ValcopIA facility in Toulouse demonstrates how cutting-edge technology and artificial intelligence are transforming advanced waste sorting operations, delivering exceptional efficiency rates of over 92%.
The facility is the result of a collaborative effort led by Decoset, a joint association in Haute-Garonne, with operational responsibility entrusted to a consortium comprising Paprec, GCC Occitanie, SWA, and Aktid under a comprehensive performance contract. The project exemplifies the industry’s move towards integrated partnerships that combine expertise across multiple disciplines.
Next-generation optical sorting technology
Pellenc ST, a major player in optical sorting both domestically and internationally, has supplied the technological backbone of the facility. The installation includes 21 Mistral+ CONNECT™ machines, which work to recover 13 distinct fractions of recyclable materials, excluding metals and aluminium. This represents one of the most sophisticated sorting configurations currently operational in France.
The facility’s mission encompasses recycling packaging waste from over one million residents across the Toulouse region, processing nearly 68,000 tonnes annually of selective collections. The operation runs from an 11,900 square metre industrial building housing two parallel sorting lines, each capable of processing 10.75 tonnes per hour.
Progressive mechanical separation systems
Before materials reach the optical sorters, an extensive array of mechanical equipment performs preliminary separation. Feed hoppers—one equipped with a bag opener—work alongside decartoners, disc screens, ballistic separators, a trommel, magnetic belts, and eddy current machines. No fewer than 14 machines conduct this advanced mechanical sorting phase, demonstrating the complexity required to prepare materials for final separation.
The facility’s design draws on Pellenc ST’s extensive international experience with large-scale sorting centres, including PreZero Ölbronn in Germany, Loeches in Spain, and Ambiente in Italy. This experience informed the development of a cutting-edge process designed to maximise material recovery value.
Specialised sorting configurations
The two lines feature nine machines dedicated to separating flat items (2D) and 12 focused on hollow items (3D). For fibrous materials, precision sorting separates three paper fractions—including office paper separated from deinking—and two cardboard types. The polymer sorting operation employs 12 Mistral+ CONNECT™ machines to recover five plastic families: PE/PP, Treta, PET, and flexible and rigid development streams, the latter addressing specific French regulatory requirements.
To ensure effective sorting of light fractions, Pellenc ST installed the TURBOSORTER™ on the nine machines dedicated to flat sorting. This system stabilises light objects on the conveyor, a particularly important function given that the Mistral+ CONNECT™ machines are equipped with the TOP SPEED™ option, enabling operation at 4.5 metres per second compared to the standard 3 metres per second.
Another innovation is the AEROLIGHT™ ejection hood for sorting light paper and film. The system features a lowered roof and profiled wings designed to prevent turbulence and better control the trajectory of blown objects, improving airflow without additional energy consumption.
Intelligence-enhanced quality monitoring
Quality control extends beyond the sorting room, where operators work in two teams across 11 conveyor belts. Their efforts are augmented by AISEE™ gantries—Pellenc ST’s latest development in artificial intelligence characterisation.
These AI-based units monitor the purity of almost all output streams, covering 12 of the 13 sorted materials. Positioned at the end of conveyor belts, the 13 AISEE™ gantries continuously assess stream quality, recovery rates, and overall sorting centre performance. A final unit will be installed on the refuse conveyor belt.
Whether positioned upstream, downstream, or at key process points, these units provide real-time information on stream composition. The technology has proven valuable in accelerating commissioning phases and supporting operational decision-making.
Data-driven performance management
The collected data is translated into customised dashboards and reports available through the SMART&SHARE™ application. This information proves essential for operators to maintain required purity levels and detect and correct deviations. ISO 27001 certification ensures data security and sovereignty, whilst the units will soon communicate directly with other machines using the OPC UA protocol.
The project benefited significantly from experience gained at previous sites built in collaboration with Aktid and Paprec. From sizing assistance through to commissioning, the support provided by Pellenc ST teams proved instrumental to the project’s success.
The team’s advice and recommendations have positioned the site to accommodate future developments and potential increases in incoming tonnages without compromising the current process design.
„Thanks to all these technologies, we achieve recycling rates of over 92%,“ summarises Vincent Castaignède, Director of ValcopIA.
The facility represents a benchmark for the industry, demonstrating how integrated mechanical systems, advanced optical sorting, and artificial intelligence can combine to deliver exceptional material recovery rates. As the sector faces increasing pressure to improve recycling performance whilst managing growing waste volumes, ValcopIA provides a template for next-generation infrastructure investment.