Turnkey Waste Sorting Line Provider in Europe: Case Studies with Azortum

Azortum has solidified its reputation as the turnkey waste sorting line provider in Europe, delivering end-to-end engineering, installation, and commissioning services for a diverse range of recycling facilities. From the Baltics to the Nordics and Central and Eastern Europe, our projects highlight how we design and implement energy-efficient automated waste sorting line designs, modular retrofit waste sorting solutions, and MSW and packaging hybrid sorting systems for zero-landfill residual management. Below, we explore six flagship installations that exemplify our turnkey approach, showcasing the technical rigour, engineering vocabulary, and operational results that plant managers and R&D leaders expect.

When Ecoservice’s packaging waste line was destroyed by fire in early 2023, they selected Azortum as their waste sorting line engineering partner to rebuild within the existing footprint and strict 18-month deadline. Our energy-efficient automated waste sorting line design incorporated:

• Variable-speed drives (VSDs) on all conveyors to reduce kWh/tonne by 22 %.

• Low-power NIR optical sorters calibrated for PET, HDPE, and PP, reducing power consumption per tonne by 15 %.

• Optimized belt widths and chute geometries to minimize material bridges and conveyor idling.

By phasing detailed design and installation in parallel, we hoisted critical components—drum screens and optical sorter modules—through a partially built roof. The result: a 1.5× throughput improvement (12 t/h → 18 t/h) and a 20 % increase in recyclables recovery. Integrated fire-detection sensors and an automated suppression system ensure future resilience. Ecoservice now operates a facility that exemplifies energy-efficient recycling line engineering, meeting EU Mandate 2019/904 on single-use plastics and local sustainability targets.

NG Group, a cornerstone of Nordic circular infrastructure, enlisted Azortum in 2022 to replace their legacy wood-shredding line—processing ~90 000 t/year—without a major operational shutdown. Our modular retrofit waste sorting solutions included:

• Skid-mounted conveyor modules and plug-and-play control panels to minimize onsite assembly time.

• Pre-assembled eddy current separators and overbelt magnets tested offsite for rapid commissioning.

• ISO P623-compliant chip classification via a modular trommel deck, ensuring downstream energy producers receive sub-20 mm chips with < 5 % fines.

Installation proceeded in under seven days of downtime by erecting modules in parallel with the old line. Real-time throughput monitoring optimized belt speeds and VSD profiles, achieving < 1 % mechanical downtime. NG Group’s new line now yields consistently high-caliber wood chips for both energy and furniture manufacturers, exemplifying how modular waste sorting line installation can be executed in constrained Nordic facilities.

EcoBaltia challenged us to engineer a dual-stream system handling 30 t/h of municipal solid waste (MSW) and 7 t/h of packaging waste, targeting zero-landfill residual management. Key features included:

• Adaptive screening to remove oversized items (appliances, construction debris) via a dual-deck trommel.

• High-resolution optical sorters for PET, HDPE, PP, paper, film, and tetrapak fractions.

• Sequential overbelt magnets and eddy current separators to eliminate ferrous and non-ferrous contaminants.

• Pneumatic dust-suppression systems at transfer points to maintain compliance with EU Directive 2008/50/EC on ambient air quality.

Prior to full commissioning, we conducted in-situ yield tests—quantifying recovery rates (PET: 94 %, paper: 92 %, tetrapak: 87 %)—and fine-tuned sensor profiles. EcoBaltia now achieves an 88 % overall diversion rate, positioning them as a regional leader in circular economy recycling plant design.

Rising landfill fees prompted CleanR Verso to seek a dedicated C&D line engineered by Azortum. We delivered a construction and demolition waste sorting solution featuring:

• A heavy-duty vibratory screen that separates aggregates (> 20 mm) and finer fractions, preserving stone integrity without a primary shredder.

• Air-classifier modules and ballistic separators to sort wood, textiles, plastics, and metals.

• A low-floor ergonomic picking cabin with anti-fatigue flooring and adjustable workstations to reduce operator strain by 30 %.

• Outdoor dust-suppression systems (misting nozzles at drop points) to meet Latvian Environmental Regulation LVR 2021/07 on particulate emissions.

Post-load-testing metrics show a stable 25 t/h of high-quality concrete aggregate (0–16 mm) with < 3 % fines. CleanR Verso now diverts 85 % of inbound C&D materials away from landfills, illustrating how dust-suppression systems for outdoor C&D sorting plants elevate both compliance and operator health.

1. NG Group Automated Paper Sorting (Oslo, 2018–2019)

   • Designed for 20 t/h (≈ 120 000 t/year), this line uses multiple AI-driven optical sorter integrations to achieve ≤ 3 % residue and ≥ 97 % ink-fiber purity.

   • We optimized chute angles (20°–25°) to prevent thin-fiber bridging and synchronized sorting robots for real-time contaminant removal.

   • A 2024 NIR-retrofit bypass module added tetrapak separation, boosting fiber recovery by 8 %.

2. Ragn-Sells Hybrid Paper & Packaging Sorting (Estonia, 2020–2022)

   • Operating in a 7 m-tall hall, we designed a compact hybrid system for mixed paper/OCC and mixed plastic packaging.

   • Ballistic separators and narrow-belt conveyors doubled capacity from 2.2 t/h to 6 t/h, while modular NIR sorters and an external glass-break trommel (due to height constraints) seamlessly integrated without downtime.

   • Safety zoning and material-feed routing prevented bottlenecks, yielding near 2× throughput improvement and residue rates < 4 %.

These projects demonstrate how optical sorting line integration—augmented by AI and machine-learning algorithms—enables clients to maximize material purity and minimize manual picks.

By combining energy-efficient automated waste sorting line design, modular retrofit waste sorting solutions in Nordic countries, and MSW and packaging hybrid sorting systems for zero-landfill residual management, Azortum has proven its capability as the turnkey waste sorting line provider in Europe trusts. Our engineering-led, data-driven approach—from feasibility analysis and 3D layout simulations to commissioning and aftermarket support—ensures that each facility consistently meets throughput, purity, and sustainability targets. Whether a plant seeks to upgrade legacy equipment, build a new hybrid system, or reduce carbon footprint, Azortum’s turnkey methodology delivers measurable ROI, regulatory compliance, and a sustainable path toward circular economy goals.