METZEN’s Environmental Technology division has once again demonstrated its role as a reliable and forward-thinking partner in the recycling sector. In a technically demanding and logistically complex undertaking, METZEN designed, delivered, and installed a fully bespoke washing and separation line for a long-standing client—one of the world’s leading operators of Europe’s largest plastic film recycling facility. The client processes an impressive 80,000 tonnes of recyclable plastic annually, converting it into 170,000 tonnes of premium-grade output material.
Time and Space: The defining challenges
To meet increasing demand, the client required a second washing and separation line at short notice to boost its plastic film processing capacity. The target: a throughput of three tonnes per hour, distributed across two lines. The entire project had to be completed within a highly ambitious 12-month timeframe.
Space constraints added further complexity: the new line had to be installed within a curved-roof industrial hall measuring just 90 x 20 x 9 metres. The plant not only needed to fit within this tight footprint but also be seamlessly integrated into the existing structural environment. This included a wave-shaped layout spanning three interconnected halls, mandatory separation of plant sections, and the incorporation of pre-existing equipment. These architectural limitations also significantly restricted access for materials handling and equipment installation.
Creativity and precision at the forefront
“A highly engaging project where we couldn’t start with a clean slate,” explains Senior Engineer Philipp Portz, reflecting on the initial conditions. “All existing plant components had to remain in place within an architecturally unconventional hall. Repositioning of equipment was not an option—all this while managing complex coordination with suppliers, subcontractors, and project partners.”
To overcome these challenges, METZEN leveraged interdisciplinary collaboration, precise engineering, and in-house manufacturing of several critical components. The system layout underwent multiple iterations before the optimal configuration was achieved. Portz adds: “It was a project that would push even the best Tetris players to their limits.”
The Result: Bespoke efficiency, delivered on schedule
Through strategic planning and innovative design, METZEN successfully integrated 19 system components within the restricted spatial framework. The new washing and separation lines not only meet the client’s technical and economic targets, but were also delivered, installed, and commissioned within the tight schedule.
“We delivered a plant in record time that fulfils both demanding performance specifications and complex logistical constraints,” Portz concludes.
This project serves as a strong testament to METZEN’s ability to develop and implement tailored, client-centric solutions—even under challenging conditions. The successful execution once again underscores METZEN’s competence in managing complex plant engineering projects, particularly when time and space are critical factors.
About Philipp Portz
Philipp Portz is a seasoned Senior Engineer with over a decade of experience in industrial and environmental engineering, specialising in bulk material handling and process systems. At METZEN, he develops practical, efficient solutions for clients in the environmental technology sector—ensuring technical feasibility even under the most demanding conditions. His combination of deep hands-on experience and comprehensive design expertise makes him a respected authority within the industry.
METZEN’s Environmental Technology division has once again demonstrated its role as a reliable and forward-thinking partner in the recycling sector. In a technically demanding and logistically complex undertaking, METZEN designed, delivered, and installed a fully bespoke washing and separation line for a long-standing client—one of the world’s leading operators of Europe’s largest plastic film recycling facility. The client processes an impressive 80,000 tonnes of recyclable plastic annually, converting it into 170,000 tonnes of premium-grade output material.
Time and Space: The defining challenges
To meet increasing demand, the client required a second washing and separation line at short notice to boost its plastic film processing capacity. The target: a throughput of three tonnes per hour, distributed across two lines. The entire project had to be completed within a highly ambitious 12-month timeframe.
Space constraints added further complexity: the new line had to be installed within a curved-roof industrial hall measuring just 90 x 20 x 9 metres. The plant not only needed to fit within this tight footprint but also be seamlessly integrated into the existing structural environment. This included a wave-shaped layout spanning three interconnected halls, mandatory separation of plant sections, and the incorporation of pre-existing equipment. These architectural limitations also significantly restricted access for materials handling and equipment installation.
Creativity and precision at the forefront
“A highly engaging project where we couldn’t start with a clean slate,” explains Senior Engineer Philipp Portz, reflecting on the initial conditions. “All existing plant components had to remain in place within an architecturally unconventional hall. Repositioning of equipment was not an option—all this while managing complex coordination with suppliers, subcontractors, and project partners.”
To overcome these challenges, METZEN leveraged interdisciplinary collaboration, precise engineering, and in-house manufacturing of several critical components. The system layout underwent multiple iterations before the optimal configuration was achieved. Portz adds: “It was a project that would push even the best Tetris players to their limits.”
The Result: Bespoke efficiency, delivered on schedule
Through strategic planning and innovative design, METZEN successfully integrated 19 system components within the restricted spatial framework. The new washing and separation lines not only meet the client’s technical and economic targets, but were also delivered, installed, and commissioned within the tight schedule.
“We delivered a plant in record time that fulfils both demanding performance specifications and complex logistical constraints,” Portz concludes.
This project serves as a strong testament to METZEN’s ability to develop and implement tailored, client-centric solutions—even under challenging conditions. The successful execution once again underscores METZEN’s competence in managing complex plant engineering projects, particularly when time and space are critical factors.
About Philipp Portz
Philipp Portz is a seasoned Senior Engineer with over a decade of experience in industrial and environmental engineering, specialising in bulk material handling and process systems. At METZEN, he develops practical, efficient solutions for clients in the environmental technology sector—ensuring technical feasibility even under the most demanding conditions. His combination of deep hands-on experience and comprehensive design expertise makes him a respected authority within the industry.