STADLER’s first dedicated battery sorting line opens in Germany

STADLER Anlagenbau GmbH has opened one of Europe's most advanced household battery storage facilities for Saubermacher and Meinhardt Städtereinigung GmbH & Co. KG in Ginsheim-Gustavsburg, near Mainz, Germany.

The project brought together STADLER, weeeSwiss Technology AG, a STADLER Group subsidiary specialising in WEEE recycling technologies and process development, and METZEN Industries GmbH, responsible for the recycling section, control system, and CE conformity. This combination of expertise created an integrated, near-turnkey solution for Saubermacher.

An existing relationship between weeeSwiss and METZEN shaped the overall system concept and ensures smooth integration across all process stages. From the early design phase through to installation and commissioning, the teams worked closely to address challenges in a structured and efficient way. "The communication was always professional, open, and efficient, which made it possible to address challenges quickly and effectively," states Andrea Zirkl, process engineer and project manager at Saubermacher.

The facility marks a significant milestone for STADLER, weeeSwiss, and the battery recycling sector, as STADLER's first dedicated battery sorting line, while also setting a new benchmark for reliable, high-quality processing of complex household battery streams at an industrial scale. With a processing capacity of up to 100 tonnes of household batteries per day, it also positions itself as a key reference for large-scale battery sorting in Europe.

As Jochen Apfel, CEO of weeeSwiss Technology AG, explains: "This project represents an important step for STADLER in entering the battery recycling sector. It demonstrates how combining process expertise with mechanical engineering can deliver integrated solutions for highly demanding applications."

Participating in Europe's circular economy goals 

Growing regulatory requirements and market dynamics are reshaping the battery recycling landscape in Europe. The EU Battery Regulation sets ambitious targets, including collection rates of 63 percent by 2027 and 73 percent by 2030 for portable batteries, as well as high material recovery targets for critical raw materials such as lithium, cobalt, and nickel. As battery volumes continue to increase and material compositions become more complex, this creates a clear need for industrial-scale, highly controlled sorting solutions.

In response to this evolving context, Saubermacher invested in a dedicated household battery sorting facility designed to increase throughput to up to 5 tonnes per hour while significantly reducing manual sorting. As Andrea Zirkl explains: "We see a clear need for solutions that can handle heterogeneous input streams while ensuring safety and material quality. This facility is a key step in preparing for future market growth and regulatory developments."

By bridging the gap between collection systems and downstream recycling, it is designed to deliver reliable, scalable pre-treatment and support the efficient recovery of valuable materials.

Prioritizing safety for complex recycling streams 

Designing a facility capable of handling the full spectrum of household batteries presented a significant technical challenge. The input stream ranges from very small button cells to larger batteries from devices such as cordless tools or e-bikes, each with different shapes, chemistries, and safety requirements. Ensuring safe handling throughout the process was therefore a central consideration. 

The plant was designed to operate within a compact building footprint, requiring a fully enclosed system with controlled material flow and sealed transport to minimise risks such as fire or chemical exposure. Particular attention was given to the design of the feeding and conveying systems, ensuring gentle handling of batteries throughout the process to prevent damage or potential safety risks. The recycling section itself was designed as a fully sealed environment, incorporating stainless-steel construction to meet strict safety and containment requirements.

The primary material stream of the sorting plant consists of AlMn (alkaline-manganese) and ZnC (zinc-carbon) batteries, which are conveyed directly to METZEN's downstream recycling facility. NiMH batteries are separated and directed to a dedicated processing line, while lithium-based batteries and other special types are fully removed and pre-sorted for external processing.

To address these challenges, STADLER developed a tailored system concept that combines mechanical design with advanced sorting technologies. The facility processes mixed battery waste, separating it automatically into clearly defined fractions, including AA and AAA batteries, button cells, C, D, and block batteries, lithium-based batteries, NiCd and NiMH fractions, as well as battery packs and secondary materials such as vermiculite. A combination of bunkers, vibrating chutes, screening, magnetic separation, and X-ray sorting systems enables precise classification of battery type and chemistry. The plant also integrates three sensor-based sorting systems that enable classification by battery chemistry.

This configuration enables the generation of consistent, well-defined output streams, including valuable materials such as nickel, manganese, copper, zinc, and aluminium, suitable for downstream recycling processes, while maintaining strict safety standards across the entire operation.

A collaboration focused on streamlining the recycling process

Saubermacher's decision to partner with STADLER was based not only on technical expertise but also on the ability to jointly develop a new process for household battery sorting tailored to a completely new application. "We selected STADLER based on their strong track record in complex sorting solutions and their willingness to engage in a solution-oriented partnership," explains Andrea Zirkl. "What distinguished them was their ability to translate our requirements into a workable concept for battery sorting, while responding to highly specific and technically demanding project requirements."

As a first project together, the collaboration required a high level of alignment and trust between all parties involved, with a clear focus on reducing manual sorting and increasing operational efficiency.

This collaborative approach was instrumental in successfully delivering a facility within the expected timeframe and marks an important step for STADLER in expanding its capabilities in the battery recycling sector.

Industrial-scale battery recycling at the facility will contribute to Europe's overall goals

At a broader level, the facility plays a key role in supporting circular economy objectives and strengthening Europe's battery recycling infrastructure. By enabling the precise separation of battery types and chemistries, the plant contributes to the generation of consistent, well-defined output streams and improves the quality of input material for downstream recycling processes.

The new facility processes batteries and achieves efficient recovery of valuable materials such as nickel, manganese, copper, zinc, and aluminium, helping to reduce dependence on primary raw materials and supporting more sustainable resource use. At the same time, the plant ensures that battery waste is handled in a controlled, safe, and compliant manner, a critical requirement in the context of increasing regulatory and environmental demands.

From Saubermacher's perspective, the plant represents an important step towards advancing large-scale battery sorting and establishing robust, industrial-scale pre-treatment processes for increasingly heterogeneous material streams. Its integrated design, combining multiple process stages with a strong emphasis on safety and controlled material handling, positions it as a forward-looking solution in a rapidly evolving market.

"Projects like this show how advanced sorting solutions are becoming a key enabler of the circular economy. By combining technology, process expertise, and strong partnerships such as our collaboration with METZEN, we are helping our customers prepare for increasingly complex recycling streams in the future," concludes Jochen Apfel.