中国废塑再生企业的困境与思考

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中国废塑再生企业的困境与思考：

           1 行业概貌

       废塑再生是1990年后，随着中国塑料工业的发展和全球化背景加工业的崛起而产生的，始发阶段的丰厚利润触发行内人士的投资狂潮与裂变。截至2007年底，中国已有年再生能力2000吨以下的加工企业2万多家，从业人员超过100万人，年处理能力可达5000万吨的规模，成为全球最大的塑料再生基地。

       数量庞大无序扩张以及互联网普及引发的资讯透明，加工企业的竞争空前剧烈，利润空间得到强力的压缩，绝大多数吨加工利润小于300元甚至亏损。由于行内企业规模较小，年加工能力3000吨以上的不足10%，工艺技术含量普遍较低，在日益高涨的环保浪潮中，作为循环经济环保产业中坚的废塑再生企业，面临巨大的挑战。

       2 困境分析

       事实上，我国已超过美国成为全球最大的塑料消费国，40%以上的原料缺口是由再生料来弥补的。废塑再生利用能有效减少环境污染和能源的巨大消耗，为国家的可持续发展提供力量支持的同时，也陷入了令人窘迫的境地。

       2.1 竞争性采购

       由于内地及进口废料难以满足国内过剩的加工能力，企业不由自主地提高采购价格来满足生产需要；与此同时，供货商有意无意地加大废料的杂质或水份以及废料本身的不确定性与实用分拣技术的严重滞后，在传统的工艺技术条件下，致使加工企业原有脆弱的盈利平衡向亏损的方向倾斜。在可以预见的时间内，这种局面的改变是相当困难的。

       2.2 产品附加值低

       已使用过的废料，其表面一定受到诸如泥沙、油污等自然条件下有害环境物质的污染，另外相当部分基材表面有功能性涂（镀）层、印刷油墨或不干胶标贴。任何未将与基材不同物化特性的表面物质除去或对基材有伤害所进行的再生，其产品的功能特性或外观美感都会有较大的降低，因此产品的附加值低，甚至为后继的循环使用造成不可逆转的障碍。也正是这样，展现在行内企业面前的生机勃勃日新月异的技术变革，才是也必然是企业现在及未来持续进步的基石和希望。

       2.3 工艺技术落后

       广泛调查中我们注意到：别说小规模企业，就是中大型的，其工艺技术水平与几年（甚至10年）前没有本质上的区别，只是人员、厂房、设备等的线性增加而已。这种场地、能源、人力的大量消耗，造成加工制造成本的增加，客观上收紧了利润空间。

       这主要是由于企业的技术团队构建存在实际操作上的困惑：一方面技术研发的巨额资金投入；另一方面也担心人才队伍的稳定性及商业技术机密保护的有效性。培养和造就这样一支从材料分拣、清洗、分离、环保、工艺装备等等系统全面的技术队伍所面临的巨大风险和不确定性是企业谨慎不前的重要因素。于是，我们看到绝大多数企业，企业主是企业赖以生存的技术中坚。

       在工艺装备方面，虽然近年来我国再生通用机械的制造工艺获得较大的提高，并已成为全球制造基地，但在分拣、清洗、分离方面仍有待改进完善。当然，装备提供商所生产的通用设备是难以满足使用企业的各种个性特殊要求的；再者由于制造商在广泛再生技术方面的局限和欠缺，也使装备的使用效能和企业的质量目标存在明显的差距，而任何存在的客观因素，都会使企业最终降低利润期望。

       2.4 技术信息混乱

       为迎合企业廉价获取新工艺技术的渴慕，看来似乎能带来丰厚利润喜乐的新技术（配方）转让出现在各种可能的媒介上。为数众多的中小企业从任何渠道截到的繁杂技术信息，由于缺乏专业技能和科学鉴别，难以进行有效的过滤；另外不排除发布者本身的项目技术未进行过充分的验证和可行性分析，或者掺有猜测及虚假成份的可能性，因此在实际应用中，企业往往付出了高昂的代价而无法达到预期目标。

