STADLER Anlagenbau GmbH upgrades long-standing recycling facility in Spain

More than two decades after delivering its first turnkey plant in Spain, STADLER Anlagenbau GmbH has completed a major modernisation of the lightweight packaging sorting facility operated by Bizkaiko Zabor Berziklategia (BZB) in Amorebieta-Etxano, Basque Country.

Originally commissioned in 2002, the facility marked STADLER’s first complete sorting plant project in Spain. The newly upgraded installation significantly improves automation, processing capacity and operational efficiency, helping the region meet growing recycling demands and evolving regulatory requirements.

A modern plant built on a long partnership

BZB, a collaboration involving the regional waste authority Garbiker and private partner Trienekens País Vasco, plays a key role in managing packaging waste across Bizkaia. The decision to modernise the existing facility allowed BZB to retain its established infrastructure while introducing the latest sorting technologies.

Working within the constraints of the existing building required careful engineering and compact design solutions. However, the result is a highly efficient facility capable of handling a broader range of packaging materials while improving the quality of recovered resources.

Higher capacity and smarter sorting

The upgraded plant increases throughput from three to eight tonnes per hour, more than doubling the facility’s processing capacity.

Incoming material is fed into the line through an automated system and passes through a pre-shredding stage that opens bags and prepares the waste stream for sorting. A trommel screen separates material by size before it moves through a series of mechanical and optical separation stages.

The system combines STADLER ballistic separators, magnetic and inductive separation technology and near-infrared optical sorters to recover multiple high-value material streams. These include PET, HDPE, polypropylene, polystyrene, two types of plastic film and both ferrous and non-ferrous metals.

To support efficient plant operation, the system incorporates reversible conveyors for flexible routing, bunker level sensors and automated container change alerts. A central control system monitors the entire process, providing operators with clear oversight and control of plant performance.

Digital monitoring and future-ready operations

A key addition to the upgraded facility is the integration of STADLERconnect, STADLER’s digital monitoring platform. The system enables predictive maintenance by continuously monitoring equipment condition, helping operators identify potential issues early and reduce unplanned downtime.

Combined with improved automation and a more efficient plant layout, the modernisation reduces manual handling, improves workplace conditions and increases overall plant productivity.

By improving sorting accuracy and recovery rates, the upgraded plant enables more packaging materials to be returned to the recycling stream, supporting regional circular economy targets and reducing the volume of waste sent to landfill.

Across Australia and New Zealand, CEMAC technologies works with STADLER Anlagenbau GmbH to introduce advanced sorting plant solutions. CEMAC technologies can assist recycling operators in evaluating, designing and implementing STADLER systems that improve sorting efficiency, maximise resource recovery and support future-ready recycling operations.

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