Stadler has strengthened its 25-year partnership with BZB in Amorebieta-Extano in northern Spain by delivering a new-generation light packaging sorting plant. The facility boosts capacity, efficiency and automation.
The modernisation marks a major step for BZB, a public-private partnership involving Garbiker and Trienekens País Vasco. The plant handles household and commercial packaging waste, transforming it into high-quality recyclables and supporting circular economy initiatives across the Basque region.
Carlos Manchado Atienza, international sales director at Stadler, says: ‘This plant is personally very meaningful to me. I was involved in our first turnkey facility in Spain. Signing the contract for the new BZB plant is a real source of pride.’
Pedro Goicoechea, general manager at BZB Amorebieta, adds: ‘The modernisation allows us to increase efficiency, recover more materials and meet future sustainability goals.’
A leap in capacity and automation
The facility more than doubles throughput, raising processing capacity from three to eight tonnes per hour. It handles a wide range of light packaging materials:
- Polyethylene Terephthalate (PET) – commonly used in beverage bottles and food packaging
- High-Density Polyethylene (HDPE) – used in containers and bottles
- Polypropylene (PP) – used for tubs, trays, and caps
- Polystyrene (PS) – used in rigid packaging and disposable cups
- Two separate film qualities
- Ferrous and non-ferrous metals
Incoming waste passes through an automatic feeder and pre-shredder. A trommel sorts material into three size fractions. Each fraction moves through ballistic separators, magnetic and inductive sorters, and high-performance NIR optical systems. Materials are conveyed to dedicated bunkers and baled for shipment.
Reversible conveyors, bunker-level sensors, and automatic container-change signals streamline operations. A central monitoring system provides real-time control over all processes. The plant’s automation reduces manual handling, lowers operating costs, and improves working conditions.
Digitalisation at its core
The facility integrates Stadlerconnect, the company’s digital platform for plant monitoring and predictive maintenance. BZB is the first plant in Spain to benefit from this technology, enabling continuous equipment supervision and proactive maintenance strategies.
Improved sorting accuracy and recovery rates help reduce waste sent to landfill. Energy efficiency per tonne processed has increased, further supporting circular economy objectives.
The project was completed in just three-and-a-half months and commissioning finished two months ahead of schedule.
Forward-looking partnership
Goicoechea observes: ‘Completing the project ahead of schedule shows the strength of our partnership with Stadler. The modernisation ensures we can meet future challenges while providing high-quality recycling services.’
Manchado Atienza adds: ‘Working with the Trienekens teams in Spain and Germany has been a real pleasure. Everything was handled smoothly and efficiently.’
The high level of automation and predictive maintenance integration prepares the plant for long-term operational excellence. The upgrade links Stadler’s first turnkey facility in Spain with the next generation of digitalised sorting plants.
New location
Additionally, Stadler just opened an office for Process Engineering and International Sales in Aachen, Germany. ‘It is a great addition to our existing offices in Germany,’ says company co-ceo Julia Stadler.
‘What I’m especially happy about is the proximity to RWTH Aachen University and to several close partners in the region,’ she adds. ‘This will strengthen collaboration and help bring theory and practice closer together.’
View the plant in operation here: YouTube video
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