STADLER Digital Solutions: towards a new era of smart, data-driven sorting plants
STADLER Anlagenbau GmbH is transforming recycling plant efficiency with its digital solutions specifically developed for sorting plants. At the heart of this transformation is STADLERconnect, a comprehensive cloud-based platform that offers recycling and sorting plants a single access point for its digital products, designed to optimise operations by unlocking the full potential of machine and material data to drive impactful operational improvements.
“STADLERconnect is designed to deliver added value to recycling plants of all types and sizes, improving performance through data-driven insights, enhanced machine uptime, and streamlined maintenance and reporting processes,” says Dr. Benjamin Eule, Director at STADLER UK & Head of Commissioning. “Its digital tools boost efficiency, reduce downtime, support remote diagnostics, and drive smarter decision-making for continuous improvement, with changes to operating conditions being identified swiftly.”
“Through STADLERconnect we provide a unified platform that integrates data from multiple plants and sources, offering the plant management a centralised, remote overview of all facilities,” explains Julia Stadler, Chief Digital Officer. “Our insights help improve key performance indicators, from identifying and addressing frequent downtime causes to preventing blockages that lead to plant stoppages.”
Smarter Maintenance with Real-Time Insights
Unplanned downtime is a major cost driver in sorting plants. STADLERconnect integrates real-time sensor data with existing systems to provide a complete overview of plant operations. AI-driven analytics transform complex data into actionable insights that enable predictive maintenance, reducing unexpected failures.
Automation & Material Analysis for Efficiency
STADLERconnect also enhances automation and material analysis through advanced sensors and cameras. These tools collect critical data to optimize sorting, improve resource utilization, and reduce waste. By automating various parts of the plant, STADLERconnect improves operational performance and reduces operators' workloads, while its material analysis tools increase transparency on quantity and quality. They enable precise tracking of material flows, identify inefficiencies, and allow for process adjustments that reduce waste and energy usage. The result is consistent product quality, a reduction in costly manual quality checks, increased efficiency, lower costs, and higher process quality.
Driving Customer Value and Efficiency
In developing its digital solutions, STADLER has pursued a twofold objective: delivering added value by using key data insights to enhance plant operations, and applying these insights to improve plant design and after-sales service. “Our digital solutions are purpose-built for sorting plants, directly addressing the needs of plant operators,” says Julia Stadler. “Leveraging our extensive OEM expertise, we ensure greater accuracy in areas such as determining conveyor equipment status. Our team combines software development and engineering expertise. This approach goes beyond simple data collection and visualisation: our solutions leverage new and existing data points to drive meaningful operational improvements.”
Continuous Innovation for a Smart Sorting Revolution
STADLERconnect is designed to adapt to recyclers' evolving needs. All modules receive regular updates and feature security enhancements at no additional cost to customers.
The patented STADLERconnect modules have been successfully implemented in several plants and will be rolled out across STADLER turnkey recycling plants worldwide. Upcoming modules, such as Windshifter Automation and Infeed Decision Aid, will expand capabilities even further. Our aim is to support the integration of data not only from our own equipment but also from all the equipment in our plants, paving the way for a truly smart sorting plant,” concludes Julia Stadler.