ITS' ALL IN THE NUMBERS - Marlborough's waste sorting facility journey
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ITS’ ALL IN THE NUMBERS
[Marlborough’s waste sorting facility journey]
Alec McNeil
[WasteMINZ Conference Paper October 2015]
This document contains information relating to Marlborough District Council’s Commercial
and Industrial Waste Sorting Facility (CIF) presentation at the WasteMINZ 2015 conference.
This information is a matter of public record and can be used by others considering a similar
project. Further information can be obtained from Alec McNeil, Tel: 03 520 7541 or
alec.mcneil@marlborough.govt.nz.
Contents Introduction ....................................................................................................................................... 1 What is a CIF?................................................................................................................................... 1 Why do we need a CIF? .................................................................................................................... 1 Where will the CIF be located? .......................................................................................................... 4 When will the CIF be up and running? ............................................................................................... 4 Who is involved in developing the CIF?.............................................................................................. 5 How much is the CIF going to cost us? .............................................................................................. 6 Are there any other facilities like this in New Zealand? ....................................................................... 7 Council’s Approval Process ............................................................................................................... 7 Only Marlborough .............................................................................................................................. 7 References ........................................................................................................................................ 8 Appendix 1 - Sorting Equipment Layout ............................................................................................. 9 Appendix 2 – Concept Layups of CIF Building ................................................................................. 10 Appendix 3 - Marlborough Resource Park ........................................................................................ 11
Introduction
This paper contains an overview of the strategic thinking and approval process underpinning
the development of a Commercial and Industrial Waste Sorting Facility (CIF) for the
Marlborough region. This facility will be the first of its kind in New Zealand to be developed by a
Territorial Authority (TA). The intent of this paper is to share this journey so far with other TA’s
to inform their thinking should they be considering a similar undertaking now or in the future.
What is a CIF?
The CIF is a sorting facility which will accept mixed loads of non-hazardous waste from
commercial operators and the Council’s transfer stations. The commercial loads have been
identified through an analysis of the incoming waste streams at the Regional Landfill
(Bluegums). At this stage loads likely to contain items such as liquids or other putrescible
materials have been excluded to avoid contaminating the overall waste stream and rendering
the diverted materials unfit for onward sale.
The transfer station loads will be source segregated at each location prior to dispatch to the
CIF. This will require some behaviour change and relationship building at the sites involving the
contractor Council and public.
The CIF will divert cardboard, plastic, glass, brick, soil, rubble, wood, GIB and metal for re-use or
recycling. Anything else will be sent to landfill. The diversion level has been set at 60% of
incoming waste.
Why do we need a CIF?
The region has an established network for the collection, processing and onward sale of
diverted materials from the domestic sector. This includes the provision of recycling facilities at
each transfer station and the establishment of a Resource Recovery Centre, in Blenheim, as the
main recycling processing point.
Page | 1Council have also established infrastructure for the collection of hazardous waste, ewaste and
reusable items from the community. Despite this investment the region still sends over 40,000
tons of waste (930kgs per capita) to landfill each year. The following table shows the
breakdown of landfill inputs over the period 2011 to 2015.
Product Product 2011/2012 Net 2012/2013 Net 2013/2014 Net 2014/2015 Net
ASB Asbestos 0 87 29 68
ASHId AshName T 195 T 92 T 84 T 119
BULK Bulk 6 3 3 2
C Soil Contaminate 0 0 0 4966
Polystyrene
GEN General 15632 15344 17979 17500
d Soil
GM Grape Marc 80 0 11 5
Refuse
KGW Kaikoura 0 77 21 0
LIQ Liquid Waste 33 77 122 357
General
MDCASB MDC 0 0 0 0
MDC-C MDC
Waste 1326 1266 1345 1509
Asbestos
MDC-G MDC 1093 3823 4148 3864
Cleanfill
MDC-S MDC Special 159 202 213 301
General
MSHELL Mussel 4237 2162 574 464
Waste
SAWD Sawdust
Refuse 2046 2223 2117 1315
Shells
SLDG Sludges and 1231 246 243 3356
TAG Replacement 0 0 0 0
Animal
WFM Winery filter 5127 5770 5918 4705
Key Tag
XFER Transfer
Wastes 7098 5711 6880 6749
media
XFERB Transfer 35 433 495 514
Station
Totals 38298 37516 40182 45794
Station
Waste
Bagged
Council assesses
Wastethe waste inputs to the Regional Landfill on an annual basis. This is achieved by
observing the Solid Waste Analysis Protocol (SWAP). Having visually identified potential
materials for recovery in both the General and Transfer Station waste category a SWAP was
used to quantify this.
