(Photo credit: GreenDot)

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New recycling plant

GreenDot, ARA and Bernegger mark a major construction milestone at Sort4cycle

Cologne, Germany

Around five months after the groundbreaking ceremony, an important construction phase has been completed at the new “Sort4cycle” recycling plant at Ennshafen: the structural shell is now complete. On 23 September, Altstoff Recycling Austria AG (ARA), Bernegger and GreenDot celebrated the topping-out ceremony together with employees and the construction companies involved. Upper Austria’s Governor Thomas Stelzer also toured the construction site to see the progress of this unique European project. The Austrian Federal Ministry of Agriculture, Forestry, Climate and Environmental Protection, Regions and Water Management was represented by Secretary General Johannes Abentung.

Sort4cycle is being built at the site of the TriPlast plastics sorting facility. The highly innovative recycling plant is designed to process up to 41,000 tonnes of plastics per year. It will use fractions that, due to contamination, material diversity or particle size, have so far predominantly been sent for energy recovery. The UPCYCLE process developed and patented by ARA will be combined with a novel AI-based secondary sorting system. Commissioning is planned for mid-2027.

“Upper Austria is a strong industrial and innovation hub. Sort4cycle impressively demonstrates how economic strength and a functioning circular economy can go hand in hand. This project not only creates new technological opportunities for plastics recycling, but also adds value and creates skilled jobs in our federal state. The topping-out ceremony is an important milestone on the path to commissioning,” emphasizes Thomas Stelzer, Governor of Upper Austria.

Secretary General Johannes Abentung also underlines the importance of the project: “To achieve the European recycling targets, we must further expand the material recycling of resources. Sort4cycle addresses precisely those areas where recycling has so far reached its limits and creates the conditions for turning plastic fractions that have previously been predominantly used for energy recovery back into raw materials. In this way, we are strengthening the circular economy and security of raw material supply.”

Construction progress marks the next milestone

With the completion of the structural shell, the plant is now visibly taking shape. The site was deliberately chosen directly next to the existing TriPlast sorting facility. This allows existing material streams to be used and plastics processing at the site to be expanded further. Since 2024, TriPlast has processed up to 100,000 tonnes of material from the Yellow Bag and Yellow Bin collection systems per year.

“A topping-out ceremony is traditionally a special moment for everyone involved in a construction project. We are therefore all the more pleased to celebrate this important construction milestone today together with our employees and the construction companies involved. With Sort4cycle, we are consistently developing the Ennshafen site further and creating the conditions for even more efficient use of valuable raw materials,” says Kurt Bernegger, Managing Director of Bernegger GmbH.

For ARA, the completion of the structural shell is also an important step. “At the groundbreaking ceremony in April, we gave the official go-ahead for Sort4cycle. Today, we can see this project becoming a reality step by step. By combining AI-based secondary sorting with the further developed UPCYCLE process, we are laying the foundation for recycling even more plastic fractions and keeping valuable raw materials in the loop,” says Harald Hauke, CEO of ARA.

Working together for a functioning plastics circular economy

Sort4cycle combines two technological approaches: the AI-based Advanced Scale secondary sorting system is designed to recover high-purity material from complex material streams and prepare it specifically for mechanical recycling. The further developed UPCYCLE process enables the material recycling of plastic fractions that, due to contamination, material diversity or particle size, have so far predominantly been sent for energy recovery.

“With Sort4cycle, we are continuing the successful collaboration between ARA, Bernegger and GreenDot at the Ennshafen site. The new facility is another important step towards providing quality-assured secondary raw materials for the European plastics circular economy. As a producer of advanced plastic recyclates and supplier of secondary raw materials, we see first-hand the growing need for reliable, quality-assured recyclates. Particularly in view of increasing regulatory requirements, solutions are needed that deliver results today while remaining scalable for the future,” emphasizes Denis Völler, Managing Director at GreenDot.

The commissioning of Sort4cycle is planned for mid-2027. The project will create more than 20 qualified green jobs in Upper Austria. In the future, the recovered plastic fractions are also intended to be prepared for high-value end uses, including demanding packaging applications such as food-contact packaging.

www.gruener-punkt.de    www.ara.at    www.bernegger.at

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