Altstoff Recycling Austria AG (ARA), Bernegger and Der Grüne Punkt, a GreenDot subsidiary, are building their new plant “Sort4cycle” at the site of the TriPlast plastics sorting facility in Austria.
This is a unique flagship project for the future of Europe’s circular economy using the Upcycle process. The facility will process up to 41,000 tonnes of plastics per year that previously could only be reclaimed through energy recovery keeping even more valuable raw materials in circulation and conserving resources. The goal is to produce recycled polyolefin materials suitable for contact-sensitive packaging through chemical recycling and, eventually, also through mechanical recycling.
Construction work for the highly innovative Sort4cycle recycling plant at the Ennshafen port is now underway, marking the beginning of a new era in plastics recycling. The facility will namely use the Upcycle process patented by ARA, enabling the further processing of sorting residues that previously had to be thermally recovered. These residues were considered non‑recyclable due to contamination, structure, or particle size.
Starting in 2027, Sort4cycle will give these materials new life in the circular economy including thanks to chemical recycling, making a key contribution to achieving EU recycling targets and reducing the use of fossil primary raw materials. With an investment of more than €40 mill, the owners are strengthening raw material sovereignty, innovation capacity, and supply security in Austria and Europe. Commissioning is planned for mid‑2027, creating up to 30 qualified green jobs.
“ARA has been working for over 30 years to continuously advance the circular economy in Austria. With Sort4cycle, we are setting a true milestone – not only nationally, but with a signal effect far beyond Austria. The plant is a decisive step toward closing plastics loops and preparing the use of recyclates in sensitive areas such as food packaging. This is essential for climate protection, resource conservation, European raw material independence, and the resilience of our economy,” says ARA CEO Thomas Eck.
Sort4cycle Enables Innovative Recycling at the TriPlast Sorting Facility
With the opening of TriPlast in 2024, ARA, Bernegger and Der Grüne Punkt set a new benchmark for plastics sorting in Europe. The high‑tech facility processes up to 20 tonnes of material per hour from the Yellow Bag/Yellow Bin – around 100,000 tonnes annually. Sort4cycle will build on this success story and elevate it to the next level of innovation. In addition to material from the TriPlast output, the new plant will also process additional volumes from other sorting facilities, up to a total of 41,000 tonnes per year.
“Sort4cycle once again makes Upper Austria an innovation hotspot for the circular economy. Building the plant directly at the TriPlast site ensures short transport routes and maximum efficiency. With additional fine sorting and cleaning, we create the basis for even more precise material separation and maximum value creation from waste. We are proud to contribute significantly to a functioning plastics circular economy,” says Kurt Bernegger, Managing Director of Bernegger GmbH.
Two Technological Pillars of Sort4cycle
Sort4cycle combines two independent yet complementary innovation areas: the “Advanced‑Scale Post‑Sorting” system and the enhanced Upcycle process.
- Advanced‑Scale Post‑Sorting – AI‑Driven & Mechanically Food‑Grade Ready
A central component of Sort4cycle is a novel, AI‑based, high‑performance, post‑sorting system at industrial scale. It enables the extraction of highly pure materials from complex waste streams, specifically prepared for mechanical recycling. Sort4cycle thus creates the technological foundation for future mechanically recycled food‑grade materials – a true milestone for the circular economy.
- Upcycle Process – High‑Quality Recovery of Previously Non‑Recyclable Fractions
The second key component is the Upcycle process, implemented here in an optimized version. It focuses on plastic fractions that previously had to be thermally recovered due to contamination, material diversity, or particle size. Improved processes and material flow management significantly increase their potential for material recycling including as feedstock for chemical recycling.
Next Step: Potential EFSA approved Food Grade Material Through Mechanical Recycling
Through upstream fine sorting, Sort4cycle selectively enriches and cleans individual plastic fractions. The resulting polyolefin fraction is particularly well suited for high quality applications that could eventually meet food grade packaging requirements.
“As a European platform offering the best feedstock solutions for the plastics packaging circular economy, Der Grüne Punkt is thrilled to continue its journey in Austria. The new Sort4cycle plant will be an important addition to our feedstock preparation sites for chemical recycling and our mechanical recycling sites in Italy, Germany and France. These sites match the highest quality standards to continue to best serve packaging brands and guide them towards fulfilment of the PPWR requirements. In the light of the current geopolitical tensions, rising raw material prices, and stricter EU recycling quotas, Europe needs industrial solutions that work today and can scale tomorrow”, emphasizes Denis Völler, Managing Director of Der Grüne Punkt.
Source: GreenDot