       2.5 环境友好的担忧

       绝大多数行内企业都会关心环境污染，但由于再生工艺技术落后，废水（气）处理难度高，在巨额环保治理投资方面显得力不从心，还有高昂的运行费用也无法承受。处于微利状态的中小企业无所适从，无奈之下只好以牺牲环境为代价，这样导致企业与所在社区、政府相关部门的冲突明显增加。为应对各层面的检查、声讨和罚款，企业正常的生产秩序，生产利润受到严峻的冲击。

       我国可持续发展已经走上绿色GDP之路，各地政府均在尽力破解行内企业污染的困境。于是近年在中国大地上，先后出现了众多集中再生治理的工业园区。在为中国循环经济做出巨大贡献的这些远见卓越的地方政府领导人献上我们颂赞的同时，应该注意到，无论如何，现在条件下园区内只能解决不足10%的塑料再生。这就意味着，行内企业环境友好的治理这一过程不是立竿见影的，因为有赖于工艺技术的创新。我们相信，任何环境友好的工艺技术变革，应会得到各界的支持和尊重，因此政府应在这一介面上加大技术研发投入，并对企业进行有用的引导和扶持。

       3 行进中的思考

       以节能减排循环经济为导向的工业转型期，面对劳动力、场地、能源等等成本的抬高，塑料再生价格间距的缩短，业内人士有必要静默沉思。

       3.1 提高产品附加值

       企业至今仍然沿用传统技术进行再生，由于通常无法将表面各种污染物质彻底清除，产品的附加值无法提高，而要实现这一目标，在现有工艺条件下，是完全有可能的。在实际操作中，企业应先与技术力量雄厚的专业机构建立密切的合作关系，做为企业自身的技术支撑平台，然后由专业机构对企业项目进行全面评估验证，企业应选取吨加工计算利润可达1000元以上的项目技术，从通用废料到工程废料，这样的利润目标项目有很多，只有这样，企业才有能力抵御不可预侧的风险。

       3.2 完善工艺技术条件

       现有的再生企业之所以远离城市集中在农村，主要是降低占用场地及劳动力成本。工艺装备简单、生产效率低，这种粗放型的小规模企业，其实总体劳动成本是很高的。对于有一定规模的企业，采用新的工艺路线，是降低成本的最直接途径，也是企业竞争处于优势地位的重要手段。我们曾对一家拥有一线工人约460人的企业进行工艺技术改造，全面采用连续大规模生产设计，装备费用（包括安装、配套）共投入约120万元。改造后一线工人仅需110人，节省场地约5000m2，所有投入只需不足2个月所节省的费用，而产量与质量的提高、污染治理费用的降低及安全生产带来的其它收益，也是相当令人振奋的。

       3.3 注重清洁生产

       清洁生产是指不断采取改进设计，使用清洁的能源和原料，采用先进的工艺技术装备，改善管理，综合利用等措施，从源头削减污染，提高资源利用率，减少或者避免生产，服务和产品使用过程中污染的产生和排放，以减轻或者消除对人类健康和环境的危害。

       利用浓硫酸、浓盐酸、浓硝酸有机溶剂等进行再生的企业，存在着人身伤害，火灾等安全隐患，工作条件恶化，同时严重污染环境。另外，由于塑料表面的附着物千差万别，再生清洗的COD、BOD含量高，颜色深，甚至有些刺激性异味，现有的各种废水环保处理剂是可以除去90%以上的污染成份，企业可根据生产项目、废水成份进行的选择。

       3.4 产业延伸

       国内废料的产业链是：回收、分拣、清洗、造粒（或改性）、成型。链上分工细致，但正是这样，每个环节诸多动作成本的叠加，导致废料成本大幅提升。条件成熟的再生企业可向上延伸，可大大节省成本，具备较强的竞争力。目前已有少量企业进行链接，取得较好的经济效益。

       4 结束语

       在与废塑再生的近距观察中，我们看到最近，特别是今年，已经形成行外资本大批涌入以及国外供货商在内地投资设厂的热潮。这种丰富资源与先进技术的结合，将使废塑再生行业带来崭新的风貌，同时，也必将对现有企业造成冲击。在风浪中搏击的企业，除了迅速准确地选择运用先进的工艺技术之外，可能还必需考虑企业间的整合，以便在竞争中处于优势，获得持续发展的预期利润。


Chinese plastic waste recyclers in the plight and thinking:

        1 A general picture of industry

        Plastic waste is renewable after 1990, with China's plastics industry and the development of processing industry in the context of globalization and the rise, sending phase of the huge profits trigger line with the investment craze fission. As at the end of 2007, China already has the ability to regenerate 2,000 tons below the more than 20,000 processing enterprises, employing more than 1 million people, the handling capacity of up to 50 million tons of scale and become the world's largest plastics recycling base.

