STADLER designs and installs state-of-the-art light packaging sorting plant in Eitting, Germany for PreZero Recycling

Environmental services provider PreZero is driven by the ultimate goal of reducing the consumption of natural resources in a world where they are no longer wasted through closed loops – aiming for 100 percent reusable material. As part of this strategy, it commissioned STADLER, the globally active German company specialized in the planning, production and assembly of turnkey recycling and sorting plants, to design and install a new state-of-the-art light packaging sorting facility in Eitting. The new facility is the most advanced light packaging sorting plant in Europe, capable of sorting the packaging fractions by color and, very importantly, even filter black plastics. This results in extremely high-quality output that can be recycled into new products. With an annual throughput of approximately 120,000 tons, it is also the biggest light packaging plant in Europe.

Forward-thinking innovation for high capacity and accurate sorting
The sorting plant receives light packaging made up of tin foil, ferrous and non-ferrous scrap, aluminum, composites with aluminum content, film PE plastics, nets and foam, PP and PS plastics, EPS, PET bottles, other PET, PVC and plastic packaging, TetraPak cartons, paper and cardboard. The process, which includes advanced fines preparation and automated film color sorting results in 18 different output fractions separated by material and color. The design required the innovative thinking that is the hallmark of STADLER’s design teams: “This was the largest project to date for us, with 272 conveyor belts installed filling the hall on five levels and supported by over 1,000 tons of steelwork,” explains Wolfgang Köser, joint Project Manager. “To achieve the high-quality sorting PreZero was looking for, we used state-of-the-art technology in our design,” adds Benny Kalmbach, joint Project Manager. “The advanced equipment included 38 NIR (Near Infrared) optical sorters, our ballistic separators and robot-assisted secondary sorting.”

STADLER’s design team developed a design that not only delivered the required quality output and capacity, but also ease of operation. “The continuous level concept facilitates the operation of the system and ensures good accessibility to all the equipment for cleaning and maintenance,” says Wolfgang Köser.

The fully automated bunker management at the plant is another state-of-art process: “This means, for example, that there are no longer staff members permanently tied to the baler. In addition, the desired bale weights – and consequently bale lengths – can be achieved according to the customer’s specifications through the weighing cells under all bunkers. This has the advantage that the trucks can be loaded optimally for the best possible transport result,” explains Benny Kalmbach.

A complex project delivered on time, on a tight schedule
Thanks to a successful close collaboration of the teams at STADLER and PreZero, the project was completed in a very short time, as Wolfgang Köser explains: “We had a very tight schedule, with just 12 months from signing the contract to start-up with material, but we succeeded with a good and close cooperation between us at STADLER, and the teams at PreZero and the other companies involved in the project. Short decision-making processes and a target-oriented approach enabled us to move forward quickly at every stage.” Stefan Kaiser, Head of Engineering Sorting Systems International PreZero Recycling Deutschland, is very satisfied with the whole process, and “the open communication, straightforward thinking, focused and time-efficient collaboration, and on-time delivery. I particularly appreciated how STADLER’s team listen to the customer and their proactive thinking of new ideas, acting as partners.”

The start-up of the sorting plant was on schedule in early January 2022, and “the ramp-up phase is running perfectly,” says Stefan Kaiser.

On the path towards a world where resources are not wasted

With the view that any waste that is not recycled is a wasted piece of raw material, PreZero strives for a continuous improvement of its processes, working towards the creation of a world where resources are no longer wasted through closed loops – aiming for 100 percent reusable material. As part of the Schwarz Group, a leading food retail company in Europe, it is able to develop innovative solutions along the entire value chain – from production to retail, collection, sorting and recycling to reuse – in order to close the loop.

The new light packaging plant designed by STADLER is part of PreZero’s strategy to achieve this goal: “For us, this is the first step in the transition from a waste plant to a production plant of industrial standards,” explains Stefan Kaiser.

