1. Eric Masanet, University of California, Berkeley
An Assessment and Prioritization of “Design for Recycling” Guidelines for Plastic Components
Eric Masanet, University of California, Berkeley
Rudolf Auer, Dani Tsuda, Thomas Barillot, Andrew Baynes, Apple Computer Inc.

2. Introduction
Design for Recycling (DFR) is an important environmental strategy for Apple
DFR efforts require a significant investment of time and resources
Study purpose: To assess the effectiveness of DFR strategies for plastic components based on direct feedback from computer recyclers so that both product recyclability and design productivity can be maximized
Focus on plastics: highly visible, high degree of Apple design input, important for brand identity

3. Interviews
24 site visits and telephone interviews with recyclers and recycling experts in the United States and Europe
Feedback on current recycling methods and effectiveness of DFR for plastics
Feedback on plastic recycling trends for the future
Both manual and automated recycling systems were investigated:
Number of Interviews by Disassembly and Sorting Method
Disassembly Method
Plastics Sorting Method
Manual
Automated 16 2 4

4. DFR Guidelines Assessed#
Design for Recycling
Guideline
TCO ’99
Blue Angel 1
Plastic components > 25 g labeled per ISO 11469 R 2
Large plastic parts limited to one polymer type 3
Large plastic parts must not be painted such that weight is increased by more than 1% 4
No molded-in or glued-on metal parts 5
All plastic parts of same polymer type shall be same color S 6
Use of snap fits wherever possible
R = required for certification, S = suggested

5. Definitions
A DFR strategy improves the recyclability of a plastic part if it increases the number of potential recycling applications for that part at the end of life stage
A DFR strategy is effective if it provides guaranteed improvements in recyclability for plastic parts

6. Recycling Options for Plastics
Mixed Polymer Applications
Limited Mixed Polymer Applications
Single Polymer, Multicolor Applications
Single Polymer, Single Color Applications
Sorting Detail
Value

7. General Findings Typical batch of computers highly heterogeneous
Only the highest volume plastics in a given batch are typically sorted for recycling
Polymer Type
Market Share
Study 1
Study 2
Study 3
HIPS
22.7%
25%
10% 5%
ABS
20.5%
39%
34%
57% PC
19.2% 4% -
PC/ABS
11.7% 6%
29% 2%
PPO
6.5%
17%
12%
36%
Other
19.4% 9%
>1%

8. Manual Sorting Systems
Use of ISO Labels
Intent: To allow a human laborer to identify polymer
type by visual inspection
Manual Sorting Systems
Used extensively by those sorting plastic parts by polymer type
Up to 20% of existing ISO labels are incorrect!
Effectiveness: High
Automated Sorting Systems
Polymers are sorted based on mechanical and chemical properties, thus ISO labels have no effect
Effectiveness: None

9. Use of One Polymer Type for All Large Plastic Parts
Intent: To increase the volumes of a given polymer
for recycling
Manual and Automated Sorting Systems
Recycling of a given polymer depends on batch volumes of that polymer
Choosing one polymer only effective if that polymer occurs in high volumes in a given batch
Polymer choice for any one computer model found to have little effect on batch polymer composition
Effectiveness: Low

10. Limiting the Use of Paints to <1% of Total Part Mass
Intent: To minimize the potential adverse effects of
paints on plastic recycling
Manual Sorting Systems
Most painted plastic parts were not being sorted manually for recycling
Effectiveness: High
Automated Sorting Systems
Painted plastics can be sorted and recycled into higher grade uses if paint levels are pre-screened
Effectiveness: High
reiterate here that it is not paint that is bad, but too much paint that is bad

11. Avoiding Molded-in or Glued-on Metal Parts
Intent: To ensure metal parts can be easily removed
from plastic components before recycling
Manual Sorting Systems
Plastics with molded-in metal parts not sorted
Glued-on metal parts not problematic if easily removable
Effectiveness: High*
*for molded-in metal parts only
Automated Sorting Systems
Both molded-in and glued-on metal parts can be removed during the automated process
Recent study accepted up to 25% metals
Effectiveness: Low

12. Use of One Color per Polymer
Intent: To increase the volumes of single polymer,
single color plastics for recycling
Manual and Automated Sorting Systems
Due to heterogeneity of the typical batch, likelihood is small for choosing color/polymer combinations that will occur in high enough batch volumes for recycling
Only black and “computer beige” sorted
Recycler advice: do not worry about color
Effectiveness: Low

13. Use of Snap-fits
Intent: To allow for ease of disassembly for plastic parts
Manual Disassembly Systems
Snap-fits vs. threaded fasteners a matter of preference
6 of 14 prefer fasteners
Effectiveness: Medium
Automated Disassembly Systems
Plastic parts separated via destructive techniques, thus fastening method has no effect
Effectiveness: None

14. Prioritization of DFR Guidelines
Effectiveness for: #
DFR Guideline
Manual Systems
Automated Systems
Design Priority 1
Use of ISO labels
High
None 2
Use of one polymer for all large parts
Low 3
Limiting the use of paints 4
No molded-in or glued-on metal parts
High* 5
Use of one color for each polymer type 6
Use of snap fits where possible`
Medium
* for molded-in metal parts only

15. Future Trends Based on interview results and literature review
Findings:
Increasing levels of automation for disassembly systems
Rising labor rates, less resale, decreasing precious metals profits
Will necessitate automated plastics sorting
Increasing use of automated plastics sorting systems
Economic difficulties for manual sorting systems in the USA
Delphi study predictions: 80% say attractive by 2010

16. Conclusions
Using ISO labels, avoiding molded-in metals and minimizing paint levels were found to be the most effective DFR strategies
The effectiveness of DFR strategies depends on the recycling technology employed
For the automated systems of the future, minimizing paint levels will be most important
The results of this study have helped Apple better understand and communicate DFR priorities to its design engineers