for without these
good conditions no band mill will render duty of the highest grade.
Logically, then, the same principles and elements of construction
have been embodied in all the splendid Band Saw Mills now built by
The Prescott Company herein shown.
 STANDARD HEAVY BAND MILL
Of 1910, for sawing logs

Of this type The Prescott Company builds the following sizes,

both right and left hand, single or double cutting:
Diameter of 7 feet for 10 inches wide.
wheels saws
” ” ” 8 ” ” ” 12 or 14 inches
wide.
” ” ” 9 ” ” ” 12 to 16 ” ”
 Next is shown the Pacific type of the Prescott Band Saw Mills for
cutting large logs, having wheels 9 feet in diameter, and using saws
from 12 to 16 inches wide. They are built for double cutting as
shown, as well as for single cutting. Their dimensions are about as
follows:
Base 9′ 7″ by 11′ 7″.
Maximum distance between guides 6′ 6″.
Distance from saw line to column 4′ 6″.
Maximum length of saw 53′ 6″.
Weight from 42,000 to 45,000 lbs.
When desired a steam cylinder is applied for operating the upper
guide, and a reversing engine for adjusting the top wheel when
changing saws.
Their straining mechanism is exceedingly sensitive, their shafts
are large, their boxes 18 inches long and water cooled; so that in
every respect these mills are perfectly equipped, and a 20-inch
double belt is necessary to drive them.

* * * * *
For the largest logs of the Pacific coast cut with a Band Saw Mill,
The Prescott Company advanced to a mill of the same type but
having wheels 10 feet in diameter for saws up to 18 inches in width.
The base of this mill is 10′ 7″ by 14′ 6″.
Maximum distance between guides 7′ 3″.
Maximum length of saw 60′ 9″.
Distance from saw line to column 5′.
Weight from 54,000 to 58,000 lbs.
The shafts are large with 20″ water cooled boxes. Steam is
applied to operate the top guides and adjust the top shaft when
desired. A 24-inch double belt is necessary to drive it.
PACIFIC COAST, 9 FOOT SINGLE AND
DOUBLE CUTTING BAND MILL
 PACIFIC COAST, 10 FOOT BAND MILL

In every respect these mills are splendid creations and exhibit a

vast stride in advance of the earlier mills described herein.
All of these mills are provided with a surrounding base, a
powered upper guide, quick opening lower guide (as shown on page
45), live roller, means for maintaining alignments and adjusting the
upper wheel when changing saws, the latter being done either by
hand or power as required; and the upper wheel in all of these mills
when raised to the maximum point admit of the use of a long saw
for sawing occasional large logs, a saw two feet shorter being in use
normally for medium sizes of logs which are mostly cut. And these
mills in combination with a Prescott carriage constitute an equipment
absolutely unrivaled by any other productions in the world.
Rack and pinion head blocks, every piece of which is an open
hearth steel casting, are furnished in sizes varying from 36 inches to
72 inches, being the distance the knees recede from the saw line;
and these with frames proportionate in dimensions and composed of
well seasoned southern pine timber, well ironed and braced,
comprise great strength and durability.
For mechanically exact setting, all racks, pinions, taper sets and
ratchet wheels are cut from solid blanks in a gear cutter. The knees
are operated either by hand lever and quadrant, the familiar way, or
by a Prescott Steam Setting Machine, which advances them for 4-
inch lumber or any thickness less, varying by 1-64th of an inch to
every click of a pawl on the ratchet wheel, and that too with a single
rearward and return stroke of the piston, so that great speed and
accuracy are the characteristics of this machine; and with it an
increase of cut is obtained by reason of the fact that the setter does
not get tired, and no sawyer will have to wait for him. And more,
with them a mill man can keep a good setter who otherwise might
be on the hunt for an easier job.
These carriages are also supplied with Friction, Spring or Steam
Receders, which latter can be employed in all cases where Steam
Sets are used for which steam is delivered to the moving carriage.
The value of steam receders consists in the ability to advance or
recede the knees at any time whether the carriage is moving or at
rest, and for receding the knees of large blocks sawing short logs
only.
 Standard 3-Block Carriage with 4-
inch combined steam and
ratchet set works

A Revolving or Flat Scale always indicates the position of the

knees. Dogs hold the logs. An Automatic Offset gives a clearance of
the saw when on the gigg, and Steel Trucks and Steel Track
necessarily go with such a carriage, composed either of heavy T
Rail, or the lighter rolled track, according to the size and weight of
the carriage.
For accuracy and speed these carriages have no equal, especially
when handled by a Prescott Direct-acting Steam Feed.
 PACIFIC COAST SCREW BLOCKS

