Stadler Anlagenbau GmbH
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Process Technology and Modules

We operate with a modular concept that offers the following benefits:

  • Independent control: Each module can be run individually, significantly increasing overall plant availability.
  • Targeted routing: Input material does not have to pass through every module; it can be directed only through the stages it actually needs, which cuts production costs.
  • Flexible feeding & extraction: Each module can be loaded separately, and material can be removed whenever required, boosting overall efficiency.

Below you will find each module with a concise description.

For dust‑free machinery

Module 0 – De‑dusting

Module 0 collects dust from all modules and channels it through ducting to a filtration system that separates dust from air. This keeps both the material and the workplace clean, ensuring high output quality and a healthy working environment.

Perfect pre‑processing

Module 1 - Goods‑In / Sorting Cabin

Quality assurance and transparent material flow start here, with accurate weighing on arrival. Hazardous and valuable components are removed from the stream.

Explosions reliably prevented

Module 1.1 – Toners & Cartridges

Material is fed to the shredder, where cartridges are safely opened during the shredding process. System inertisation reliably prevents explosions. After shredding, toner powder is extracted and the remaining material is passed on to Module 3.

Gentle primary separation

Module 2 – Pre‑shredding & Separation

After initial removal of hazardous or disruptive items, large and small appliances are processed in Module 2. The material is gently shredded and then optimally conditioned by a ballistic separator. Batteries and capacitors can be removed mechanically or manually, and plastics can be selectively processed. These steps greatly simplify the removal of hazardous substances. Early separation of plastics in Module 2 also relieves downstream modules and improves end‑product quality.

Using a Ballistic Separator to Produce a High-Quality Plastic Fraction

Module 2.1 – Plastic Separation

The 2-D material discharged from the ballistic separator is first precisely size-reduced. In the subsequent separation stage, ferrous metals, non-ferrous metals and other metallic constituents are efficiently removed, leaving a high-grade, single-polymer plastic fraction.

Iron of premium steel‑mill quality

Module 3 – Post‑shredding & Mechanical Separation

Material from Module 2 is further shredded so that iron can be recovered using magnetic separators, screens, air classifiers and manual sorting – producing iron of the highest steel‑mill quality.

High‑quality recyclables recovered

Module 3.1 – Extraction of Valuable Materials

Material from Modules 2 and 3 is accurately separated using non‑ferrous separators and sensor‑based systems, delivering non‑ferrous metals, mixed plastics and/or printed circuit boards in top quality. Plastics are then sent to Module 5 for further plastic‑to‑plastic separation.

Precise conditioning of precious‑metal fractions

Module 4 – Balling

Precious‑metal‑bearing material from all modules is crushed in an impact mill and formed into balls. After several passes the material is completely processed. Subsequent screening prepares it perfectly for metal‑plastic separation on the downstream machines, allowing targeted concentration of precious‑metal fractions.

The future of plastic recycling

Module 5 - Plastic / Plastic Separation

Flame‑retardant and target plastics are separated by precise sensor technology, recovering ABS, PS, PP and PE at superior quality. This new, highly efficient, dry mechanical process represents the future of plastic recycling from e‑waste.

Environmentally sound processing

Module 6 – Refrigerators & Air‑conditioners

Stage 1 drills into the cooling circuit and removes oils and climate‑relevant gases, which are safely collected. Stage 2 shreds the remaining material, followed by state‑of‑the‑art separation of iron, non‑ferrous metals and plastics, including PUR foam. The entire system is fully enclosed to safely capture harmful gases.

Efficient modern PCB processing

Module 7 – Printed Circuit Boards

PCBs are first shredded; iron and non‑ferrous metals are then removed by magnetic and eddy‑current separators. A mill further reduces the material for the next separation stage. Screens prepare the material for an air separator that removes plastics from non‑ferrous metals. Finally, an electrostatic system precisely separates precious metals from dust.

Precise separation for maximum value recovery

Module 8 – Cables

Cables are cut into smaller pieces in a pre‑shredder, then further reduced in a granulator and mill. Subsequent steps efficiently separate copper, plastics, dust and ferrous metals.

Up to 95 % material recovery

Module 9 - LCD Screens, PV Panels & Lamps

LCD screens and lamps are fed via two separate inlets. Shredders and drums process the material, followed by additional separation stages to recover iron, non‑ferrous metals, plastics and mercury. The fully automated PV‑panel line precisely separates the junction box, aluminium frame and glass from the solar element, enabling up to 95 % of the materials to be returned to the recycling loop.

Industrial collaboration with Hiro Robotics

Patented, safe dismantling

Module 10 - Lithium‑ion Battery Recycling

Batteries are completely discharged and then continuously shredded under inert conditions using our patented process, leaving as little reactive mass as possible in the shredder. All material is transferred directly to the separation phase, where the electrolyte is removed and black mass is separated and cleaned.

Achieve maximum precious-metal yield through precise processing

Module 11 – Dust Precious-Metal Concentration

Dust containing precious metals is treated in a specialised system that first removes capacitor foils and other coarse components. Subsequent screening and separation stages then selectively concentrate the valuable metals present.

Efficient recovery of precious metals

Module 12 – Precious‑Metal Extraction Plant

Precious‑metal concentrates are further processed in Module 12. Hydrometallurgical recovery extracts precious metals from the non‑metallic fraction.