This is a self-contained and pollution free plant, which reduces the unsorted municipal waste into useful products, yet emits no noxious or hazardous waste, and leaves less that 2% residue, whilst employing up to 66 people.

Unsorted municipal waste arrives at the secure entry to the site of the treatment plant, in trucks typically carrying 20 to 25 tons of material each. 

These delivery trucks are checked in at the perimeter security gate and proceed to the weigh station, from where they are allowed to enter the discharge area of the enclosed and hermetically sealed plant building.

The waste trucks discharge their loads into the individual receiving hoppers which hold each separate batch of the waste.  Each truck will discharge into a different hopper, prior to inspection.  There will be a row of such hoppers acting as a reservoir to ensure that the plant is continuously fed with material, yet only requiring deliveries on 5 days per week. The separation by delivery ensures that each truckload of waste is individually examined for suitability prior to being processed. 

Each of the hoppers provides for inspection of the material on arrival, by several means, including visual inspection, air sampling and analysis, and by the insertion of sampling probes into the material.  This analysis is conducted in an on-site laboratory before clearing the individual load for onward processing. Any liquid is drained down and separated to go to a separate liquid treatment plant. 

Once the received material has passed inspection, it will be transferred by conveyor into the initial screening system which will include:

- Screens to remove larger particles;

- Ferrous Metal removal;

- Non-ferrous metal removal;

The separated material is then deposited onto an inspection conveyor.  Here it undergoes a preliminary physical sort by use of remote controlled combs and pickups, will select out any material considered unsuitable for the main process.  This material will go into separate retention bins for other processing elsewhere, either on or off site, as appropriate.

The selected main stream of material now flows through screening separation process where much of the plastic is separated for later use. It then undergoes shredding and grinding, before being delivered to the primary treatment tunnel, where it will be sterilized, pasteurized and air processed. 

This is a flow-line process ending in air separation.  At this point it is possible to remove the allied fluff, suitable for animal bedding and filler. 

The bulk residue now passes through a grinder, into the heater and mincer.  At this stage, the appropriate Plasticizers and Catalysts are added before the material is churned into the plastics processor, where the raw plastic material is formed. 

The material output of the plastics processor is fed into an extruder which produces the plastic boards, fence posts and other salable forms. From there, it feeds into injection molders which in turn pass the material under high pressure through dies, by both pushing and pulling, to form the resulting desired bulk product.

This formed product then passes to the saw table where it is cut to length and delivered into the process parts bins for sale to manufacturers.

There is also an intermediate residue of fluff, which can be used as compost, animal bedding, or landscaping mulch.

Physically, the plant will occupy a site of some 2 to 5 acres including parking and access ways, being housed in a one-story building of 30,000 sq. ft, having a hopper level excavated below ground to receive incoming material, with a sump level below that, the main plant being at ground floor level with the control room and offices arranged as a viewing gallery above.

At full operation, the plant will run 3 shifts, operating some 24 hours per day, with a total staff of up to 27 persons, including management, environment engineer / operators, maintenance, health and safety personnel and general laborers.
 
 The enclosed plant is separated into the following compartments:
- Hermetically sealed receiving area containing many hoppers;
- Environmental Laboratory;
- Hermetically sealed main process plant room;
- Generator, power plant, air scrubber and compressor room;
- Overhead control room incorporating fire control center;
- Offices for management, quality control and administration;
- Staff changing rooms, toilets and canteen;
- Training room, first aid room, decontamination room;

Separate satellite small treatment plants deal with all byproducts, including water, ferrous metals, non-ferrous metals, larger items, polluted air and detected contaminants, as appropriate.

And for each shift:
- Shift Supervisor (based in control room);
- Security / Weigh bridge Operator
- Maintenance Technician 
- Loader
- sorter x 2
- materials handler x 2