Industrial Pilot Plant

Large-scale separation processes
The plant illustrates the separation process on an industrial scale, thus validating the procedure for different applications.

Normally a corresponding micro-emulsion for separating the
relevant composite material is initially developed in the laboratory,
before being used in the plant to treat larger quantities of the 
shredded material. The evaluation includes the success of the
separation, process times and other relevant parameters. Contact
us if you are interested in recycling a composite material and would
like to validate the feasibility of this on an industrial scale.

Saperatec has launched a project to build and operate the world's first recycling plant of its kind for the processing of composite flexible packaging waste as an integrative approach. Flexible Multilayer wastes, derived from the packaging industry and consisting of the materials PET/Al/PE, PET/Al, Al/PE, PE/Al/PE will be treated in the facility.

We take care of all complex, industrial interfaces of inbound, outbound and recycling processes as well as manage the entire value chain, from purchasing of waste and recycling to the distribution of the reclaimed materials. The first plant will have a capacity of app. 18,000 t/a infeed of post-production composite packaging films and an output of around 16,000 t/a of high quality secondary raw materials. The output consists of nearly 10,000 t/a RE-LD-PE granules, 3,400 t/a Al-briquettes or -sequins and 2,900 t/a RE-PET flakes.

The recycling plant will represent a significant step towards waste material use, a reduction of waste incineration and CO2 emissions. Start of Production is planned for January 2017. More than 40 new, highly skilled and sustainable jobs will be created. Additional plants follow in intervals of approximately 18 - 24 months.


We look before we leap!

Feasibility studies reduce the technological and economic risk. As a first step to an innovative recycling solution for a new application, we usually perform a feasibility study for our clients in order to demonstrate the technical feasibility of the specific composite material and to assess the business case. This package includes:
Development of an individual separating liquid
Conduct the experiments in our own laboratory and pilot plant
Definition of the industrial process
Assessment of the economic feasibility

Licence to separate

Basic engineering involves plant planning with all fundamental guidelines and specifications that are required to correctly construct the plant. It puts clients in the position to establish their own recycling plant. In particular this package includes the process flow chart, the safety concept, P&I diagrams, balance of materials, the process description, a list and specification of the equipment and a basic layout and installation plan. In addition to its expert competence in process technology, Saperatec also draws on its experiences from its own industrial pilot plant.
Plant Construction

Realisation by plant engineers

The recycling plant is realised by an established plant construction company based on Saperatec basic engineering. The plant construction is selected jointly with the client and taking the application and location into account. Thus potential synergy effects as well as the individual risk profile of the client can be considered.


Industrial pilot plant
For demonstrating the entire process of
recycling composite materials - successfully
commissioned in November 2013.
Industrial pilot plant
Pilot plant
For recycling photovoltaic modules – operational since September 2011. Production waste from thin-layer PV modules is broken down into glass and semi-conductor material (CdTe). 
Pilot plant
Innovation awards
 The Saperatec procedure has won several awards including the German Business Innovation Award and the Deutscher Rohstoffeffizienz-Preis (German Award for Efficient Handling of Raw Materials). 
Innovation awards