For STADLER, the project provided a further opportunity to develop innovative solutions to serve the recycling industry with high-quality recyclates, supporting the transition to an efficient circular economy.

The three large German plastics associations GKV Gesamtverband Kunststoffverarbeitende Industrie, Plastics Europe Deutschland and VDMA Fachverband Kunststoff- und Gummimaschinen have forged a unique alliance in the value chain to achieve greater sustainability – ecological, social and economic.

Including the five GKV member associations, the partners are committed to the mission of a circular economy and intend to actively promote the transformation of the plastics industry, with open communication playing a key role. By providing more facts and information on the transformation of the industry – for instance the latest studies on the transition towards becoming more circular – the participants want to achieve greater appreciation for plastics as a material of the future. The new platform www.dein-kunststoff.de (available in German and English) is also intended to contribute to this.

Circular Economy: for plastics, the future is round
The plastics industry is changing: Together, the companies in the plastics industry and their customers want to use fewer resources and significantly reduce their environmental footprint. Besides introducing new raw materials for use in plastics production, such as biomass or CO2, the resource plastic is to be recycled as completely as possible. This is already working quite well with PET bottles or the industry’s own collection systems, such as for window profiles, but yet not everywhere.

Industry and many initiatives are researching sustainable solutions at full speed, often in close cooperation with customers, policy makers and NGOs. Some of these programmes are already underway or established: “Eco Design” for sustainable product design, research partnerships on chemical recycling, the “Zero Pellet Loss” alliance on preventing pollution, or the “ERDE” initiative for collecting and recycling agricultural films.

“We are plastics” wants to share the enormous wealth of experience of its more than 3,000 member companies in the future, network individual initiatives more closely, think and act outside the box, support members with the transformation and jointly represent positions on shaping the circular economy.

Self-critical and self-confident communication
For the associations, the fact that in the past people have mainly talked about the plastics industry rather than with it also has to do with the fact that contacts were not always easy to find. This is to change with the new platform: The dialogue with consumers and NGOs is a particularly important concern for “We are plastics.” At the same time, the associations are aware of the problems associated with plastics at the end of their useful life – above all due to littering and disposes into waters and oceans. These challenges can only be mastered by working together. This is also a main concern of the initiative.

While the public debate on plastics has thus far focused on the undoubtedly important issue of waste, the associations are bringing in other equally important aspects such as new (raw) materials, processes and resource efficiency. Plastics are essential to create value, participation, prosperity and, above all, to enable climate protection. One focus of the web offering is therefore on innovations that inspire through their more sustainable use of the material of the future in a functioning circular economy.

LEADING INNOVATOR BOREALIS AGAIN FILES RECORD BREAKING NUMBER OF INTERNATIONAL PATENT APPLICATIONS IN 2021

In 2021 Borealis filed a total of 210 international patent applications at the European Patent Office, once more breaking its own record of 182 patent applications filed in the previous year. With this achievement, Borealis cements its position as a leading European innovator and pioneering industry leader in the fields of advanced and circular polyolefins, mechanical recycling of plastics, base chemicals and fertilizers.

Providing intelligent and sustainable solutions to the challenges faced by society is a core Borealis mission. Patents play a crucial role in safeguarding visionary ideas when developing novel approaches, technologies, and applications.

“We, as Borealis, have committed to spearheading the transformation of our industry,” says Borealis CEO Thomas Gangl. “Breaking our own record in the number of patent applications is testimony to our dedication on creating value through innovation. We will continue to develop new technologies and novel, value-added products that enhance the circularity of plastics and thus benefit society as a whole.”

The 210 patent applications filed by Borealis in 2021 put the company at the top of the European Patents Office national rankings, taking the leading position in the Austrian statistics. In 2021 the company was able to top its own record with a total of 210 filings. In sum, the Borealis Group now possesses more than 11,000 individual patents or patent applications which are subsumed in approximately 1,200 patent families. The growing number of patents underscores the company’s position as leading industry innovator true to its spirit of “keep discovering”.

