Stadler and Iren unveil Italy’s largest sorting facility
Iren SpA, in collaboration with Stadler Anlagenbau GmbH, has launched Italy’s largest sorting facility in Borgaro, near Turin. The Circular Plastic plant, designed and built by Stadler, can process 100,000 t/a of mixed plastics and cans , contributing to Italy’s efforts to enhance recycling and close the loop on plastic waste.
The state-of-the-art facility, operated by Iren’s environmental management division, Iren Ambiente, is equipped with advanced sorting technology capable of handling 17 types of materials, including various polymers, aluminium, and ferrous materials. The plant returns up to 80% of the sorted input materials to recycling, significantly boosting Italy’s circular economy by converting waste into resources.
The Circular Plastic facility utilises Stadler’s advanced ballistic separators, optical sorters, and other technologies to ensure precise sorting and high-quality output. The process begins by separating incoming materials into three streams: bulky, medium-sized, and fines. A standout feature of the plant is the dedicated fines line, which recovers small plastic components, such as bottle caps, alongside aluminium and other valuable materials.
The medium-sized stream undergoes further separation, with a focus on sorting plastic materials such as PET, HDPE, PS, and PP. Stadler’s optical sorters are claimed to efficiently differentiate between clear, blue, coloured, and opaque PET, while specialised equipment handles other plastics like HDPE. The facility ensures minimal waste by recovering remaining materials through an advanced bottle recovery line.
Stadler says that a range of innovations to streamline operations and improve maintenance have been incorporated: The plant features a load cell system for precise monitoring of material quantities, as well as a mobile control system that allows operators to manage machinery on-site efficiently. Additionally, a sophisticated remote monitoring system provides real-time data to aid in predictive maintenance, ensuring smooth and efficient operation.
Comfort for operators is also a priority, with the sorting cabin equipped with air conditioning systems designed to maintain optimal working conditions.
This project aligns with Italy’s broader goals of promoting sustainability and reducing environmental impact by improving recycling infrastructure and reducing waste.
Photo: F.l.t.r.: Willi Stadler, CEO Stadler Anlagenbau, Mirko Tutino, Plant Manager Iren SpA, Massimiliano Gurnari, Environmental engineer and Julia Stadler, Chief Digital Officer at Stadler Anlagenbau
