Infrastructure investment increases recycling processing efficiency up to tenfold at BVRio-supported cooperative
A new horizontal baling press acquired by the Cooperative Coopama, through the BVRio-supported Cooperate to Recycle project, has increased recycling processing efficiency by up to 10.8 times, according to an operational assessment conducted at the cooperative in Rio de Janeiro. The findings demonstrate the impact of mechanisation while highlighting a broader challenge for the sector: translating increased equipment capacity into higher volumes of recovered materials requires coordinated investment across the entire operation.
For PET, the press’s processing capacity increased from 2.5 kg per minute to 27 kg per minute, a 10.8-fold improvement. For rigid plastics, capacity rose from 5 to 27 kg per minute (5.4 times), while cardboard processing increased from approximately 7.3 to 19 kg per minute (2.6 times). Across the three materials analysed, the average improvement in baling efficiency was more than sixfold.
However, increased baling capacity does not automatically translate into an equivalent rise in the cooperative’s overall output. Fully utilising the equipment requires sufficient volumes of recyclable materials entering the facility, alongside adequate capacity for collection, sorting, storage, transport and sales.
“When we significantly improve efficiency at one stage, the bottleneck can simply shift to another part of the operation. A press capable of processing six times more material can only reach its full potential if collection, sorting and logistics can keep pace. That is why investment needs to consider the operation as a whole system,” explains Pedro Succar, BVRio’s Director of Circular Economy and project manager.
Mechanisation improves working conditions and safety for cooperative members
Another investment through the project, a forklift, has delivered significant improvements in working conditions. Previously, moving bales of recyclable materials onto trucks required considerable manual labour.
“For PET baling, we went from 2.5 to 27 kilos per minute. With the forklift, three cooperative members were able to load 10.8 tonnes in around 30 minutes; previously, the same task required six people, took more than an hour and left the team exhausted. Our challenge now is to expand collection and ensure enough material comes in to make full use of this new capacity, generating greater productivity, safety and income for our members,” says Luiz Fernandes, President of Coopama.
The experience highlights the benefits of modernising recycling cooperatives by combining new equipment with improvements across the wider value chain. These advances also build on the project’s previous investments in occupational health and safety, including the installation of a vertical baling press and training for cooperative members in its safe operation.
“More than simply installing equipment, the objective is to create the conditions for the cooperative to make full use of its capacity. When collection, processing and logistics improve together, investment can translate into more materials recovered, better working conditions and increased income for cooperative members,” adds Succar.
The initiative forms part of BVRio’s broader work to strengthen and professionalise waste picker cooperatives, combining technical assistance with improvements in infrastructure and operational management to promote safer working conditions, greater productivity and long-term economic sustainability.
