Development and series production of EPS compaction systems and tailor-made recycling plants

FZ-Recycling GmbH & Co. KG

56651 Niederzissen (Brohltal Ost industrial park)New on Amplifa

2016Founded (Passau, June 2016)

NiederzissenLocation in Rhineland-Palatinate

FZR-320Screw compactor, compaction up to 50:1

approx. 300 kg/m³Block density of the compacted EPS

99.2 kWpPhotovoltaic system at the site

About FZ-Recycling

FZ-Recycling develops and manufactures systems for the material recycling of expanded polystyrene (EPS/Styrofoam). The core product is the FZR-320 screw compactor, which compacts EPS to a ratio of up to 50:1; the blocks reach a density of approx. 300 kg/m³ and can be transported palletized. The systems operate fully automatically, use friction heat for compaction without additional heat input, and are accompanied by remote monitoring and remote maintenance. The offering includes stationary systems, variants in a sidedoor sea container for outdoor use and construction sites, and mobile solutions in a 3.5-tonne box trailer. In addition, the company develops tailor-made special systems for the processing of raw materials, also in 20–40-foot containers, and separates composite panels made of aluminum and EPS, such as those used in hall and door construction. Customers come from the trades, industry, waste management, and demolition. The company has been based since 2020 in Niederzissen in the Brohltal Ost industrial park (Rhineland-Palatinate); the company building operates largely CO2-neutrally with pellet heating, concrete core activation, and a 99.2 kWp photovoltaic system.

Site: Niederzissen
Processes: EPS recycling / EPS compaction (screw compaction up to 50:1, also wet, contaminated or, Recycling of composite materials made of aluminum and EPS (separation of composite panels, e.g., Plant construction / tailor-made special systems for raw material processing, process analysis and, EPS compaction systems (screw compactor FZR-320, compaction up to 50:1, density approx. 300 kg/m³), Systems in a 20" sea container (sidedoor), Systems in a 3.5t trailer, Remote monitoring and remote maintenance of the systems, Tailor-made special systems for the processing of raw materials
Materials: EPS (expanded polystyrene / Styrofoam), HBCD-laden EPS, Aluminum, EPS (expanded polystyrene/Styrofoam), Composite materials aluminum/EPS
Founded: 2016
Industries: Trades, Industry, Waste management companies, Demolition companies, Recycling/circular economy

01
Process development
02
System design/engineering
03
Plant construction
04
Remote monitoring & remote maintenance
05
Organization of transport of the compacted material

Materials & Processes

EPS

EPS (expanded polystyrene/Styrofoam)

Compaction even with wet, contaminated, or HBCD-laden EPS.

EPS+Al

Composite materials aluminum/EPS

Separation of composite panels, e.g. insulation panels used in hall and door construction.

Aluminum

Component of composite panels that is recycled and returned to the material cycle.

Locations

Niederzissen

Development, plant construction and sales

Materials: EPS, aluminum/EPS composites

EPS compaction system (screw compactor FZR-320)
System in a sidedoor sea container (20 ft)
FZR-320 compactor in a 3.5t box trailer (Humbauer)

Systems

**System in a sidedoor sea container (20 ft)**Container solution · Waste management/demolition companies

**System in a 3.5t box trailer**Mobile solution · Trades/industry

Inside the production

Industries

TradesIndustryWaste management companiesDemolition companiesRecycling/circular economy

Processes & technical limits

Processes	Tolerance	Max. part	Weight	Lot size	Materials
EPS recycling / EPS compaction (screw compaction up to 50:1, also wet, contaminated orRecycling	–	–	–	–	EPS (expanded polystyrene/Styrofoam)
Recycling of composite materials made of aluminum and EPS (separation of composite panels, e.g.Recycling	–	–	–	–	EPS (expanded polystyrene), Aluminum
Plant construction / tailor-made special systems for raw material processing, process analysis andEngineering	–	–	–	–	–

3 Anlagen & Maschinen

Machine	Manufacturer / model	Quantity	Working area	Year built	Site
EPS compaction system (screw compactor)	FZ-Recycling	–	Compaction up to 50:1, block density approx. 300 kg/m³, fully automatic with remote monitoring	–	Niederzissen
EPS compaction system in a sidedoor sea container (20" container)	FZ-Recycling	–	System in a 20" sea container, flexibly installable, for outdoor use/construction sites, storage	–	Niederzissen
FZR-320 compactor in a 3.5t trailer (Humbauer trailer)	FZ-Recycling / Humbauer FZR-320	–	mobile system in a 3.5t box trailer, changing locations daily	–	Niederzissen

Additional services

EPS compaction systems (screw compactor FZR-320, compaction up to 50:1, density approx. 300 kg/m³)Systems in a 20" sea container (sidedoor)Systems in a 3.5t trailerRemote monitoring and remote maintenance of the systemsTailor-made special systems for the processing of raw materialsDevelopment of recycling processes (e.g. separation of aluminum/EPS composite panels)Consulting: plant setup, start of production, disposal, dismantling, reuseAnalysis and optimization of production processesOrganization of the removal transport of compacted material

History

2016
Dr. Frank Ziebeil and Leif Ziebeil found FZ-Recycling in Passau; the goal is the development of systems for closing local material cycles.
2017
Development of an EU-funded process for separating composite panels made of aluminum and EPS.
2018
Start of the development of an EPS recycling process.
2019
Construction and testing of the EPS system.
2020
Move into the new location in the Brohltal Ost industrial park (Im Schülert 13, Niederzissen).
2021
Start of series production of the EPS compaction system.
2021
SUCCES award "Advantage through Innovation" from the Investment and Structure Bank Rhineland-Palatinate (27.10.2021).
2022
Prizewinner film of the Zukunftspreis Heimat 2022.