Page 19 - HUB-4 Magazine Issue 94

Material Recycling Facilities
Planning for performance: how
STADLER designs MRFs that deliver
By Dr Benjamin Eule, Director at STADLER UK and Head of Commissioning.
Today’s Materials Recovery Facilities (MRFs)
must carefully balance operational efficiency,
regulatory compliance, high material recovery
rates, and future scalability. At STADLER, we
approach each project as a customised solution –
one that reflects not only the material realities of
today but also the uncertainties of tomorrow.
Understanding the input and the required output
The first essential step in MRF design is understanding the
feedstock. Whether the system is single-stream, dual-stream,
or comingled, the input composition directly influences every
downstream decision. Plastics, paper, metals, glass, and the
contaminants mixed in determine the choice of equipment and
how the plant is configured. We assess not only what is in the
material stream but also the specific densities, particle sizes,
and seasonal variations.
Building on this foundation, we establish performance targets:
recovery rates, contamination thresholds, and the quality
standards expected by downstream reprocessors or offtake
partners. Whether you supply high-grade PET to a bottle-to-
bottle recycler or mixed paper to a pulp mill, the MRF must
deliver material that meets market expectations. That’s why
product quality requirements are central to every STADLER
planning discussion.
Designing from the ground up
Our project planning process is rooted in close collaboration
with clients. During initial briefings, we identify input types,
throughput targets, and specifications for the final product. A
comprehensive site audit then takes place, alongside a
feedstock sampling programme or a review of existing data.
From there, we create conceptual 2D and 3D layouts to
visualise the equipment and material flows. Each component –
from screens and optical sorters to conveyors and bunkers – is
specified based on simulations, trials, and decades of
experience. Equipment is sized to accommodate peak loads
and ensure smooth flow with minimal bottlenecks. We also
plan for vehicle movement, material storage, and future
expansion space during this initial phase.
Built-in flexibility for a changing waste stream
Designing for comingled input presents specific challenges.
Achieving the right balance between flexibility and efficiency
is key. Included in our designs are recovery conveyors, bypass
routes, bidirectional conveyors, and backup systems for built-in
redundancy. This will ensure operational flexibility and
maintenance redundancy. The combination of using proven
mechanical pre-sorting with precision optical sorters enables
adaptability without sacrificing performance.
www.hub-4.com Sept/Oct - Issue 94
| p19 |