Stadler develops second Republic Services Polymer Center

Anlagenbau, headquartered Germany, has completed the design and installation of the new Republic Services Polymer Center in Indianapolis, marking the second facility of this type it has developed for Republic Services. The Las Vegas Polymer Center opened in late 2023.

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The new facility further strengthens Republic Services’ vertically integrated plastics recycling operations. The plant is designed to process presorted plastics collected by Republic Services to recover polyethylene terephthalate (PET) and polyolefins. It will provide food-grade recycled plastics for use in producing new bottles, jugs and containers.

"This new facility represents another major step forward in our plans for a nationwide network to close the loop on plastics recycling and help customers achieve a true plastics circular economy," says Pete Keller, Republic Services vice president, Recycling and Sustainability. "With the addition of a second Polymer Center, we are expanding our processing capacity to produce high-quality recycled resins, contributing to a more sustainable future for packaging in the U.S.”

“The new Indianapolis Polymer Center is a testament to Stadler’s commitment to innovation and excellence in the U.S. recycling industry, contributing to the development of a plastics circular economy,” says Jürgen Berger, head of International Sales at Stadler Anlagenbau GmbH. “We are proud of the trust that Republic Services has placed in our company and in our collaborative efforts to drive positive change in the PET and Polyolefins markets in this country,” added Willi Stadler.

The Republic Services Polymer Center in Indianapolis incorporates a Stadler-designed dual-line system. Bales of mixed plastics are opened using Stadler’s 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 Stadler 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 are processed through Stadler’s Label Remover and Label Separation Hood. Clear PET, caps and rings are directed to the washing line for granulation and cleaning, while colored PET is compacted into bales.

On the mixed plastics line, materials are sorted into fines and sieve overflow. The heavier fractions from the overflow are separated into four polyethylene PE fractions—natural, white, red/orange/yellow and other/color—and two polypropylene fractions—natural/white and other/color. 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 presort area and a control room with a comprehensive view of material flow and baler operations, Stadler says. The facility also prioritizes workplace quality, offering an open, well-lit environment.

"The Indianapolis Polymer Center is amazing; it might be the nicest-looking buildout I’ve ever seen in any plastics plant in the world. The whole installation has a light and airy feel to it, making it a great environment to work in," says Mat Everhart at Stalder America, which is based in Colfax, North Carolina. 

Republic Services selected Stadler for the Indianapolis Polymer Center following their collaboration on the Las Vegas facility. This new facility also incorporates additional processing steps to provide Republic Services with greater flexibility in selecting markets for its recycled materials and expanding the range of accepted inputs.

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Our partnership with Republic Services goes beyond constructing state-of-the-art recycling facilities,” Everhart says. "It’s about shaping the future of plastics recycling in North America. The success of the Indianapolis plant marks another milestone in our commitment to supporting a more circular economy through advanced sorting technology and strategic collaboration."