Plastic reclaimed from infectious medical waste and medical devices manufactured therefrom

1. A method of making a medical device comprising:

providing one or more medical sharps containers containing medical waste;

sterilizing, shredding and washing the medical sharps container or containers and their contents to provide shredded, sterilized and washed flakes, sterilizing, shredding and washing being performed simultaneously with one or more of water and steam;

extruding and pelletizing the shredded, sterilized and washed flakes into pellets; and

forming the pellets into a medical device.

2. The method of claim 1 , wherein the medical device is a medical waste container.

3. The method of claim 1 , wherein the medical waste is removed from the one or more sharps medical containers prior to sterilizing, shredding and washing.

4. The method of claim 1 , wherein the one or more medical sharps containers containing medical waste are segregated from chemotherapy containers and/or pharmaceutical waste containers prior to sterilizing, shredding and washing.

5. The method of claim 1 , wherein the medical sharps container or containers and their contents are sterilized at a temperature of at least about 250° C. for at least about 15 minutes.

6. The method of claim 1 , wherein the shredded, sterilized and washed flakes are subjected to one or more additional processes prior to extrusion and pelletization.

7. The method of claim 6 , wherein the shredded, sterilized and washed flakes are further ground prior to extrusion and pelletization.

8. The method of claim 6 , wherein the shredded, sterilized and washed flakes are screen-sorted prior to extrusion and pelletization.

9. The method of claim 6 , wherein the shredded, sterilized and washed flakes are fed into an air classifier prior to extrusion and pelletization.

10. The method of claim 6 , wherein the shredded, sterilized and washed flakes are float sink-separated prior to extrusion and pelletization.

11. The method of claim 10 , wherein the shredded, sterilized and washed flakes are separated from material comprising metal, glass, rubber and/or heavy plastics.

12. The method of claim 6 , wherein the shredded, sterilized and washed flakes are subjected to a metal separation process prior to extrusion and pelletization.

13. The method of claim 6 , wherein the shredded, sterilized and washed flakes are subjected to a color separation process prior to extrusion and pelletization.

14. The method of claim 6 , wherein the shredded, sterilized and washed flakes are subjected to a polymer separation process prior to extrusion and pelletization.

15. The method of claim 14 , wherein the separation process comprises spectroscopy.

16. The method of claim 15 , wherein the pellets formed into the medical device consist essentially of polypropylene.

17. The method of claim 6 , wherein the shredded, sterilized and washed flakes are devolatilized prior to extrusion and pelletization.

18. The method of claim 1 , wherein the shredded, sterilized and washed flakes are mixed with one or more additives prior to extrusion and pelletization.

19. The method of claim 18 , wherein the one or more additives include resins, nucleating agents, anti-static agents, antioxidants and/or stabilizers.

20. A method of reclaiming plastic from infectious medical waste, comprising:

providing one or more medical sharps containers containing infectious medical waste;

simultaneously shredding, sterilizing, and washing the medical waste container or containers with one or more of water and steam to provide shredded, sterilized and washed plastic flakes;

further grinding the shredded, sterilized and washed plastic flakes;

float sink-separating the further ground flakes; and

subjecting the float sink-separated flakes to one or more spectroscopy-based separating processes to obtain reclaimed plastic.

21. The method of claim 20 , wherein substantially all of the plastic in the containers and the medical waste is reclaimed.