Gerhard Lang Recycling partners with Tomra Recycling in aluminum alloy sorting project

German metal recycling company Gerhard Lang Recycling GmbH has installed an Autosort Pulse unit from Tomra Recycling, also based in Germany, at its metals sorting plant in southwestern Germany as part of a research project funded by the German Federal Ministry for Economic Affairs and Climate Action.

The KANAL, or Kreislaufsystem für funktionales Aluminium-Neuschrottrecycling aus der Automobilproduktion mittels LIPS, project, which translates to "Circular System for Functional Aluminum Scrap Recycling from Automotive Production Using LIBS,” seeks to close the loop on aluminum scrap generated in automotive production. Gerhard Lang Recycling GmbH has partnered with Pforzheim University of Applied Sciences, Tomra Recycling and engineers from Jeanvré for the 3.9 million euro ($4.08 million) project, using Tomra’s “dynamic” laser-induced plasma spectroscopy (LIBS) technology. Gerhard Lang Recycling GmbH is a research and field validation partner in the project.

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The plant’s infeed material consists of stamping scrap generated in producing car parts and panels. Of the aluminum used in this process, an estimated 30 percent to 50 percent ends up as scrap, which is a mixture of 5xxx (high-magnesium) and 6xxx (low-magnesium) aluminum wrought alloys.

When material arrives at Gerhard Lang Recycling’s metals sorting plant in Gaggenau, Germany, it is shredded before undergoing a multistage magnetic separation process to remove the ferrous metals and then the nonferrous material is fed into the Autosort Pulse to be separated based on the precise analysis of the elemental composition of each material and using highly advanced dynamic laser detection, which enables it to distinguish between alloys.

Before the Autosort Pulse was installed, the Gerhard Lang Recycling team sold the mixed material to aluminum manufacturers immediately after the shredding process. With the Autosort Pulse in place, Gerhard Lang Recycling can sort the 5xxx and 6xxx series aluminum scrap by alloy family.

Tomra says object singulation also allows the unit to accurately identify and separate overlapping and adjacent materials, maximizing yield and efficiency in the sorting process. Its 3D object scanning feature recognizes an object’s shape, height and position and identifies the ideal shooting point for the Dynamic LIBS laser.

This laser offers two focus modes: multipoint, where the laser shoots in a line across the sample, and single-point, where the laser drills down into a specific spot, providing ideal detection conditions. The latter mode, which Tomra developed, has demonstrated superior performance in tests, according to the equipment manufacturer.

Gerhard Lang Recycling consulted with Tomra’s metals experts before investing in the new aluminum sorting process. Development of the project spanned several years, with initial discussions beginning in 2018.

“With the integration of Autosort Pulse, we are able to process a throughput of around 4-7 tons per hour and achieve exceptionally high purity levels, exceeding 95 percent and potentially reaching 97 percent," says Maximilian Lang, managing director at Gerhard Lang Recycling. "As a result, our material is suitable for use in the production of aluminum without downgrading. We can now sell the recovered materials to leading aluminum manufacturers and recyclers for direct integration into the production of new aluminum alloys. What’s more, we are considering the potential to explore additional applications for other aluminum alloys.”

“This is a very exciting project for Tomra to be involved in, and we are delighted that Gerhard Lang Recycling GmbH is reaping the benefits that our Autosort Pulse can offer,” says Frank van de Winkel, market strategy manager, metal, at Tomra Recycling. “With the European Union's commitment to climate neutrality by 2050, as outlined in the Green Deal, and the specific target of a 55 percent reduction in greenhouse gas emissions by 2030 under the ‘Fit for 55’ initiative, there has never been a more crucial time to explore ways of making the aluminum supply chain more sustainable.

“Our Autosort Pulse system empowers aluminum manufacturers to enhance the utilization of recycled aluminum in their production processes. This innovative solution unlocks access to previously untapped scrap sources, enabling the recovery of high-quality, ‘alloy-true’ recycled aluminum. By preventing downcycling and conserving material value, we are closing another gap towards full material circularity. The successful implementation of our technology at Gerhard Lang Recycling GmbH’s plant demonstrates the feasibility of closed-loop recycling for production scrap and paves the way for a less carbon-intensive aluminum supply chain.”

Recyclers in North America can test their aluminum scrap at the new Wendt Corp. Test Center in Buffalo, New York, which features the Autosort Pulse.