Stadler helps Iren advance paper and board recycling in Italy

German tech provider Stadler has completed a new high-performance paper and cardboard sorting facility for Iren in Collegno, Italy.

The facility processes up to eight tonnes of material per hour and was developed in partnership with Pellenc ST. It is said to be the first plant of its kind to separate six different paper-based fractions within a single sorting line. The fractions include large cardboard, deinking paper, white paper, fine paper, multilayer material with aluminium and multilayer material without aluminium.

Italy currently boasts a 71% recycling rate for paper, with cardboard exceeding 85%.

Large and fine fractions

The sorting process starts with mechanical separation. Stadler’s double-deck PPK2000 and STT2000 ballistic separators remove large cardboard and fines at an early stage. The remaining medium fraction then moves to six Pellenc ST COMPACT+ optical sorters.

These units use near-infrared and visible spectroscopy, supported by artificial intelligence software. The system identifies different paper grades with high accuracy, including complex multilayer materials.

After optical sorting, each fraction undergoes manual quality control and automatic composition analysis. Operators then bale and store the sorted material for downstream markets.

Additionally, the plant includes flexible feeding options and direct bypasses, allowing operators to respond quickly to changing input streams or market demand.

Reconstructed plant

Iren required a compact, flexible system that could operate within an existing building. As a result, layout efficiency and automation played a central role in the design. Despite spatial constraints, Stadler dismantled the old installation in three weeks and completed construction on schedule.

According to the project partners, the facility delivers higher output quality while maintaining operational reliability. It also provides Iren with future-proof capacity as recovered paper specifications evolve.

The recycler believes the updated plant will strengthen recycling capacity in the Turin region while supporting local circular economy targets.