GEALAN Fenster-Systeme GmbH has officially begun construction of a new state-of-the-art recycling facility at its production and logistics site in Tann, Germany. A ceremonial groundbreaking event was held with project partners and invited guests in attendance. The total investment amounts to approximately €6 million.
The new facility will measure around 70 by 26 metres. The larger section, covering 58 by 26 metres, will be dedicated to PVC waste recycling. PVC offcuts and waste materials will be shredded, sorted and pelletised there. The recycled material produced will be returned to the manufacturing cycle. This will enable the production of window and door profiles with a lower proportion of virgin PVC.
The remaining area, measuring 12 by 26 metres, will house a racking system for storing extrusion equipment. This will centralise all required tooling in one location and simplify production processes.
Adjacent to the facility, a storage area with silos for recycled material will be constructed. The initial plan includes one fixed silo with a capacity of 130 tonnes and two mobile silos with capacities of 55 tonnes each. The platform has been designed to accommodate up to four large silos. Space for storing recovered waste heat has also been included.
Tino Albert, Managing Director for Technology and Finance at GEALAN, commented: “Following the construction of the fully automated high-bay warehouse just a few metres from here, we are taking another important step forward. These new capabilities will help us reduce transport distances, optimise processes and demonstrate that GEALAN continues to develop in the most efficient and responsible way possible.”
Earlier, GEALAN opened a multi-level automated warehouse in Tann. The construction of the recycling facility now represents the next major development step for the site.
The entire recycling process will be consolidated in Tann. This will eliminate transport operations between Oberkotzau and Tann, while production processes will no longer be interrupted by changes of location.
Construction of the facility is scheduled for completion in the fourth quarter of 2026. Internal fit-out works and equipment installation will then begin. The full transfer of all recycling operations to the new facility is expected to be completed in 2028.
The recycling of PVC profiles is becoming increasingly important across the industry. According to Rewindo GmbH Fenster-Recycling-Service, Germany recorded a positive trend reversal in the recycling of old PVC windows, doors and roller shutters in 2024.