        The large number of Internet penetration and expansion of disorder triggered by information transparency, processing enterprises unprecedented fierce competition, profit margins are strong compression, the vast majority of tons of processing less than 300 yuan of profits or even losses. As smaller firms within the enterprise, the processing capacity of 3,000 tons more than the less than 10 percent, generally low technology content, in the rising tide of environmental protection, environmental protection industry as a cycle of economic backbone of waste plastic recycler, faced with tremendous challenges.

        2 plight of

        In fact, China has surpassed the United States as the world's largest consumer of plastics, more than 40 percent of the raw materials shortage is expected to make up for the regeneration. Plastic waste recycling can be effective in reducing pollution to the environment and the huge consumption of energy for the sustainable development of countries to provide forces to support the meantime, into a state of distress.

        2.1 competitive procurement

        As the Mainland and waste imports to meet domestic excess processing capacity, businesses who could not help but raise the purchase price to meet production needs at the same time, intentionally or unintentionally increase the supplier of impurities or waste water and waste their own uncertainties and Sorting technology for the serious lag in the traditional technology conditions, resulting in the original processing enterprises vulnerable to the loss of earnings balance tilted in the direction. In the foreseeable time, this situation is very difficult to change.

        2.2 low value-added products

        Has been used by the waste, its surface will be like sand, oil and other natural substances harmful to the environment under the conditions of the pollution, and a significant portion of the substrate surface features of the Tu (plated) layer, printing ink or adhesive labels. Not be any different with the physical and chemical characteristics of the substrate material on the surface of the substrate is removed or hurt by the renewable, its product features or appearance of a greater sense of beauty will be reduced, low value-added products, even as the successor Recycling cause irreversible obstacles. It is also the case, show the enterprises in line in front of the ever-changing dynamic of technological change, is also bound to the enterprise now and in future the cornerstone of continued progress and hope.

        2.3 technology behind

        We have taken note of the extensive investigations: Do not say small-scale enterprises, is in large-scale, technology level and years (or even 10) before not fundamentally different from the only staff, plant, equipment and other linear increase it. This venue, energy, the large number of human consumption, caused by the increase in manufacturing costs, the profit objective on the tightening of space.

        This was mainly due to their technical team on the construction of the practical operation of the confusion: on the one hand the enormous amount of technical research and development investment; On the other hand also worried about the stability of personnel and protection of commercial secrets of the effectiveness of technology. Train and bring up such a material from the sorting, cleaning, separation, environmental protection, technology and equipment, and so on a comprehensive system of the technical team faced the enormous risks and uncertainties is not prudent business before an important factor. Thus, we see that the vast majority of enterprises, business owners for the survival of the enterprise backbone technology.

        In the process equipment, although in recent years China's renewable general machinery manufacturing process was greatly improved and has become a global manufacturing base, but in sorting, cleaning, separation is still to be improved sound. Of course, the provider of equipment produced by the common use of equipment is difficult to meet the business requirements of the various special personality; Furthermore due to manufacturers in a wide range of renewable technology limitations and lack of equipment also make use of performance objectives and the quality of existing enterprises Obviously the gap, and any existence of objective factors, so that enterprises will eventually reduce profit expectations.

        2.4 technical information chaos

        In order to meet enterprises cheap access to new technology in Kemu, it seems to bring huge profits joy of new technologies (prescription) in the possible transfer of the media. SMEs from any number of channels cut to the complicated technical information, the lack of professional skills and scientific identification, difficult to effectively filter; does not rule out another publisher's own technology projects have not been fully verified and a feasibility analysis, or Chanyou speculation and the possibility of false elements, in practical applications, enterprises are often paid a high price and can not achieve the desired objectives.

        2.5 friendly environment concerns

        The vast majority of the industry enterprises will be concerned about environmental pollution, but because of renewable technology backward, waste water (gas) deal with difficult, the huge investment in environmental management is力不从心, high operating costs also can not afford. A meager profit status of SMEs at a loss, but only under the cost of sacrificing the environment, leading to such enterprises and their communities, relevant government departments of the conflict significantly increased. To deal with all levels of inspection, condemnation and a fine, normal production order of business, production profits are severe blow.

