STADLER and Republic Services Open Second U.S. Polymer Center in Indianapolis
In addition to strengthening Republic Services’ vertically integrated plastics recycling operations, the new Indianapolis Polymer Center expands on the success of the Las Vegas site. The plant’s purpose is to recover PET and PO from pre-sorted plastics that Republic Services collects. It will supply premium, food-grade recycled plastics that may be used again to make new bottles, jugs, and containers.
The new Polymer Center was inaugurated with an official ceremony that included remarks by Jon Vander Ark, Republic Services President and CEO; Tim Oudman, Republic Services Senior Vice President, Sustainability Innovation; and Chris Nie, Republic Services Area President, and attended by Willi Stadler, CEO of the STADLER Group; Mat Everhart, CEO of Stadler America LLC; and Jürgen Berger, Head of International Sales at STADLER Anlagenbau GmbH.
“This new facility represents another major step forward in our plans for a nationwide network to close the loop on plastics recycling and help customers achieve a true plastics circular economy,” said Pete Keller, Republic Services Vice President, Recycling and Sustainability. “With the addition of a second Polymer Center we are expanding our processing capacity to produce high-quality recycled resins, contributing to a more sustainable future for packaging in the U.S.”
“The new Indianapolis Polymer Center is a testament to STADLER’s commitment to innovation and excellence in the U.S. recycling industry, contributing to the development of a plastics circular economy,” stated Jürgen Berger. “We are proud of the trust that Republic Services have placed in our company and in our collaborative efforts to drive positive change in the PET and Polyolefins markets in this country,” added Willi Stadler.
A State-of-the-art recycling process to close the plastics circular economy loop
The Republic Services Polymer Center in Indianapolis incorporates a cutting-edge dual-line system designed by them. Bales of mixed plastics are opened using their WireX machine for fully automated wire removal. The materials are fed into the facility and processed separately on two dedicated lines: one for PET and one for mixed plastics, with capacities of 5.5 and 5 tons per hour, respectively.
The process on the PET line begins with mechanical separation and cleaning to remove ferrous particles. A STADLER STT2000 ballistic separator then sorts materials into rigid, flexible, and fines fractions, which undergo near-infrared (NIR) sorting to further separate caps, rings, and labels. The 3D fractions go on to be processed through their Label Remover and Label Separation Hood. Clear PET, caps, and rings are directed to the washing line for granulation and cleaning for reuse, while color PET is compacted into bales.
On the mixed plastics line, materials are first sorted into fines and sieve overflow. The heavier fractions from the overflow are then separated into four polyethylene (PE) fractions –Natural, White, Red/Orange/Yellow, and Other/Color – and two polypropylenes (PP) fractions – Natural/White and Other/Color. PET is recovered from this stream and redirected to the PET line for further processing. The final sorted products are stored in dedicated bunkers before being baled for market distribution.
The linear flow of the plant’s design enhances operational efficiency by improving access to all areas, simplifying maintenance, and incorporating a fully enclosed pre-sort area and a control room with a comprehensive view of material flow and baler operations. The facility also prioritizes workplace quality, offering an open, well-lit environment.
“The Indianapolis Polymer Center is amazing; it might be the nicest looking build-out I’ve ever seen in any plastics plant in the world. The whole installation has a light and airy feel to it, making it a great environment to work in,” said Mat Everhart at STADLER America.
A Growing Partnership for a Circular Economy
Republic Services selected STADLER for the Indianapolis Polymer Center following the successful collaboration on the Las Vegas facility and STADLER’s proven expertise in delivering high-performance recycling solutions. The expansion of Republic Services’ Polymer Centers underscores the growing demand for high-quality recycled plastics in the U.S., driven by both regulatory requirements and consumer preference for sustainable packaging.
This new facility also incorporates additional processing steps to provide Republic Services with greater flexibility in selecting markets for their recycled materials and expanding the range of accepted inputs.
“Our partnership with Republic Services goes beyond constructing state-of-the-art recycling facilities,” concluded Mat Everhart. “It’s about shaping the future of plastics recycling in North America. The success of the Indianapolis plant marks another milestone in our commitment to supporting a more circular economy through advanced sorting technology and strategic collaboration.”
As Republic Services continues to expand its network to close the loop on plastics recycling, they remain a key partner in designing and delivering world-class recycling infrastructure. The Indianapolis facility is expected to make a significant contribution to increasing the availability of high-quality recycled plastics, reinforcing the industry’s transition to a more sustainable future.
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