Battery recycling : Advanced technology sets a new standard in battery recycling and sorting

Following its official inauguration on 21 April 2026, a state-of-the-art household battery sorting facility in Ginsheim-Gustavsburg, near Mainz, has opened its doors — and with it a new chapter in European battery recycling. Delivered by STADLER Anlagenbau GmbH for Saubermacher and Meinhardt Städtereinigung GmbH & Co. KG, the plant represents STADLER's first dedicated battery sorting line and is already being cited as a key reference for large-scale battery processing on the continent.

The project brought together STADLER, its subsidiary weeeSwiss Technology AG — which specialises in WEEE recycling technologies and process development — and METZEN Industries GmbH, responsible for the recycling section, control system and CE conformity. Together, the three companies developed an integrated, near-turnkey solution that, according to the partners, no other single supplier was able to offer at the time.

Designing a facility capable of handling the full spectrum of household batteries presented a formidable technical challenge. The input material ranges from tiny button cells to larger units from cordless tools and e-bikes, spanning multiple chemistries, shapes and safety profiles. Ensuring safe handling throughout the entire process was therefore central to the design brief from the outset.

The plant was engineered to operate within a compact building footprint, requiring a fully enclosed system with controlled material flow and sealed transport to minimise risks such as fire or chemical exposure. Particular care was devoted to the feeding and conveying systems, which were designed to handle batteries gently throughout the process and prevent damage or potential safety incidents. The recycling section was built as a fully sealed environment, with stainless-steel construction to meet strict containment requirements.

The primary material stream consists of alkaline-manganese (AlMn) and zinc-carbon (ZnC) batteries, which are conveyed directly to METZEN's downstream recycling facility. NiMH batteries are separated and directed to a dedicated processing line, while lithium-based batteries and other special types are fully removed and pre-sorted for external processing.

To address these considerable technical demands, STADLER developed a bespoke system concept combining robust mechanical design with sophisticated sorting technologies. The facility processes mixed battery waste and separates it fully automatically into clearly defined fractions: AA and AAA batteries, button cells, C, D and block batteries, lithium-based batteries, NiCd and NiMH fractions, as well as battery packs and secondary materials such as vermiculite.

A combination of bunkers, vibrating chutes, screening, magnetic separation and X-ray sorting systems enables precise classification by battery type and chemistry. The plant also integrates three sensor-based sorting systems capable of classifying batteries by chemistry — a first-of-its-kind approach at industrial scale. With a processing capacity of up to 100 tonnes per day and a throughput of up to five tonnes per hour, the facility is positioned as one of the most capable battery sorting operations in Europe.

"This project represents an important step for STADLER in entering the battery recycling sector. It demonstrates how combining process expertise with mechanical engineering can deliver integrated solutions for highly demanding applications", said Jochen Apfel, CEO, weeeSwiss Technology AG.

One of the central objectives of the facility is to generate consistent, well-defined output streams that can serve as reliable feedstock for downstream recycling processes. The configuration enables the recovery of valuable materials including nickel, manganese, copper, zinc and aluminium, all separated to a standard suitable for further processing.

By bridging the gap between collection systems and downstream recycling, the plant is designed to deliver scalable pre-treatment while supporting the efficient recovery of critical raw materials — a growing priority as the EU Battery Regulation sets ambitious targets. These include collection rates of 63% by 2027 and 73% by 2030 for portable batteries, alongside stringent material recovery targets for lithium, cobalt and nickel.

The efficiency gains delivered by the new facility are as much a product of the partnership model as of the technology itself. A pre-existing cooperation between weeeSwiss and METZEN played an important role in shaping the overall system concept and ensuring smooth integration across all process stages. From the early design phase through to installation and commissioning, the teams worked in close alignment to resolve challenges in a structured manner. "The communication was always professional, open and efficient, which made it possible to address challenges quickly and effectively", said Andrea Zirkl, Process Engineer and Project Manager, Saubermacher

Saubermacher's decision to work with STADLER was grounded not only in the company's technical track record but also in its willingness to jointly develop a new process for a completely novel application. "We selected STADLER based on their strong track record in complex sorting solutions and their willingness to engage in a solution-oriented partnership. What distinguished them was their ability to translate our requirements into a workable concept for battery sorting, while responding to highly specific and technically demanding project requirements," Zirkl explained. 

As a first project together, the collaboration required a high level of alignment and mutual trust, with a clear focus on reducing manual sorting and increasing operational efficiency. The result — delivered within the expected timeframe — marks an important step in STADLER's expansion into the battery recycling sector.

At a broader level, the facility plays a significant role in supporting circular economy objectives and strengthening Europe's battery recycling infrastructure. By enabling precise separation of battery types and chemistries, the plant contributes to improved input quality for downstream recyclers and helps reduce dependence on primary raw materials.

At the same time, the plant ensures that battery waste is handled in a controlled, safe and compliant manner — a critical requirement given the increasing regulatory and environmental pressures facing the sector. From Saubermacher's perspective, the facility represents an important step towards establishing robust, industrial-scale pre-treatment processes for increasingly heterogeneous material streams.

"Projects like this show how advanced sorting solutions are becoming a key enabler of the circular economy. By combining technology, process expertise and strong partnerships such as our collaboration with METZEN, we are helping our customers prepare for increasingly complex recycling streams in the future," said Apfel.