SEVEN INNOVATORS JOIN FASHION FOR GOOD’S 2022 ASIA INNOVATION PROGRAMME

MUMBAI – Fashion for Good is pleased to announce seven new innovators selected to participate in its 2022 Asia Innovation Programme. Chosen by Fashion for Good brand and manufacturing partners during a hybrid digital / in-person event in Mumbai from a group of global innovators, the nine-month programme provides the participants with tailored support to help them scale – matching the innovators with relevant industry partners to drive piloting, implementation, and investing activities.

“We are extremely excited to kick off our third year in Asia and continue to generate tangible impact in the region with the addition of these seven new innovations. By providing them with a platform to learn and grow, and connecting them with leading industry players, the programme offers an opportunity to drive the implementation of their solutions in the supply chain at scale.” – Priyanka Khanna, Head of Asia Expansion at Fashion for Good.

Focusing on processing, one of the most impactful steps in the value chain, this year’s selection of innovators are developing technologies with the potential for positive disruption within this area in the Asia region. Innovators AN Herbals, Fermentech Labs, Gaiacel and Sodhani Biotech, are developing unique solutions in dyeing, pretreatment and finishing from plant, forest and agricultural waste using technologies such as bioprocessing, nanocellulose and microorganisms. The remaining innovators present pioneering innovations in raw materials, impact and end-of-use, with UKHI Hemp Foundation exploring alternative materials from hemp, Vaayu tracking carbon impact through the value chain, and Picvisa enabling the recapture of value from existing materials.

As with previous selections, these innovators receive bespoke support based on the immediate requirement of each innovator to scale, as well as exposure to corporate partners and industry ecosystem players vital to their continued growth and development. The seven new innovators mark the third selection of innovators to participate in the Asia Innovation Programme since establishing a presence in Asia in 2020, which has supported a total of 28 innovators through the Programme.

ABOUT THE INNOVATORS

AN HERBALS (INDIA)
An Herbals has a patented circular herbal dye extraction, herbal dyeing and bioprocessing technology, that converts waste from the forest, food and ayurvedic medicine industries to dyes that are non-toxic with self-binding, antiviral, antimicrobial, antifungal, anti odour, UV resistant and mosquito repellent properties for up to 50 washes in all textiles.

FERMENTECH LABS (INDIA)
Fermentech Labs is addressing the disposal of agricultural and forest residues, such as straw, peels and pine needles, through a patented biotechnology using microorganisms. They convert organic waste, otherwise destined for incineration, into industrial enzymes that are used for textile bio-polishing, desizing and bio-scouring. Along with reducing environmental carbon footprint, collecting these sustainable feedstocks ensures farmers have an alternative income stream.

GAIACEL (USA)
Gaiacel develops a novel dyeing innovation to make industrial rope and slasher dyeing processes sustainable and cost-effective. Their patented nanocellulose hydrogel along with dye particles sticks to textile surfaces and eliminates the need for multiple dipping, indigo reduction and additional chemicals. The process is less water and energy intensive compared to conventional indigo dyeing.

PICVISA (SPAIN)
PICVISA is an innovative technology based company that designs, manufactures and supplies optical sorting and separation equipment to recover and grade textiles. PICVISA offers advanced solutions based on robotics, artificial intelligence and vision that can classify textile, fully customised to the clients needs, by its composition and colour in an efficient and automated way.

SODHANI BIOTECH (INDIA)
Sodhani Biotech produces non-toxic chemical free natural dyes and colours from plants, plant waste and microorganisms. They produce 16 natural dye extracts using optimised extraction processes that have resulted in better yields, a wider range of shades, better water solubility and good colour fastness for printing and dyeing applications.

UKHI HEMP FOUNDATION (INDIA)
UKHI Hemp Foundation is a farm-to-market company, producing more than five hundred products from hemp, including hemp textiles, papers, bioplastics, composite, food products and medicines. They improve farmer and artisan livelihoods by training them to cultivate hemp and produce fabrics with higher hemp content using improvised fibre extraction processes.