        China's sustainable development has embarked on the road of green GDP, local governments are trying to resolve the plight of pollution within the enterprise. So in recent years in China, has a large governance focus on renewable industrial park. For the economic cycle in China make a great contribution to the vision of excellence in these local government leaders present at the same time we praise, it should be noted that, in any case, now under the conditions of the park can only solve less than 10 percent of the plastics recycling. This means that, within the enterprise environment friendly to the management of this process is not immediate, because depends on technology innovation. We believe that any environment-friendly technology changes, should receive all the support and respect, the Government should intensify in this interface technology R & D investment, enterprise and useful guidance and support.

        Reflections on the road in three

        Energy-saving emission reduction to the economic cycle-oriented industries in transition, in the face of labor, space, energy, and so on the cost of elevation, plastics recycling to shorten the distance between the prices, the industry need to quiet contemplation.

        3.1 increase value-added products

        Enterprises still use traditional techniques of renewable, because the surface is usually not possible to completely remove all contaminated material, can not raise the added value of products, and to achieve this goal, the existing process, it is entirely possible. In practice, enterprises should first and strong technical force of the professional bodies to establish close cooperation between the enterprises themselves as a technology platform, and then by the professional bodies to conduct a comprehensive assessment of enterprise project validation, processing enterprises should select tons of calculating profits can be Up to 1,000 yuan to the project, from engineering to scrap universal waste, so the profit goal of the project are many, the only way, enterprises have the ability to resist can not be pre-side risk.

        3.2 perfect conditions Technology

        The regeneration of existing enterprises are concentrated in rural areas away from cities, is mainly occupied space and reduce labor costs. Technology and equipment simple and low production efficiency, such an extensive type of small-scale enterprises, in fact, the overall labor costs are high. For a certain scale enterprises, the introduction of new process line, is to reduce the cost of the most direct way, is also competitive in a dominant position in the important means. We have a first-line workers have about 460 of the technological transformation of enterprises, comprehensive use of continuous large-scale production design, equipment costs (including installation, supporting) a total investment of about 1.2 million. After the transformation of frontline workers only 110 people, about saving space 5000 m2, all in just less than two months by the cost savings, and the production and the improvement of quality of pollution control to reduce the cost of production safety and the other income, is also quite Exciting.

        3.3 focus on cleaner production

        Clean production is continuing to take to improve the design, the use of clean energy and raw materials, the use of advanced technology and equipment to improve management, and comprehensive utilization of such measures, to reduce pollution at source, improve resource utilization, reduce or avoid production, services and products to use In the generation and pollution emissions to reduce or eliminate the human health and environmental hazards.

        Use of concentrated sulphuric acid, concentrated hydrochloric acid, concentrated nitric acid and other organic solvents for renewable business, there is personal injury, fire and other security risks, the deterioration of working conditions, and serious pollution of the environment. In addition, because the plastic surface of different fixtures, renewable cleansing of COD, BOD content was high, deep color, and even some irritating smell, the various existing environmental waste water treatment agent can be removed more than 90 percent of the pollution elements, enterprises under Production projects, waste-water element of choice.

        3.4 Industrial Extension

        Domestic waste industry chain is: recovery, sorting, cleaning, granulation (or modified), the molding. Chain and meticulous division of labor, but it is the case, every link of the superposition of many moves cost, resulting in waste costs substantially increase. Conditions are ripe renewable enterprises can be extended upward, can greatly reduce costs, with strong competitiveness. At present, a small number of enterprises link, made better economic benefits.

        4 Conclusion

        And plastic waste in the regeneration of close observation, we have seen recently, this year, in particular, has been formed to the mass influx of foreign capital and foreign suppliers to set up factories in the mainland investment fever. This rich resources and advanced technologies, will enable the waste plastic renewable industry brand-new outlook, and will also impact on the existing enterprises. Fighting in storms in the enterprise, in addition to quickly and accurately select the application of advanced technology, may also need to consider inter-enterprise integration, in order to compete in a dominant position, access to the sustainable development of anticipated profits.