Recycling plant in Indiana

In addition to the one in Las Vegas, Nevada, which will be commissioned in 2023, Stadler also built Republic Services' new Polymer Center in Indianapolis, Indiana. The plant, which strengthens Republic Services’ vertically integrated plastics recycling operations, is designed to process pre-sorted plastics collected by the company to recover PET and polyolefins (PO). It will provide high-quality, food-grade recycled plastics for reuse in the production of new bottles, jugs, and containers.

The structure in Indianapolis incorporates a cutting-edge dual-line system. Bales of mixed plastics are opened using WireX machine for fully automated wire removal. The materials are fed into the facility and processed separately on two dedicated lines: one for PET and one for mixed plastics, with capacities of 5.5 and 5 tons per hour, respectively.

The process on the PET line begins with mechanical separation and cleaning to remove ferrous particles. A STT2000 ballistic separator then sorts materials into rigid, flexible, and fines fractions, which undergo near-infrared (NIR) sorting to further separate caps, rings, and labels. The 3D fractions go on to be processed through label remover. Clear PET, caps, and rings are directed to the washing line for granulation and cleaning for reuse, while color PET is compacted into bales.

On the mixed plastics line, materials are first sorted into fines and sieve overflow. The heavier fractions from the overflow are then separated into four polyethylene fractions – natural, white, red/orange/yellow, and other colour – and two polypropylene fractions – natural/white and other colour. PET is recovered from this stream and redirected to the PET line for further processing. The final-sorted products are stored in dedicated bunkers before being baled for market distribution.

The linear flow of the plant’s design enhances operational efficiency by improving access to all areas, simplifying maintenance, and incorporating a fully enclosed pre-sort area and a control room with a comprehensive view of material flow and baler operations. The facility also prioritizes workplace quality, offering an open, well-lit environment. This new facility also incorporates additional processing steps to provide Republic Services with greater flexibility in selecting markets for their recycled materials and expanding the range of accepted inputs.