Sustainable Innovation in Action: STADLER Anlagenbau GmbH Delivers Advanced Packaging Sorting Plant in Austria

STADLER Anlagenbau GmbH has completed and commissioned a state-of-the-art lightweight packaging (LVP) sorting facility for PreZero in Sollenau, Austria. The highly automated plant is one of the most advanced recycling facilities in Europe and the largest and most complex system STADLER has delivered to date.

Developed to strengthen regional recycling infrastructure, the facility helps address a geographic gap in Austria’s waste management network. By reducing transport distances and increasing processing capacity, the project supports more efficient and lower-emission recycling operations. The plant is designed to process approximately 104,500 tonnes of lightweight packaging annually across two modules.

Despite the technical complexity and a demanding construction schedule, STADLER delivered the turnkey facility on time. Installation began before the building halls were fully completed, requiring close coordination between multiple trades and project partners throughout the process.

Advanced sorting technology at the core

At the core of the plant is a highly automated sorting system capable of processing household lightweight packaging, plastic bottles and similar commercial waste streams. Incoming material is automatically extracted from bunkers using a gantry crane before undergoing size reduction and screening.

The system incorporates 35 near-infrared (NIR) sorting units supplied by STEINERT GmbH, enabling the precise separation of film plastics, metals, beverage cartons and rigid plastic fractions. Multiple redundant sorting stages and recovery loops return misclassified materials back into the process, ensuring high material recovery rates and consistent output quality.

A key safety innovation within the facility is the AI-powered BatterySort system, designed to detect and remove hazardous batteries early in the sorting process. This technology significantly reduces fire risk while improving material recovery.

Automation designed for continuous performance

To maintain continuous operation, the plant also features intermediate buffering systems, redundant sorting lines and automated baling systems capable of producing up to 20 different output fractions. The entire facility is designed for stable 24/7 operation, even during maintenance periods.

Advanced automation plays a major role in the plant’s efficiency. Fourteen volumetric flow sensors developed by STADLER continuously monitor material flow across the plant, allowing real-time adjustments to balance throughput and maintain optimal performance across each sorting line.

The result is a highly intelligent system that adapts to changing waste streams while maintaining consistently high sorting accuracy. With minimal manual intervention required, the plant delivers improved reliability, reduced downtime and greater operational efficiency.

Supporting circular economy outcomes

By combining high-performance technology, automation and integrated safety systems, the Sollenau facility sets a new benchmark for modern recycling infrastructure and will contribute significantly to improving regional recycling rates in Austria.

In Australia and New Zealand, CEMAC technologies works closely with STADLER to bring these advanced sorting solutions to market. CEMAC technologies supports local businesses with system design, project development and the implementation of STADLER technologies. Organisations looking to optimise or develop new recycling facilities can work with CEMAC technologies to assess whether a STADLER solution could deliver improved efficiency, recovery rates and long-term circular economy outcomes.

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