On 21 April 2026, a facility for sorting spent household batteries was officially inaugurated in Ginsheim-Gustavsburg, Germany, near Mainz. Delivered by Stadler Anlagenbau GmbH, the site was built for Saubermacher and Meinhardt Städtereinigung GmbH & Co. KG and is Stadler’s first dedicated battery sorting line. According to information provided by the project partners, the plant is intended to set a reference point for safe, high-quality processing of complex household battery streams at industrial scale. Its declared processing capacity is up to 100 tonnes of batteries per day, with an assumed throughput increase to up to 5 t/h and a reduced share of manual sorting.
The project was implemented in cooperation between Stadler, weeeSwiss Technology AG (part of the Stadler Group and specialising in WEEE recycling technologies and process development) and Metzen Industries GmbH. Metzen was responsible for the recycling section, the control system and CE conformity. The importance of the existing cooperation between weeeSwiss and Metzen was also highlighted, as it was intended to facilitate the overall concept and the integration of subsequent process stages. Andrea Zirkl, Process Engineer and Project Manager at Saubermacher, states: "Communication was always professional, open and efficient, which made it possible to address challenges quickly and effectively".
The investment is set against growing regulatory pressure and market changes related to battery recycling in Europe. The EU Battery Regulation includes target collection rates for portable batteries of 63% by 2027 and 73% by 2030, as well as high material recovery targets for critical raw materials such as lithium, cobalt and nickel. As volumes increase and battery material compositions become more complex, demand is rising for tightly controlled, industrial-scale sorting solutions. As Andrea Zirkl assesses: "We see a clear need for solutions that can handle heterogeneous input streams while ensuring safety and material quality. This facility is a key step in preparing for future market growth and regulatory developments".
Plant design and safety requirements
Designing a system capable of handling the full spectrum of household batteries was described as a significant technical challenge. The input stream includes very small button cells as well as larger batteries from, among others, power tools or e-bikes, with different shapes, chemistries and safety requirements. For this reason, safe handling of batteries at every process stage was a core assumption.
The plant was designed for a compact building footprint, which translated into a fully enclosed system with controlled material flow and sealed transport intended to minimise risks such as fire or chemical exposure. Particular attention was given to feeding and conveying to ensure gentle handling of batteries and to limit the risk of damage. The recycling section was designed as a fully sealed environment with stainless-steel construction in order to meet safety and containment requirements.
Fraction sorting and separation technologies
The main material stream of the plant consists of AlMn (alkaline-manganese) and ZnC (zinc-carbon) 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.
According to the solution description, Stadler developed a tailored system concept combining robust mechanical design with advanced sorting technologies. The facility processes mixed battery waste and automatically separates it into defined fractions, including 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. The set-up includes, among others, bunkers, vibrating chutes, screening, magnetic separation and X-ray sorting, intended to enable precise classification of battery type and chemistry. The plant also integrates three sensor-based sorting systems enabling classification by battery chemistry, described as a first-of-its-kind approach at industrial scale.
The assumption of this configuration is to generate stable, clearly defined output streams, including valuable material fractions such as nickel, manganese, copper, zinc and aluminium, prepared for downstream recycling processes, while maintaining the required safety standards across the entire system.
Project cooperation from concept to commissioning
Saubermacher indicates that the selection of Stadler was driven not only by technical expertise but also by a willingness to jointly develop a household battery sorting process for a new application. Andrea Zirkl emphasises: "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".
The statement notes that, as the first joint project, the undertaking required a high level of alignment and trust between all parties involved, with a focus on reducing manual sorting and increasing operational efficiency. In the partners’ assessment, this approach made it possible to deliver the facility within the expected timeframe and represents a step for Stadler towards expanding capabilities in the battery recycling sector.
Relevance for recycling and the circular economy
More broadly, the facility is intended to support circular economy goals and the development of battery recycling infrastructure in Europe. Precise separation of battery types and chemistries is expected to improve the quality of material supplied to downstream recycling and facilitate the recovery of valuable raw materials such as nickel, manganese, copper, zinc and aluminium. At the same time, the emphasis is on controlled, safe and compliant handling of battery waste under increasing regulatory and environmental requirements.
Jochen Apfel, CEO of weeeSwiss Technology AG, comments: "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." Summarising the project’s relevance in the market context, he adds: "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."
Stadler: scope of activities
The Stadler Group, founded in 1791, operates globally in the planning, production and assembly of sorting systems and components for the recycling industry. The company delivers turnkey solutions covering stages from conceptual design and engineering to installation, modernisation and servicing. Its portfolio includes, among others, ballistic separators, conveyor belts, trommel screens, label removers, bale dewiring units, as well as steel structures and electrical switch cabinets for complete recycling plants.
The statement also refers to the Stadlerconnect platform, using AI-based solutions for real-time data acquisition, predictive analytics and process optimisation. Stadler also operates test and innovation centres in Europe, offering research support and sorting process simulations to optimise performance.
