Extrusion International 2-2026

46 Extrusion International 2/2026 RECYCLING the remaining non-target materi- als are removed through negative sorting, where contaminants are ejected to leave a high-purity nal product. This combination maxi- mizes both recovery and nal purity while maintaining high throughput. The ability of the AUTOSORT™ to reliably detect and separate mono- layer and multilayer PET trays – even within highlymixed streams –makes it uniquely suited for demanding tray-to-tray applications where pre- cision and long-term stability are non-negotiable. Following shredding, the INNO- SORT™ FLAKE performs the nal puri cation step to secure the need - ed critical quality levels required for food-grade applications. The sys- tem detects akes by polymer type, color and transparency in a single sorting step, ensuring precise sepa- ration even at small particle sizes. The unit’s multi-stage con gura - tion enables sequential puri cation steps, while a dedicated recovery stage allows any valuable PET still present in the rejected fractions to be reintroduced into the process. This recirculation logic maximizes overall yield and supports economic ef ciency. The result of this integrated setup is consistently high and stable purity levels above 99.8% under real op- erating conditions. This enables im- mediate reuse in food-grade appli- cations and supports Sulayr’s goal of transparent tray-to-tray recycling. The quality achieved is comparable to virgin material, reducing depen- dence on primary PET and enabling converters to meet demanding recy- cled-content requirements without compromising functionality. Operational impact and strategic partnership At the same time, material recov- ery has increased and the volume of rejects has been reduced, further strengthening both quality and op- erational pro tability. While the pri - mary target fraction remains trans- parent PET trays, certain colored tray fractions can also be valorized depending on market demand and customer speci cations, adding sig - ni cant exibility to Sulayr’s indus - trial model. “What made the difference was how closely we worked together with TOMRA during integration,” says Antonio Jesús Marcos, Head of Marketing at Sulayr. “It was not just about installing equipment. We aligned on process details, perfor- mance targets and long-term stabil- ity. The focus was always on results under real operating conditions, rather than on theoretical gures.” Stability that enables commercial growth The increased stability of output quality has allowed Sulayr to meet stricter customer speci cations and access new customer segments. This includes converters and packag- ing producers requiring certi ed, traceable recycled content for food- grade trays across multiple Europe- an markets. This consistency paves the way for higher value-added ap- plications and strengthens Sulayr’s position as a reliable strategic sup- plier in a tightly regulated environ- ment, where long-term supply se- curity and documented compliance are increasingly decisive. A reference for scaling real circularity As pressure grows to recycle more complex packaging formats, PET trays are becoming a key focus across Europe. The Sulayr project demonstrates that advanced sort- ing technology, combined with close collaboration and shared op- erational responsibility, can make tray-to-tray recycling of complex PET streams viable on an industrial scale. Beyond the technical solu- tion, the partnership has unlocked new business opportunities and strengthened Sulayr’s position in an increasingly demanding market. “Advanced technology is essen- tial,” says Jesús Espinar. “But what really makes projects like this work is the partnership approach. When strong partners bring their com- bined expertise to the table and work closely together, tray-to-tray recycling can be scaled reliably. This benchmark process for the recycling industry is de nitive proof of that.” TOMRA Recycling www.tomra.com INNOSORT™ FLAKE detects akes by polymer type, color and transparency in a single sorting step, ensuring precise separation even at small particle sizes