In 2024, a large-scale automated waste sorting project – a high-capacity PE film and other rigid plastics sorting line – was successfully implemented in the Baltic region. This is a strong example of how international collaboration can drive innovation in plastic recycling. The project was initiated by UAB ECSO, and full engineering responsibility – from concept to commissioning – was entrusted to Lithuanian engineering company UAB Motecha.

As the lead solution provider, Motecha integrated equipment from multiple technology partners into one cohesive, automated system designed for precise material flow control, ergonomic operation, and exceptional sorting performance.

The line was designed to process up to 4.5 tons of plastic per hour, separating it into five distinct fractions, with target materials fractions achieving a purity level of over 99%. The system was designed to meet the client’s strict requirements for automation, quality, and ease of maintenance.

Although the implementation timeline was set for 12 months, the line was commissioned one month ahead of schedule. The engineering solution was carefully tailored to ECSO’s operational needs, facility layout (1800 m²), and productivity targets.

“Our approach to engineering solutions goes beyond supplying equipment. Every project starts with listening – understanding the customer’s input material, goals, available space, workforce, and the constraints that will ultimately define the system’s success. We then develop a concept that not only met the expectations and market realities of the time, but is also ready for tomorrow’s challenges. Equally important for us is ensuring safety, both of the system itself and of the people operating and maintaining it. Special attention is paid to ergonomic layout, safe access, and intuitive control of the entire line,” – said Algimantas Ramaneckas, CEO at Motecha.

“The ECSO project was just like that – technically demanding and requiring constant coordination with international partners. Our team was responsible for bringing everything together into one seamless system: from NIR sorting logic to baling, from walking floor bunkering to ergonomic operator stations. We are grateful to all partners involved. Today, this is not just a functioning line, but a new benchmark in PE film sorting,” – he added.

To realize this project, Motecha brought together leading technology providers from across Europe, each playing a dedicated role in the integrated process chain.

At the heart of the sorting line were 7 NIR optical sorters supplied by TOMRA, a global leader in sensor-based waste sorting technologies. These machines ensure accurate fraction separation based on material type and spectral signature.

“The collaboration on the LDPE and LLDPE film recycling project implemented by ECSO demonstrates how advanced technology can effectively address the increasing demands for higher recycling rates. TOMRA provided comprehensive support at every stage of the project – from the testing phase, through process and layout design, to the final commissioning of the installation. This investment in LDPE and LLDPE film recycling marks a significant step toward meeting the EU’s ambitious targets, including the goal of achieving a 50% plastics recycling rate by 2025. The fully automated line, equipped with seven optical sorters, enables the production of three high-quality output fractions tailored to the specific requirements of end users”, – said  Michał Bula, TOMRA Sales Manager Baltics.

At the final stage of the process, Presona balers operate in tandem with Motecha’s walking floor bunkering system, enabling fully automated accumulation and baling of the sorted fractions.

“Working with Motecha has been a valuable collaboration marked by their consistent delivery of high-quality work and innovative problem-solving. Their willingness to trust our expertise while developing effective recycling solutions together has been key to our success as project partners,” – said  Stefan Ekström, CEO at Presona.

Westeria played a key role by supplying disc spreaders, which helped to evenly distribute the material flow across the sorting line, ensuring smooth throughput and maximum equipment utilization.

“Motecha has proven to be a high-value partner in plant building for the recycling industry. Their commitment to delivering state-of-the-art solutions, backed by excellent engineering and service, has been instrumental to the success of this outstanding project. At Westeria, we’re proud to collaborate with a partner who is integrating our technologies seamlessly and effectively,” – said Levin Giebel, Sales Manager at Westeria.

Primary size reduction was handled by a Lindner shredder, which prepared the plastic input for downstream processing.

SPALECK vibrating screening machines provided precise material separation by size, efficiently removing unwanted fines and impurities – a critical step for achieving the required material purity. “Achieving best-in-class recycling results means aligning technology and expertise seamlessly. This project with ECSO and Motecha and all technology partners involved shows how excellent teamwork between partners and machinery can push recycling efficiency to the next level. With accurate separation by size and optimized material distribution from our SPALECK Waste Screens, we are proud to contribute to a solution that truly lives our philosophy: BEST SCREENING. BEST SORTING.” – said Marc Steffen, Expert for High-Performance Screening Technology at SPALECK.

As one of the leading producers of high-quality LLDPE pellets from secondary raw materials in the Baltic region, UAB „ECSO“ demands consistent input quality and efficient processing to meet customer-specific requirements. The implementation of this new sorting line represents a major step forward in achieving those goals.

„For ECSO, this project with Motecha was not just about upgrading recycling technology – it was about setting a new standard for plastics sorting in the Baltic region. Working with Motecha allowed us to implement a tailor-made solution that meets our high expectations regarding quality, efficiency, and automation. The result is a system that strengthens our operational performance and supports our long-term goals in sustainable materials processing“, – said Roman Grigaravičius, CEO of ECSO.

“Projects like this are more than just technology deployments. They are the result of shared understanding, mutual trust, and precise execution. Only by working closely with both the client and the technology partners can deliver solutions that don’t just work – they move the industry forward.” – Algimantas Ramaneckas, CEO at Motecha.

Motecha’s experience in waste sorting and plastics recycling engineering enables clients like Nordic Plast to scale operations with confidence. From system planning to process flow optimization, Motecha delivers solutions built for efficiency, quality, and long-term impact.

Looking for a partner who understands both technology and your operational goals?
Contact Motecha – we design solutions that work.