Page 2The following table indicates the tonnage potential identified.
SWAP Classification % XFER Waste Possible Tonnage % Skip Possible Tonnage
Paper - Newspaper 0.6% 37 0.1% 6
Waste
Paper - Cardboard 7.7% 473 2.8% 168
Paper - Other Paper 3.0% 184 1.7% 102
Plastic - Recyclable 9.9% 608 4.3% 258
Plastic - Non 7.4% 454 8.8% 528
Putrescible - Garden 5.6% 344 8.3% 498
Recyclable
Putrescible - Kitchen 2.1% 129 1.1% 66
Ferrous 5.0% 307 4.4% 264
Non Ferrous 1.0% 61 0.3% 18
Glass 5.1% 313 2.0% 120
Textile - Clothing 1.6% 98 0.2% 12
Textile - Other 6.5% 399 2.9% 174
Sanitary 0.1% 6 0% 0
Rubble - Soil 1.2% 74 0.6% 36
Rubble - Gib 2.7% 166 7.6% 456
Rubble - Other 8.4% 516 23.5% 1410
Timber - Treated 17.1% 1050 19.4% 1164
Timber - Untreated 10.8% 663 11.1% 660
Rubber - General 2.5% 153 1.0% 60
Rubber - Tyres 1.6% 98 0% 0
Hazardous 0.1% 6 0% 0
Totals 100.0% 6,139 100% 6,000
This is why we need the CIF. Without this type of facility we would be unable to sort through
this tonnage.
The domestic diversion levels will continue to be grown through appropriate infrastructure
investment such as our Rural Community Recycling (RCR) program and by sustaining and raising
awareness through our education programs. However the single biggest impact on diverted
tonnage will be achieved through the establishment of the CIF. Once fully operational this
facility will divert over 8,000 tons of material compared to the 2,000 tons that pass through the
existing Resource Recovery Centre and the 2,500 tons of colour sorted glass that is collected
and sent to OI in Auckland for reprocessing.
Page 3Where will the CIF be located?
The CIF will be built on the existing Blenheim transfer station site in a building similar in size and
shape to the existing Resource Recovery Centre (L40m W26m H15m). This location was chosen
because of the operating cost savings ($400k per annum) that were established during the
contract tender process.
Having a standalone CIF would have introduced an additional overhead and cost structure.
Integrating it with the existing Blenheim transfer operation showed the greatest synergy. In
addition the proximity to other reuse and recycling facilities along with the existence of
established infrastructure such as roading networks was also taken into consideration.
The ability to construct the new facility whilst operating the existing transfer operation has also
been considered. In order to minimise the risks associated with having these two activities side
by side Council have decided to operate a temporary transfer station on an adjacent site during
the construction phase. This will reduce the overall risk profile for all parties by separating the
construction and existing operational activities.
When will the CIF be up and running?
The CIF will commence operations in September 2016. The weighbridge and sorting equipment
contracts have already been tendered and preferred suppliers selected. Actual contract awards
will be confirmed after the tender of the Design and Build contract for the CIF building and
associated site infrastructure. The operations contractor has already been appointed after a
tender process in 2013. This contract was for the provision of waste management and
minimisation services including the proposed operation of the CIF.
The start date for construction has been set for mid-January 2016 to avoid any clashes with the
holiday period and allow the existing transfer operation to remain open as long as possible
during our busiest period.
Page 4Who is involved in developing the CIF?
The CIF is part of the existing Waste Management and Minimisation Contract between Council
and Metallic Sweeping (1998) Limited. This contract began in July 2014 and runs to June 2021.
Metallic Sweeping will operate the CIF once construction is complete. A two year extension will
be issued once the operation commences to return the contractor to a 7 year term. This term
was identified during the tender process as a reasonable period to provide a rate of return on
any contractor capital investment.
Council will be funding the CIF building, sorting equipment and weighbridge system. The
contractor will fund internal mobile plant and equipment.
