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United Group’s new high-tech sorting system with Process Solutions designed controls boosts recycling rates, reducing landfill waste

With a growing demand for improved green initiatives and manufacturing efficiency, companies such as The United Group are beginning to implement new equipment and systems aimed at reducing waste and their overall environmental footprint.

Process Solutions is uniquely positioned to help these companies improve manufacturing efficiency by designing and building custom control panels, which utilize technologies for operating equipment at optimal speeds and durations, reducing energy consumption and prolonging their useful life. When The United Group, a Puget Sound region recycling conglomerate committed to environmental stewardship, decided to move forward with plans to build a new material recycling facility at their location in Snohomish, WA, they turned to Process Solutions to manufacture the controls to operate the facility’s high-tech sorting system.
Designed in Europe, the sorting system is highly efficient, requires minimal maintenance, and can capture more recyclables from the waste stream, resulting in less reusable materials going to landfills. The United Group’s new facility will feature two of these sorting systems, doubling their material intake capacity while also helping increase their recycling rates, which were already the highest in Western Washington. The sorting system also includes dust filtering screens and water misters to reduce the amount of airborne dust created during material processing.
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PLC control panel installed in the electrical room at The United Group
To operate the sorting system, Process Solutions designed and built new controls consisting of a main PLC panel and a separate operator station. The PLC control panel is equipped with (12) variable frequency drives (VFDs) to provide full control over the speed of the sorting system’s feeders, conveyors, and screens. The VFDs also provide motor start-up sequencing, which can reduce the sorting system’s energy consumption by preventing all the motors from starting simultaneously. The main PLC control panel will also operate the sorting system’s band magnets, eddy currents, and air separators, which are devices used for pulling specific recyclables such as metal or drywall out of the waste stream.
In addition, HMIs installed on the control panels will provide real-time alerts for faults, errors, and overloads, as well as display useful information, such as time-run/time-stop, to help operators correct issues and optimize the systems to run at the highest capacity with a consistent flow. The control system also has multiple safety features, including emergency stops, pull stops, and safety disconnects to ensure operator safety.
HMI control panel installed in the employee hand sorting room at The United Group

With a growing demand for improved green initiatives and manufacturing efficiency, companies such as The United Group are beginning to implement new equipment and systems aimed at reducing waste and their overall environmental footprint.

Process Solutions is uniquely positioned to help these companies improve manufacturing efficiency by designing and building custom control panels, which utilize technologies for operating equipment at optimal speeds and durations, reducing energy consumption and prolonging their useful life. When The United Group, a Puget Sound region recycling conglomerate committed to environmental stewardship, decided to move forward with plans to build a new material recycling facility at their location in Snohomish, WA, they turned to Process Solutions to manufacture the controls to operate the facility’s high-tech sorting system.

About The United Group

The United Group is a local, family-owned company, consisting of six divisions, including United Metals, United Recycling & Organics, United Recycling Seattle, Clearview Nursery & Stone, United Construction & Recycling, United Recycling & Container, and KT Recycling & Container. For over 25 years, The United Group has lived out its values of stewardship by taking a holistic approach to recycling and capturing the most reusable materials from waste as possible to create new landscapes, safer roads, cleaner communities, and a healthier planet. Through these values, The United Group is innovating the construction industry with recycled products and leading the recycling industry with the highest diversion rates in Western Washington.

About Process Solutions

Based near Seattle, Washington, Process Solutions is the Northwest’s largest control systems integrator. With a focus on providing industry-leading quality and service, Process Solutions offers a range of control system solutions, including UL control panel design and fabrication, PLC and HMI programming, SCADA integration, industrial refrigeration control systems, and machine monitoring software. Over its 34-year history, Process Solutions has successfully completed thousands of projects for end-users, OEMs, and government entities across industries and applications. With 100 engineers and technicians on staff combined with over 56,000 sq. ft. of engineering and production space, Process Solutions has the capacity and expertise to execute projects of almost any size or complexity.
Panel Example 1
Drive Panel Example
Stacklight Panel Example
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Panel Example 4
Panel Example 2
GE PLC Panel
VFD Panel Example 2
HMI Enclosure Interior Example
PLC Example Two
PLC Panel 2-door Example
Sloped Enclosure Example
Stainless Steel PLC Panel Example
Three Door VFD control panel with remote I/O and a disconnect switch
Two Door Panel Example
Two-door VFD Control Panel in stainless steel enclosure
Custom Control Panel with Servo Drives Installed
Custom PLC Control Panel Built by Process Solutions
Industrial Control Panel With and IO rack and Stainless Steel Enclosure
Custom Control Panel Builder
Electrical Control Panel in Stainless Steel Enclosure
VFD control panel with yellow terminal wiring
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Vaclav Mydlil
Sr. Director of Advanced Automation
Vaclav leads the dynamic Energy Management and Refrigeration Division at Process Solutions. With an impressive 20 years of experience in power demand management and refrigeration control systems, Vaclav is the driving force behind one of the company’s most innovative systems.

