• How does the Circular Plastic sorting plant contribute to advancing the circular economy in Italy?
The Circular Plastic sorting plant, with its ability to separate 19 different products—17 of which are plastic polymers—and its high recovery rates, has become one of the most efficient facilities in Italy. Capable of processing over 100,000 tons of plastic per year and achieving a recovery rate of more than 97%, the plant ensures that nearly all plastics from separate collection remain within the supply chain, reinforcing the principles of waste valorization and the circular economy.
• What were the key challenges in designing and building the largest plastic sorting plant in Italy, and how did STADLER overcome them?
The main challenges in a project of this scale were related to the installation timeframe and space constraints, as the entire plant had to fit into a single-span building. STADLER overcame the time constraints by leveraging its extensive experience, completing the installation in just over six months. Space was optimized through smart engineering, resulting in a solution that is both efficient and aesthetically pleasing.
• How does the plant ensure high-quality material recovery, and what impact does this have on recycling rates?
High material recovery rates are achieved thanks to clever design solutions, which split the material flow into two parallel lines that separate 2D and 3D materials. These are then processed by 22 NIR sensors that sort the different plastic polymers, achieving high recovery and purity rates. This enables better recycling outcomes and reduces downtime due to maintenance, while delivering consistently high-quality output.
• How does STADLER’s approach to predictive maintenance help maximize uptime and reduce operational costs?
STADLER's predictive maintenance solutions have already proven effective by anticipating machine failures weeks in advance. This allows maintenance to be scheduled proactively, significantly reducing both costs and unplanned downtime.
• How do partnerships between companies like Iren and STADLER help accelerate the transition to a circular economy?
The combination of STADLER’s long-standing expertise and Iren’s strong local presence and commitment to investing in cutting-edge technologies has enabled the creation of plants like Circular Plastic. These facilities are crucial for achieving the goals of the circular economy and the sustainability targets outlined in the UN 2030 Agenda.
• What innovations in plastic sorting and recycling do you see as the next big step for the industry?
Artificial intelligence will drive the next major advancements in the sector, supporting customers with more automated and streamlined plant management—from real-time machine optimization and automatic blockage or fault detection to predictive maintenance. These are areas where STADLER is already making significant investments. The adoption of robotics will further enhance the quality of sorted materials while enabling personnel to focus on higher-value tasks.
• How does the plant's design and technology improve worker efficiency, safety, and overall operational ease?
STADLER’s design philosophy places a strong emphasis on safety and ease of operation as core elements of effective plant management. At the Circular Plastic plant, all areas are safely accessible for maintenance and monitoring. The machines are user-friendly, while maintaining the reliability and durability for which STADLER is renowned.
• What lessons from this project can be applied to future recycling facilities?
This project has shown us that large-scale plants, when well-designed and managed, can be the optimal solution for maximizing environmental and economic resources by centralizing waste collection and treatment in a few specialized locations.