RFID in the waste stream: Digitally sorted – sustainably developed

Packaging waste, which has been collected by the Dual Systems in Germany since 1993, ends up in waste sorting plants such as the one in Ochtendung near Koblenz. The disposal company Veolia sorts 90,000 tons of packaging waste every year in this highly automated sorting plant. Packaging that citizens dispose of in yellow bags and bins is separated into a total of 13 different material streams, including main streams of polypropylene (PP), polyethylene (PE) and polyethylene terephthalate (PET), both in film and solid packaging, as well as metal and paper.

Automated precision: How packages are sorted in Ochtende

In the first sorting step, rotating drum screens separate packaging parts from the main flow based on their size. In the end, the entire material, which falls through the last three by three centimeters of sieve openings, is not sorted further and fed into thermal recycling, i.e. burned. In the subsequent sorting process, near-field infrared sensors (NIR) detect different types of plastic and fiber packaging. Magnets and eddy current separators remove ferrous and non-ferrous metals, and so-called wind sifters remove light films by vacuuming.

CIRCPACK by Veolia wants to continuously increase the proportion of recyclable packaging. Since February 2025, the Packaging and Packaging Waste Regulation (PPWR) has been in force, which is intended to reduce the amount of waste through various measures – firstly through recyclable materials, and secondly through the prevention of waste by means of a returnable obligation in certain areas.

Automated RFID-based tests improve validity

David Wardle was looking for a solution that would automatically track the way packaging passes through the sorting system, providing ever more reliable data. His idea was to use RFID. "I had the idea, but not the technology," Wardle recalls. "That's why we were looking for a partner who was not only familiar with RFID, but also able to reliably run this technology in harsh environments such as a sorting plant."

TURCK as a technology partner

Through contact with Avery Dennison, CIRCPACK came to Turck Vilant Systems – and they were quickly convinced. Together, a setup was developed that today consists of nine readers and 32 antennas – distributed across the entire sorting system.

Transparency that creates trust

For CIRCPACK's customers – mainly large brand manufacturers – the system is a groundbreaking innovation. It demonstrates their commitment to improving the recyclability of packaging. The results of the tests are incorporated into certifications such as RecyClass. They help manufacturers to improve their packaging – and to meet legal requirements.

Scaling and further development

So far, the system in Ochtendung is unique – but that is about to change. "We want to roll it out – to other plants, to other countries," says the environmental engineer. "And we want to develop it further – with optimized tags, with higher reading accuracy, with more automation. In the future, manufacturers will have to prove that their packaging is recyclable and, above all, sortable. Our system provides this proof – objectively, comprehensively and reliably."

Conclusion: A project with radiance – and technological vision

What started as an idea is now a functioning test system under real conditions – and a model project for the entire industry. "We have proven that technological innovations can pave the way for a more circular economy," sums up CIRCPACK's test specialist David Wardle. “With TURCK, we have found a partner who not only supplies us, but also thinks with us – and makes real change possible through technology.”

Customer | www.circpack.veolia.com