STADLER’s latest sustainable innovation project in Austria demonstrates how cutting-edge recycling systems and intelligent automation are reshaping the waste management landscape.
The completion of STADLER’s groundbreaking lightweight packaging sorting plant for PreZero in Sollenau, Austria, marks a significant milestone in European waste management infrastructure. This state-of-the-art facility, which began operations in late summer 2025, represents the most complex and largest installation STADLER has delivered to date, processing 104,500 tonnes annually across two modules.
For PreZero, the international environmental service provider of the Schwarz Group, the Sollenau facility addresses a critical geographic gap in Austria’s recycling infrastructure. The strategic location enables shorter transport routes, reduced emissions, and more efficient waste management while strengthening the region’s circular economy capabilities.
Engineered excellence under pressure
The project’s execution required exceptional technical coordination and precision. With multiple trades working simultaneously and installation beginning before hall construction was complete, the complexity was unprecedented. STADLER’s project management capabilities proved crucial in navigating these challenging conditions.
“This project was undertaken under a very tight schedule and required continuous coordination with all involved trades working in parallel,” said Benny Kalmbach, Project Manager at STADLER. “Despite the logistical challenges, we delivered a complex, high-performance facility on time through close collaboration with PreZero, STEINERT, and all on-site partners.”
PreZero’s assessment of STADLER’s performance highlighted the company’s partnership approach and technical expertise. Marya Brandt, Project Manager at PreZero, noted: “STADLER successfully overcame challenges like integrating the AI-based fire protection system, ensuring high automation, and meeting strict safety and environmental standards. Their tailored approach enabled the smooth implementation of a complex, future-ready facility.”
Smart automation revolutionizes material recovery
The heart of the Sollenau facility lies in its highly integrated and automated sorting system, capable of processing both lightweight household packaging and plastic bottles from commercial waste streams. The process begins with fully automated extraction from deep bunkers using an overhead gantry crane, followed by size reduction and material sorting into different grain sizes.
The facility employs 35 Near-infrared (NIR) sorters from STEINERT throughout the process. Film materials undergo separation using NIR sorters with air separation before passing through four redundant sorting stages. Ferrous and non-ferrous metals, along with beverage cartons, are removed during dedicated sorting stages, while 3D material streams are sorted into multiple final product fractions.
A standout innovation is the AI-based BatterySort system, enabling early detection and safe removal of hazardous batteries. This technology represents a vital advancement in fire prevention and material recovery that PreZero highlighted as a key plant feature.
The heart of the Sollenau facility lies in its highly integrated and automated sorting system, capable of processing both lightweight household packaging and plastic bottles from commercial waste streams. – © STADLER
The system’s design prioritizes continuous operation through intermediate buffering systems, redundant sorting lines, and fully automated baler control for up to 20 material fractions. Julius Henn, Project Manager at STADLER, explained: “One of our priorities in this project was to design a system architecture that ensures maximum availability and operational flexibility. By integrating redundant sorting lines, intermediate buffering, and fully automated systems, we created a facility that can operate continuously, even during maintenance.”
Intelligent process control sets new standards
The facility’s distinguishing characteristic is its comprehensive intelligent automation throughout the entire process. Fourteen volumetric flow sensors, developed in-house by STADLER, continuously monitor material throughput, enabling real-time adjustments to maintain stable, balanced feed to each sorting line.
Julia Stadler, Co-CEO of STADLER, explained the technology’s impact: “Volume flow sensors ensure a consistent and balanced material flow throughout the entire plant. For instance, our patented screen-cut-control solution enables precise distribution across multiple sorting lines, forming the basis for automated operation and long-term process stability.”
The facility operates as a fully automated system that dynamically adapts to changing material compositions, allowing optimal capacity utilization while maintaining consistently high sorting quality. By minimizing manual intervention, the system increases efficiency, reduces downtime, and enables 24/7 operation through comprehensive, deeply integrated automation logic.
Driving regional sustainability forward
The operational impact has already exceeded expectations. Tristan Merk, Project Manager at PreZero, emphasised the built-in redundancy benefits: “This built-in redundancy ensures continuous plant availability, minimises downtime and maintains high throughput even during technical servicing. It makes a real difference by increasing operational efficiency and reliability.”
PreZero’s satisfaction with the facility’s performance reflects its contribution to regional sustainability goals. Marya Brandt confirmed: “PreZero is very satisfied with the facility’s performance. It meets high standards in safety, efficiency, and material recovery, making it a key contributor to regional recycling and sustainability goals.”
The plant’s expected contribution to regional recycling rates through improved sorting precision and material recovery positions it as a model for future-oriented recycling. Tristan Merk concluded: “PreZero tasked STADLER with delivering a highly automated, safe, and efficient sorting system tailored to complex recycling needs. STADLER exceeded these expectations by designing and implementing a cutting-edge facility that integrates AI-based safety and meets the highest standards in sustainability and performance.”
As environmental regulations tighten and resource efficiency demands grow, the Sollenau plant demonstrates what scalable, intelligent, safe, and sustainable recycling can achieve in the modern waste management industry.