Recycling material replaces valuable raw materials

The processing of internal production waste into cullet material that can be melted down again – this is what our recycling systems are designed for. This is our contribution towards environmental protection and recovering energy and raw materials.

Factory cullet recycling

Scraping conveyors – FACTORY CULLET RECYCLING 24/7

A by-product (to a certain degree) in the production of glass articles is always glass waste in form of hot and cold glass. Glass cullet however represents a valuable secondary raw material for glass production. This is one of the important sources for saving on raw material and energy.

A mature technique is required to treat accordingly hot, liquid waste glass that can occur in drops (hot gob) or strings.

The goal is to feed back to the melting process the production waste glass in a suitable ecological and economic form.

cullet preparation systems

Crushers – crushing to size

We have the right glass crushers for every application - be it factory cullet or foreign cullet processing, or glass recycling. The cullet can then be melted down again and be returned to the production process. Single or multiple, different crusher models manufactured in-house are used depending on the type of glass. All feature very low levels of wear and minimum maintenance overhead. As one of the largest manufacturers in this sector, we have a broad level of experience and know the issues to which attention should be paid.

cullet preparation systems

Post-Consumer Glass Recycling

The topic “recycling” gains more and more in importance. What used to be the norm in industrial countries already a long time ago, is now on the agenda in almost all countries of the world. However, there are still big differences in the quality of the collection systems. Thus, in some countries the raw material glass is sorted and collected according to its colour; sometimes however, it is also collected with completely mixed glass. Also, the proportion of foreign substances (metals, ceramics, waste in general…) differs from country to country.

At the beginning all this information as well as the required capacity of the plant are discussed by ZIPPE and the customer to work out a recycling plant according to exact customer needs.

Post-consumer glass recycling plants typically comprise conveying, crushing, screening, and sorting technology (for example CSP, all-metal separation, colour sorting). Company ZIPPE designs, supplies, and builds complete post-consumer glass recycling plants.


cullet preparation systems
  • Steps of a Recycling Process

    In recycling plants, manual sorting stations are often included after cullet feeding to allow a first sorting out of bigger foreign materials.

    After that, unbroken bottles and large cullet is crushed to make the subsequent sorting as efficient as possible.

    At the beginning of the recycling plant, a first suction of light parts (such as paper, light plastic particles) is also often foreseen. Here, a special organic separator is used which separates light parts from the heavier glass with the help of an air blower. In order to minimize the ejection of incorrectly detected cullet (because of existing labels) at a later stage, the installation of a system for removing labels is recommended.

    In the last step, cullet is sorted according to the required colours.

  • Examples of Technology

    • manual sorting stations

      First sorting out by manual sorting stations. Here, coarse impurities / waste is removed manually.

      Application example of manual sorting stations
    • twin-roller-crusher

      Cullet crushing is executed with a twin-roller-crusher. Thus, the spectrum of the cullet size is precisely defined.

      Application example of crusher
    • organic separator

      At the organic separator, light parts are separated from cullet and removed by means of an air stream.

    • label remover

      The label remover ensures that the amount of rejected material in the subsequent sorting procedure is as low as possible. In addition, a smaller proportion of organic material in the sorted cullet will be achieved.

    • screens

      By means of different screens, material is split into different grain fractions. Moreover, foreign materials are screened out from cullet.

      Application example of screen
    • eddy current separator system

      Metallic materials (non-ferrous parts) are sorted out by means of an eddy current separator system. Through a previously installed magnetic drum, also Fe-metals are separated once again.

    • Optical sorting systems

      Optical sorting systems sort out foreign materials such as ceramics, stone, and porcelain. The possibility to separate heat-resistant glass, leaded glass, and magnetic metals still exists. In the same machine type, cullet is sorted according to colours.

  • Example of a Recycling Plant

    1 – Material feeding

    2 – Manual sorting, organic separation, Fe-metal separation, crusher

    3 – Label remover

    4 – Fe-metal and non-ferrous metal separation (according to eddy current principle)

    5 – CSP sorting

    6 – Colour sorting

    7 – Storage

  • Synergies of Competences

    In order to handle projects in the field of recycling optimally, ZIPPE works together with specialists in sorting technology. Their systems do not only separate various impurities like ceramics, stones, or porcelain (CSP) from cullet, but also detect and eliminate metals by means of a metal detector. Furthermore, it is also possible to detect heat-resistant or leaded glass by means of special sensors which will be integrated depending on customer requirements.

    Since each of these sorting machines have several sorting stages, additional sorting according to colours will be executed – apart from contaminants. Several sorting systems can be connected in series depending on customer requirements (information as to incoming material and required sorting quality).

  • „All-inclusive“ by ZIPPE

    ZIPPE and its partners will design, construct, and offer optimum plants according to customer information– and this worldwide!
    The customer decides whether “only” basic engineering, equipment, installation supervision, and commissioning should be quoted by ZIPPE, or e.g. also services like steelwork, installation on site, or trainings.
    ZIPPE will advise each customer individually with extensive experiences.
    The superordinate control system, which is developed and designed by ZIPPE, regulates all processes of the applied machines.

    Of course, the ZIPPE quotation also comprises a layout. This already indicates important information such as building dimensions and the positioning of machines.
    This way the customer can estimate which buildings and what amount of space will be required far in advance.
    ZIPPE will realize modifications in direct communication with the customer to adapt the new recycling plant to any existing structures.

    Furthermore, ZIPPE services also include the installation and finally of course the commissioning support of these plants.
    Advanced services (error elimination, customer support…) are certainly quality standards as for all ZIPPE supplied plants.
    It is also certain for us that we are available 24 hours for our customers via our hotline.


  • Reference projects - ZIPPE

    For our customer in Thailand we already designed and commissioned several batch plants.

    The scope of our last order comprised a recycling plant including metal and non-ferrous metal separation, organic separation, ceramics, stone, and porcelain separation (CSP), as well as colour separation.
    The capacity of the first expansion stage was 30 t/h.
    By an adjustment ordered at a later stage, the capacity was increased to 45 t/h.
    Furthermore, a label remover was added during a later modification in order to minimize the discharge of labelled cullet.

    ZIPPE designed and delivered the complete plant control system as well as all core components like the screening and magnet technology, and optical sorting machines.


    Recycling plant – 3D model – in Thailand
    Recycling plant – 3D Model – in Tunisia

Glass fiber treatment

We offer suitable all-inclusive solutions for the processing of special glass waste such as fiber glass. For your specific requirements, we are glad to make ourselves available to you with our extensive wealth of experience. Talk to us.