STADLER, the globally active German company specializing in the planning, production, and assembly of turnkey sorting plants, has completed and commissioned a groundbreaking lightweight packaging (LVP) sorting facility for PreZero Sorting Austria GmbH in Sollenau. The plant represents a major advance in automation, safety, and performance 鈥� and stands as the most complex and largest facility STADLER has built to date.
For PreZero, the international environmental service provider of the Schwarz Group, the Sollenau project is a strategic investment aimed at strengthening Austria鈥檚 regional recycling infrastructure. Its location was selected to fill a geographic gap, enabling shorter transport routes, reduced emissions, and more efficient waste management. Designed to process 104,500 tonnes annually across two modules, the facility combines innovation and scalability to help Austria achieve its sustainability ambitions.
The project鈥檚 delivery required technical expertise and precise coordination across multiple teams and phases. With many trades working simultaneously and installation beginning before the construction of the halls was complete, the complexity of execution was unusually high. STADLER鈥檚 ability to navigate these conditions was crucial to delivering the turnkey facility on schedule, with commissioning finalised by late summer 2025.
This project was undertaken under a very tight schedule and required continuous coordination with all involved trades working in parallel,鈥� said Benny Kalmbach, Project Manager at STADLER. 鈥淒espite the logistical challenges, we delivered a complex, high-performance facility on time through close collaboration with PreZero, STEINERT, and all on-site partners.”
PreZero also emphasized STADLER鈥檚 strong partnership approach and technical expertise throughout the process, as Marya Brandt, Project Manager at PreZero, pointed out: 鈥淪TADLER 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.鈥�
What makes the Sollenau plant especially distinctive is the high level of 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 a stable, balanced feed to each sorting line.
Julia Stadler, Co-CEO of STADLER, explained: 鈥淰olume 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.鈥�
The plant operates as a fully automated system that dynamically adapts to changing material compositions. This allows for optimal use of capacity while maintaining consistently high sorting quality. By minimizing manual intervention, the system increases efficiency, reduces downtime, and enables 24/7 operation. This is thanks to the comprehensive, deeply integrated automation logic that provides a robust and stable system foundation.
PreZero has already observed the impact of these innovations in the plant鈥檚 operation: 鈥淧reZero is very satisfied with the facility鈥檚 performance. It meets high standards in safety, efficiency, and material recovery, making it a key contributor to regional recycling and sustainability goals,鈥� said Marya Brandt.
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