VAAYU (GERMANY)
Vaayu is the world’s first automated carbon-tracking software for retailers, enabling businesses to reduce their footprint by providing accessible, real-time data to drive carbon-reduction at scale. By integrating with point-of-sale systems, such as Shopify, and leveraging proprietary AI and machine learning technology, Vaayu draws insights from production, sales and logistics to deliver a tangible solution in the fight against climate change and a more sustainable future for retail.

“There is no doubt that sustainability comes at a cost”

Interview with Uwe Rothaug, Managing Director of Kurtz GmbH & Co. KG

Mr. Rothaug, Kurtz Ersa is a very old and long-standing company. What does sustainability mean to you?
It’s precisely because we are a company with such a long tradition that sustainability is our main priority, and why we have also set ourselves the goal of being completely CO2-free by the time we celebrate our 250th anniversary in 2029. We are working intensely on both on our internal processes – sustainable development, sustainable sales, sustainable purchasing – and on the products we supply to our customers.

Is it easier to achieve this goal internally rather than through yourproducts?
Internally, you are the one in control, while at an external level it depends on whether the customer wants to buy a product that is more sustainable and serves climate protection. For example, we have developed a machine that can weld particle foams, such as EPS, without the use of steam. So, you no longer need a steam generation system or a cooling tower installation with a water basin. This saves not only water, but also a considerable amount of energy and therefore CO2 emissions. This machine is based on completely new technology however, and many customers are not yet ready to replace their conventional equipment, as they are generating money with their current processes. In the daily production process, climate targets such as those postulated by the European Green Deal for 2050 are a long way off.

What is so fundamentally different about the new machine?
This machine, which we call Wave Foamer, uses a radio frequency process. It makes the molecular chains vibrate at an alternating voltage, they rub against each other, and the resulting heat leads to the welding process. Previously, we supplied steam from the outside, which entailed heating the water beforehand until it became steam. That was a CO2-guzzling process. We can now produce the same foamed parts as before, like car parts such as shock absorbers or sun visors, except now these are emitting much less harmful greenhouse gas. The electromagnetic process is also much more finely adjustable, and you can dose the electromagnetic energy very well, allowing you to process materials that you couldn’t process before.

What impact does the new process have on recycling?
With the new process, we are able to replace recycled EPS with new polystyrene in a much better manner. There is currently already up to 20 per cent recycled EPS used in foamed parts. With our method, you can process up to 100 per cent EPS; that’s a world of difference, considering the amount of EPS used in the global packaging industry alone. EPS in packaging will not survive without recycling. That’s one aspect that needs to be fully understood.

Despite all these advantages, your customers are still apprehensive regarding the innovation.
For the customers, this is a paradigm shift – one that is initially also expensive. It will take some time to get a good grip on our new process. There is no doubt that sustainability comes at a cost, but those who start making their processes sustainable in time will emerge as winners. With our new machine and processing method, energy consumption can be reduced by 90 per cent, water consumption by up to 100 per cent. We have calculated CO2 savings of 70 percent over the entire process; that is our contribution to climate protection.

Will the image of plastics improve as a result of technological innovations that serve to protect the climate and resources?
I hope so. It’s a fact that the plastics industry is putting a lot of effort into contributing towards climate protection and also to the circular economy; something that is not perceived by the public however. We have to become more visible, in line with the motto “do good and talk about it”. We have to inform the public in a broad manner, by using all available communication channels. Nowadays, this also means making greater use of social media.

Will a better image also help to remedy the shortage of skilled workers?
The young people of Generation Y and Z look very carefully at which company they want to work for. They don’t want to work in industries they consider harmful or dirty; that’s why a good image is key in terms of recruitment. We already have a shortage of workers in Germany, and it will become even more severe over the next few years because of demographic developments. I’m convinced that only those companies that act sustainably will find the skilled workers they need in the future.

Video statement by Uwe Rothaug: https://vimeo.com/685384005