Stadler Anlagenbau GmbH
DE EN-US EN-GB EN-ALL FR IT ES PT SLO

Automation & Material Analysis

Leveraging material data for enhanced plant performance

STADLERconnect integrates material data to increase transparency, reduce personal dependency, and improve plant performance both in throughput and yield.

Automation with STADLERconnect

Automation modules

In today’s modern sorting plants, the complexity of operations demands skilled personnel, yet finding and retaining such experts can be challenging. Even when qualified operators are in place, their daily responsibilities are often consumed by urgent tasks that prioritize keeping the plant running smoothly over optimizing its performance. This is where a self-optimizing, automated plant makes all the difference—relieving the workload of operators and ensuring the plant consistently operates at its full potential, driving greater efficiency and productivity.

STADLER Connect with bale data

Material Analysis modules

Our sorting plants are renowned for their high sorting quality. To maintain these standards, manual sorting has traditionally been used for quality control, requiring precision and consistency. However, manual sampling and analysis is both resource-intensive and costly, with quality checks only performed on a limited sample of materials. Automated quality control, powered by cutting-edge inline sensor technologies, allows plant operators to allocate their personnel to other tasks without compromising on quality. Unlike human workers, sensors don't tire or require breaks, ensuring continuous, reliable quality control.

Cutting-edge products from our team

Optimize your sorting process with our intelligent solutions

Achieve new levels of precision and efficiency with our advanced tools. AI Material Compass allows you to predict bale composition with high accuracy, ensuring better sorting outcomes and maximizing material value. Production Report keeps you informed with automated updates on key performance indicators, giving you real-time insights and enabling faster decision-making. Meanwhile, Adaptive Material Split Control provides automated control of movable units, streamlining material flow and reducing bottlenecks in your operation. Adaptive Screen Cut Control automatically adjusts screen cut settings based on near real-time monitoring, ensuring stable throughput and consistent grain-size distribution without manual intervention. Volume Flow Monitoring provides continuous, real-time insights into material throughput, delivering additional information on material volume that complements mass-based data and supports stable plant feeding. Our technology empowers you to enhance operational control, boost material recovery, and holistically optimize your sorting performance.

Production Report

Challenge in plant: 

Inefficient organization of logistics and input composition planning without monitoring of production quantities 

Solution and benefits: 

Near real-time overview of bales, bunkers and distribution of material fractions 

  • Shift-based assessment of production quantities trough automatic tracking 

  • Improved upstream decisions with accurate estimates on input composition and sorting performance 

  • Improved inventory management 

AI Material Compass

Challenge in plant: 

Quality of material is often unknown or checked on an irregular basis through sampling and manual sorting analysis 

Solution and benefits: 

Automated inline monitoring of material regarding its mass-based composition and purity  

  • Increased quality transparency tracing back to individual infeed batches and suppliers 

  • Reduced costs for manual sampling and analysis 

  • Early detection of plant performance fluctuations and optimization potential 

  • Improved customer trust through reduced claims 

Adaptive Material Split Control

Challenge in plant: 

Uneven distribution of material between two parallel lines due to fluctuating material characteristics manual adjustments significantly affecting plant performance 

Solution and benefits:  

  • Automated, material-dependent control ensures balanced loading and stable plant performance.  

  • Continuous automatic adjustment based on near-real time material flow  

  • Consistent design-based balance of line distribution 

  • Reduced risk of blockages and manual interventions 

Adaptive Screen Cut Control

Challenge in plant: 

Changing material characteristics lead to uneven distribution between size fractions when operating with fixed screen cut settings 

Solution and benefits: 

Automatic screen cut adjustment based on real-time line monitoring. 

  • Stable and balanced throughput across both size fractions 

  • Consistent grain-size classes for reliable downstream sorting 

  • No manual readjustments required 

Volume Flow Monitoring

Challenge in plant: 

Lack of reliable throughput information results in limited process transparency and uneven feeding 

Solution and benefits: 

Simple-to-install sensors provide continuous volume flow insights. 

  • Real-time throughput monitoring at key process points 

  • Enables stable and even feeding of the plant 

  • More relevant than weight-based data for most aggregates 

dummy