His expertise extends to PLC and cloud-based systems, ensuring seamless integration and optimal performance. Vaclav’s commitment to excellence is underscored by his Master of Science degree, specializing in control systems and electrical engineering, which he earned from the University of Life Sciences in Prague, Czech Republic.

Beyond the office, Vaclav’s passions include kayaking, snow skiing, and woodworking. Most of all, he enjoys moments spent with his wife and three kids.
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Steve Pelton
Vice President of Sales
With over 20 years at Process Solutions, Steve Pelton has held various roles, including Sales Engineer, Sales Director, and his current position as Vice President of Sales.

In addition, Steve oversees Process Solutions’ Energy Management and Refrigeration Division — ensuring the company remains at the forefront of energy-efficient solutions that cater to diverse food production applications. Steve also spearheads the strategic development of the company’s machine monitoring solutions, aligning them with client needs and market trends.

Steve’s background includes mechanical engineering, but his career trajectory has mainly focused on control systems marketing and management. His ability to bridge technical expertise with business acumen has been instrumental in Process Solutions’ growth.

Outside the office, Steve passions include conquering rugged trails on his mountain bike, perfecting his golf swing, and exploring new destinations with his family.
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Matt Barnes
Chief Financial Officer
Matt, with 28 years of financial strategy and accounting experience, plays a pivotal role at Process Solutions. As the Chief Financial Officer (CFO), he spearheads the company’s growth strategy, ensuring financial stability and health.

Beyond traditional financial management, Matt also oversees strategic initiatives aimed at optimizing Process Solutions’ on-hand inventory costs and availability. By fine-tuning inventory management, Matt ensures the company can meet client needs efficiently and maintain a healthy bottom line.

Matt graduated with a degree in accounting from Western Washington University and previously served as a financial executive at a large retail corporation. Outside of work, Matt enjoys traveling, soccer and spending time with his family.
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Kevin Orr
Executive Vice President
Kevin boasts an impressive tenure of over 25 years at Process Solutions. His position in the company has been multifaceted, spanning roles as a project engineer, engineering manager, and Process Solutions’ first Executive Vice President.

Under Kevin’s leadership, the food processing division has flourished, earning its reputation as of the most respected in the industry. Today, Kevin closely collaborates with executives from leading food processors and food processing equipment manufacturers across the country.

Kevin is a devoted husband and father with a passion for international travel.
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Todd Busby
Chief Executive Officer
Todd has dedicated over 30 years to Process Solutions, where he has worn multiple hats—from panel builder to project engineer and sales representative.

As the CEO of Process Solutions, Todd has spearheaded significant transformations. Under his leadership, the company has diversified into new industries, acquired a world-class facility, and more than doubled its size.

Todd, a native of the Puget Sound region, is a devoted husband, father, and avid outdoorsman. When he’s not at work, you’ll find him supporting his three kids in all their pursuits or hunting and fishing in Eastern Washington.
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David Crumpley
President
David has dedicated over 15 years to Process Solutions, where he has served as a Senior Engineer, Vice President, and now Chief Operating Officer. His multifaceted experience spans technical expertise, strategic leadership, and operational efficiency.

As the head of Process Solutions’ Water/Wastewater division, David orchestrated the modernization of the company’s internal systems and boosted operational efficiency across the organization.

In his current role as President, David continues to drive innovative initiatives aimed at expanding the company’s reach and further streamlining internal processes.

Outside of work, David enjoys spending quality time with his family and pursuing his passions as an avid outdoorsman.
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