German recycler adds Stadler technology to improve PET recycling

RCS, Werne, Germany, specializes in recycling management, providing companies with commercial waste disposal, raw material recycling and plastics recycling. A key area of focus at RCS is recycling polyethylene terephthalate (PET) bottles to produce plastic flakes for a variety of applications and high-quality regranulate for the food sector. 

The company says this activity is performed at its sorting plant, where it separates clear PET from colored PET, which accounts for about 85 percent of the input, as well as aluminum, ferrous cans, film and other materials. With a capacity of about 7 metric tons per hour, the plant operates on a continuous shift system, processing used PET bottles into high-quality food-grade plastic flakes. 

To achieve high purity and optimize processes at its plant, RCS has used expertise and technology from Stadler, Altshausen, Germany, in a few applications.

Gerd Francke, joint CEO of RCS, says the company first purchased a ballistic separator from Stadler in 2005. “On the basis of the good experience with their technology, we decided again to choose Stadler for a new ballistic separator in 2014.”

Then, in 2017, the company modernized its plant and partnered with Stadler on that project.

“Stadler offered us the complete package, from project planning to the construction of the modernization of the entire plant, managed and implemented by their staff,” says Alexander Rimmer, joint CEO of RCS. “We particularly appreciated their technical know-how and the support during the entire project. Their advice was flawless, and they offered us great technical experts who advised not only on the technology and processes, but also on the implementation possibilities specifically adapted to our technical requirements with good solutions to problems.”

He adds that Stadler was able to complete that project with very tight deadlines in order to meet RCS’ expectations. RCS reports that the modernization that year brought several benefits to the sorting plant, including the quality of the output as well as improved operation and running costs. Francke and Rimmer say the biggest advantage was a “triple increase in quantity, quality and yield.” They add that processes are also easier for their employees as a result of the modernization project. 

Evolving requirements

© Stadler

The packaging used by manufacturers has been evolving in recent years, which impacts sorting operations at recycling plants. According to Stadler, more PET bottles coming to recycling plants are packed in full-body sleeves, and to optimize sorting, separation of these labels from PET bottles can help.

In 2019, Stadler launched its Delabeler label remover to help customers remove labels from bottles of all types. The company reports that its label remover achieves a quality standard of up to 80 percent of labels removed, and it processes a mass flow of up to 9 metric tons per hour, depending on particle size and material consumption. 

Germany-based RCS recently installed Stadler’s Delabeler to improve on PET recycling. 

“We are very satisfied with the label remover because it requires less maintenance and its throughput is geared to that of our plant,” Rimmer says. “With this machine, there is less wear on the knives and the machine is not very susceptible to impurities such as foil or wood. In addition, it does not cause any damage to the PET bottles. With the label remover, we can separate the labels from the bottles before sorting, which enables us to guarantee a consistently high level of purity.” 

“I am very proud of having worked side by side with RCS over the years, building a real partnership that has enabled us to support them as their business has grown and evolved,” adds Willi Stadler, CEO of the Stadler Group. “Together, we have been able to anticipate the changes in market demand and find effective solutions for their operation.”