Making better use of opportunities and possibilities
More than 100 billion tonnes of raw materials are consumed annually, and more than 90 per cent of these are not recycled, according to an alarming report by the European Investment Bank (EIB). Ever-rising CO₂ costs, fluctuating raw material prices and various geopolitical crises are putting companies under additional pressure. Smart facilities are the key to increasing the recycling rate and recovering valuable resources by type. High-precision, automated processes in ‘smart recycling plants’ are set to soon replace labour-intensive manual or inefficient mechanical sorting methods.
Enablers of the circular economy
Digitalisation plays a key role not only in sorting, but throughout the entire product life cycle (Smart Circular Economy). Smart sensors (IoT systems) monitor the flow of materials continuously and in real time. The data collected forms the basis for data-driven decisions and the control of plant operations. Data analysis and predictive maintenance are essential. AI systems identify bottlenecks and inefficient processes, suggest optimisations and predict when machinery will require maintenance. This reduces downtime and operating costs. Technologies such as blockchain and digital twins will ensure seamless traceability of materials in future. The integration of digital technologies results in a scalable, transparent and highly efficient waste management system.
Precise sorting controlled by AI
As part of the ‘Smart Recycling-Up’ project, which falls under the ‘AI Lighthouses for the Environment, Climate, Nature and Resources’ funding programme run by the Federal Ministry for the Environment, Nature Conservation, Nuclear Safety and Consumer Protection (BMUV), a novel, AI-based integrated concept has been successfully developed. It combines state-of-the-art AI-supported sensor technology, machine learning and automated control systems. For the first time, this solution enables the automated sorting of bulky waste using a crane or excavator. The focus was on recovering valuable materials such as wood, plastic and metal, which have previously been difficult to separate from mixed waste. Another advantage is that the AI can identify and remove contaminants such as batteries and other hazardous substances, which significantly enhances the safety of staff and the plant. The Smart Recycling-Up project impressively demonstrates how AI and robotics are improving the efficiency and quality of recycling in the waste management sector.
Flagship projects everywhere
Through the Smart Recycling Factory (SRF), the active landfill site at Pohlsche Heide is set to evolve over the coming years, in several stages, into a supra-regional centre of innovation for recycling and the circular economy, showcasing the full scope and scale of these fields. The aim is to conduct forward-looking, transdisciplinary research into the circular economy in order to conserve resources, reduce CO₂ emissions and strengthen the regional economy. As a ‘Science-to-Business Centre’, the SRF will put scientific findings into practice.
A prime example of pioneering recycling
Since autumn 2025, Pre Zero Sorting Austria in Sollenau has been operating a sorting plant for lightweight packaging (LVP), which – not least thanks to the integration of AI – ranks among the most innovative recycling plants in Europe. At the heart of the plant is a highly integrated and automated sorting system capable of processing both light household packaging and plastic bottles, as well as light packaging waste from commercial waste streams. The plant is particularly impressive due to its high level of intelligent automation throughout the entire process. By minimising manual intervention, the system increases efficiency, reduces downtime and enables round-the-clock operation.
Start-ups are showcasing their capabilities at RECYCLING-TECHNIK in Dortmund
The tech start-up Mineral Waste Manager has entered the market with its eponymous product, aiming to make the mineral waste industry fit and resilient for the future. “Our aim is to drive forward innovative solutions for digital transformation in the waste sector,” says Dr Sebastian Busse, Managing Director of Mineral Waste Manager. “By developing and providing AI-based solutions, we are helping to make the processes involved in the disposal of mineral waste more efficient and resilient.” The specific aim is to ensure the fastest possible, professional treatment of mineral waste via the optimal disposal route.
Optocycle has a clear vision: a world in which all construction waste becomes new building material. The company combines the latest optical sensor technology with advanced artificial intelligence to efficiently and transparently transform mineral construction waste into sustainable building materials. Founded in 2022 and the recipient of multiple awards, this start-up actively promotes the digitalisation of the circular economy and contributes to a transparent and environmentally friendly construction sector. Thanks to the AI-powered optical recognition system for mineral demolition waste, customers always know exactly which materials they are dealing with. “Founded with the aim of revolutionising the management of mineral construction waste, we have set ourselves the goal of redefining the industry through innovative technology, commitment and transparency,” emphasises Co-Founder & CEO Max-Frederick Gerken. “Our team works tirelessly to develop technologies that are not only economically viable but also environmentally sustainable.”
A catalyst for the green transition
The circular economy offers enormous potential and combines environmental, economic and social considerations. Through the use of AI, robotics and digital twins, processes can be designed to consume fewer resources, produce less waste and even help alleviate the shortage of skilled workers. According to the consultancy firm EY, Europe’s goal of becoming a climate-neutral continent can only be achieved through highly efficient use of resources. Using secondary rather than primary raw materials – for example, in metal, glass and paper production – results in energy savings of 20 to 90 per cent, as well as significant water savings. EU companies could save between 250 and 465 billion euros in net material costs annually, representing 12 to 23 per cent of their material costs. This provides a major incentive to drive digitalisation forward more vigorously. ‘Smart Recycling Plants’ combine sensor technology, robotics and AI to transform recycling from a linear, labour-intensive process into a highly efficient, data-driven system. As a central component of the digital ecosystem of a sustainable circular economy, they play a crucial role.
Updated on 10 December 2025, Source:
SOLIDS & RECYCLING-TECHNIK Dortmund, Easyfairs Deutschland GmbH
A pair of trade fairs for the bulk materials, process and recycling industries