Optimizing Plastic Waste Recovery at Skelmersdale Recycling Plant
Streamlining process and communication workflows to improve plastic recovery outcomes.
Project Type: Case Study — Project Management & Sustainability
Year: 2020
Institution: University of Bath (UK)
Context
Plastic waste is one of the most pressing environmental challenges in the United Kingdom. To meet rising demand for high-quality recycled materials and reduce reliance on landfills, Viridor—one of the UK's leading recycling companies—launched the Viridor Optical Sorting Equipment (VOSE) project.
This case study examines how advanced optical sorting technology can transform recycling operations at the Skelmersdale recycling facility—blending engineering, project management, sustainability strategy, and change management to deliver a more efficient and scalable plastic-sorting system.
This case study examines how advanced optical sorting technology can transform recycling operations at the Skelmersdale recycling facility—blending engineering, project management, sustainability strategy, and change management to deliver a more efficient and scalable plastic-sorting system.
Project Goals
1. Enhance Plastic Sorting Efficiency
Increase HDPE recycling rates at the Skelmersdale plant from 50% to 70% by implementing advanced, automated sorting technology.2. Integrate High-Tech Optical Sorting
Install a Buhler Sortex optical sorting system capable of producing over 500 tonnes of HDPE per month and supporting long-term processing goals of 100,000 tonnes of plastic annually by 2022.3. Strengthen Project Management Processes
Apply rigorous project management methodologies, including risk management, scope definition, Work Breakdown Structure (WBS), scheduling & critical path analysis, stakeholder engagement, and change management.
Project Context
Viridor manages recycling operations for over 100 UK local authorities, but manual sorting methods were becoming inefficient and unable to meet quality requirements for recycled plastics.
The VOSE project—valued at £1.5 million and expected to run for 23 months—aimed to:
Reduce manual sorting
Increase accuracy in HDPE separation
Improve throughput and consistency
Support market demand for sustainable materials
To deliver the technology, Viridor collaborated with Buhler Sortex, a Swiss company specializing in high-precision sorting systems. The project required 35–45 personnel across both organizations and was delivered using a matrix project structure.
The VOSE project—valued at £1.5 million and expected to run for 23 months—aimed to:
Reduce manual sorting
Increase accuracy in HDPE separation
Improve throughput and consistency
Support market demand for sustainable materials
To deliver the technology, Viridor collaborated with Buhler Sortex, a Swiss company specializing in high-precision sorting systems. The project required 35–45 personnel across both organizations and was delivered using a matrix project structure.
Technical Scope
The project's technical deliverables included:
- Development of a custom sorting algorithm
- Hardware installation: detection units, conveyor system, idler mechanism
- Integration of the material handling system
- Staff training and transition from manual to automated operations
Milestones:
- Design completion: May 2019
- Equipment assembly: September 2019
- Testing & validation: December 2019
- Full operational deployment: By the end of 2020
- Development of a custom sorting algorithm
- Hardware installation: detection units, conveyor system, idler mechanism
- Integration of the material handling system
- Staff training and transition from manual to automated operations
Milestones:
- Design completion: May 2019
- Equipment assembly: September 2019
- Testing & validation: December 2019
- Full operational deployment: By the end of 2020
Key Project Management Contributions
1. Project Scoping & Definition
Defined clear project boundaries to prevent scope creep; established SMART objectives such as HDPE output targets and annual recycling volumes.2. Project Charter Development
Formalized deliverables, schedules, stakeholder roles, resource allocation, and risk thresholds to guide execution from initiation to completion.3. Work Breakdown Structure & Scheduling
- Created a detailed WBS from high-level phases down to individual work packages.- Managed dependencies between mechanical installation, software development, and system integration.
- Applied parallel task scheduling to minimize delays.
4. Risk Management
- Identified 10 major risks, including procurement delays, hardware misalignment, and software-integration challenges.- Built a risk register with likelihood, impact, and mitigation strategies.
- Calculated Expected Monetary Value (EMV) for critical risks.
- Used probability–impact matrices to prioritize interventions.
5. Change Management
-
Applied Kotter's 8-step model to support the transition from manual sorting to automated systems.- Addressed worker concerns about job security and new processes.
- Ensured staff were trained and capable of operating the system confidently.
6. Stakeholder Engagement
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Mapped stakeholders using the Power–Interest Matrix.- Managed communication strategies for high-power roles (e.g., Finance Manager).
- Kept low-interest but high-power executives informed without over-engagement.
7. Monitoring & Control
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Maintained performance baselines- Conducted milestone tracking
- Ensured corrective measures were applied proactively
8. Sustainability & Continuous Improvement
Identified long-term reinforcement measures to ensure the new technology delivers sustained environmental and operational benefits beyond project closure.
Impact
The VOSE project provided a scalable model for modernizing recycling operations across the UK. It demonstrated how advanced sorting technology—combined with strong project management and change leadership—can dramatically improve recycling rates, reduce manual labor dependence, and support national sustainability goals.
Skills Demonstrated
Project Management
Risk Management
Change Management
Stakeholder Engagement
Systems Integration
Sustainability Strategy
Technical Writing
Risk Management
Change Management
Stakeholder Engagement
Systems Integration
Sustainability Strategy
Technical Writing
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