The sorting equipment supply and installation has been awarded to Wastech Engineering Pty
Limited and the supply and installation of the weighbridges, traffic management and reporting
package has been awarded to Gilbarco. All procurement is subject to a competitive tender
process. The Design and Build tender will be issued, submissions evaluated and award made by
October 2015 with final design expected to be signed off by the end of November 2015.
Council have used the services of a construction engineer to develop the Design and Build
tender and concept drawings. This has required input from all contractors with Council acting
as the facilitator ensuring that anticipated issues or customer behaviours are taken into
account in the design.
Internally at Council the finance department have assisted with cost model development,
CAPEX financing and revenue impact at the landfill due to the loss of tonnage. This impact
needs to be mitigated to preserve an income stream that is used to fund capital works for
future landfill stage development. To achieve this both the CIF and landfill are considered as
linked resulting in a gate fee price differential in favour of the CIF but maintaining the overall
surplus.
Page 5How much is the CIF going to cost us?
CIF capital costs for the building, weighbridges and sorting equipment are budgeted at $2.95M.
Operating costs are commercially sensitive between Council and the contractor. Contract costs,
overhead and debt funding will be paid for by a gate fee in the region of $110 per tonne.
Council have received financial support ($776k) from the Waste Minimisation Fund (WMF) after
a successful application to the 2014 funding round. This funding was not assumed in our initial
cost model approved by Council but has now been included. The funding will be set against
capital purchase items and will be subject to retention of 10% subject to the final Milestone
report in December 2017. This application followed on from a previous submission in 2012
requesting 80% of the cost from the WMF which was declined.
Weighbridges will be used to calculate the gate fee. The site layout excluded the use of one
bridge or side by side bridges for weighing in and out. This has resulted in a traffic management
system (including intercom) that will allow site users to communicate with the weighbridge
clerk if required from the entry weighbridge and a camera system with live feed from various
points around the site.
The public will use a system similar to car parking set ups. On arrival at the entry weighbridge
they will select the weigh in button which will generate a barcode ticket unique to their vehicle
and weight. Once they have dropped off their waste they will then use the exit weighbridge by
surrendering their barcode ticket. The system will calculate the weight difference and generate
a gate fee against the tonnage rate. Payment for the public will be via cash, cheque or Eftpos.
Operational management systems will be in place for lost tickets, minimum weights and other
such occurrences.
Commercial customers will utilise their DALLAS ID TAG already issued for the landfill. This will
have their vehicle and company details pre-set into the system (excluding tare weights). The
driver will leave site with a proof of delivery ticket detailing the transaction. Commercial
customers will be invoiced on a calendar monthly basis.
Page 6Are there any other facilities like this in New Zealand?
There are a number of sorting facilities operated by private sector companies dealing with
commercial, industrial and construction waste in major centres such as Christchurch,
Wellington and Auckland, currently (October 2015) there are none operated by Territorial
Authorities.
Council’s Approval Process
This project was originally defined through the Waste Assessment of November 2011 and
subsequent Waste Management and Minimisation Plan (WMMP) 2012 to 2018. The approval
route through Council involved the Executive Management Team and then the Assets and
Services Committee. The initial concept had projections in relation to Capital and Operational
costs. These were subsequently confirmed and refined through a tender process.
Building an understanding through committee of the process and the methodology of funding
the project was achieved over an eighteen month period during which time the second
application to the WMF was approved adding credibility to the project.
The CIF has always been based on a user pays gate fee approach avoiding the contentious area
of rate payer funding. This ensured that its passage through the Long Term Plan was not judged
in an arena of contestable funding in competition with other projects.
Only Marlborough
The CIF will be a first for Marlborough; the only commercial and industrial
waste sorting facility to be built by a local authority in New Zealand.
Marlborough is leading the way for local government with its approach to
commercial and industrial waste diversion. There will be challenges to get the facility up and
running but, with the support of our community, we are confident it will become something the
region is very proud of.
Page 7References
No academic references have been used or cited in this paper. Information on Council’s current Waste
Management and Minimisation Plan (WMMP) 2015 to 2021 can be found at the following weblink:
http://www.marlborough.govt.nz/Services/Refuse/Waste-Management-Minimisation-Plan.aspx
Page 8Appendix 1 - Sorting Equipment Layout
Page 9Appendix 2 – Concept Layups of CIF Building
Page 10Appendix 3 - Marlborough Resource Park
CIF
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