Both the knees and bases of these blocks are composed of solid
open hearth steel castings faced with heavy steel bars, presenting
wide surfaces for the knees which are grooved to fit them. The
knees are supplied with rolls, spud and extension hook dogs. The
screws are 4-inch pitch and triple threaded. The gears are steel and
cut in a gear cutter and are actuated in setting by hand levers and
quadrant or by power in accordance with the wishes of a purchaser.
The Prescott Company furnishes these blocks in the following
sizes, viz.: 72-inch, 84-inch and 96-inch; being the distance the
knees recede from the saw line.
And in all other respects the equipment of the carriage is very
heavy and fully up to date in every respect.
 QUICK OPENING LOWER GUIDE

These Guides are applied to all Log Band Saw Mills built by The
Prescott Company. When slivers, bark or sawdust wedge in the
Guide and cause trouble and heat the saw, then the Guide is
promptly opened by the off-bearer and the stuff falls through.
When changing saws the Guide can be promptly opened.
 VERTICAL BAND RESAW
Made in 7-foot, 8-foot and 9-foot sizes

The Prescott Vertical Band Resaw

This machine is built in three sizes, viz.:
With wheels 7 feet in diameter for 10-inch saws.
” ” 8 ” ” ” ” 12 ” ”
” ” 9 ” ” ” ” 12 ” ”
It is distinctly a machine for resawing plank, cants or timber up
to 16 inches in thickness. The mill proper is provided with a
surrounding base and is constructed upon the same principles as are
all Prescott Log Band Mills. The feed works being driven by the
machine itself makes the whole self-contained. The outside pressure
rolls, are adjusted by power; and the inside rolls are operated by
hand levers and notched quadrants, and regulate all thicknesses of
lumber to 1-32 of an inch. And all of these rolls are power driven. All
gearing is steel, the upper guide is power operated, and the mill
itself is made self-centering when desired, although this feature is
not specially necessary in this machine.
No finer machine exists for resawing lumber and timber coming
from a log Band Mill or a Circular.
It is not adapted for resawing slabs.

HORIZONTAL BAND RESAW

Built by The Prescott Company, Menominee, Mich.
Standard Prescott Horizontal Band Resaw Mill
For Resawing Slabs and Planks
The machine shown upon the opposite page has wheels 6 feet in
diameter, and admits upon the feed rollers a slab nearly 30 inches
wide and about 12 inches high, so that half logs of considerable size
may be sawed as well as slabs.
Numerous feed rollers are employed instead of the endless
platen or apron, thus insuring efficiency and durability.
The feed rollers are mounted upon an independent frame which
can be withdrawn when necessary for purposes of repair. This is
adjustable vertically by means of a hand lever with quadrant for
setting the machine to saw lumber into the required thicknesses.
The base and frame are heavy and substantial, and the
machinery is located above where it is accessible and out of the way
of the dirt which may accumulate. A very sensitive saw straining
mechanism is applied.
The pressure sprockets are supplied with power for such
material as may require it, and is omitted, however, when it appears
unnecessary. The feed can be increased, diminished or reversed.
The machine is located upon beams on the line of the overlays,
requiring no special substructure to support it.
Other sizes are supplied for special uses and further information
will gladly be given by correspondence.
 The Prescott Company
Manufacturers of

Strictly Modern Saw Mill Machinery of standard

sizes for medium logs and a heavy class
for the large logs of the Pacific
Coast or elsewhere
comprising:
Band Mills
for logs and resawing purposes,
Circular Mills,
Carriages,
both Rack and Pinion and Screw Setting
Steam Setting and Steam Receding Machines,
Edgers—3 types
Trimmers—3 types
Log Stops and Loaders,
Slashers,
Lath Mills,
Live Rolls,
Transfers,
Log Jackers,
Steam Niggers,
Log Turners,
Kickers,
Dogs,
Rift Sawing Machines,
 Steam Jump and Swing Saws,
Offsetts, etc., etc.
And a full line of Transmission Machinery all built for either Wood or
Steel Construction.

PLANS OF SAW MILLS WITH SPECIFICATIONS AND ESTIMATES

FURNISHED.

SEND FOR CATALOGUES

Branch Offices
Chicago, Ill. Seattle, Wash.
New York

California Agents
The Eby Machinery Co.
San Francisco
 Plant of
The Prescott Company

Works and Main Office:

Menominee, Michigan
 Transcriber’s Notes
Punctuation and spelling were made consistent when
a predominant preference was found in this book;
otherwise they were not changed.
Simple typographical errors were corrected;
occasional unbalanced quotation marks retained.
Ambiguous hyphens at the ends of lines were
retained; occurrences of inconsistent hyphenation have
not been changed.
Page 20: “slack slide” was printed that way.
*** END OF THE PROJECT GUTENBERG EBOOK THE EVOLUTION
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