A new multi‑stage sorting approach is pushing aluminium recycling to new levels of sustainability. Together, Tomra and Cusiana plan to make near carbon-free ingots feasible.
Tomra Recycling and Raffineria Metalli Cusiana S.p.a. (Cusiana), an Italian secondary aluminium refiner, partnered to redefine aluminium recycling with advanced multi-sensor sorting technology. Together, they have pioneered a multi-stage sorting line, enabling Cusiana to move beyond traditional ingot production and create near carbon-free aluminium ingots and specific high-purity alloys. The close collaboration between Cusiana and Tomra laid the foundation for a new level of precision in aluminium recycling.
With a capacity of 100.000 t per annum plant in Verbania, Italy, Cusiana’s goal is to increase profitability by producing material of a quality previously unattainable from scrap. Cusiana’s process is powered entirely by renewable energy sources, reducing energy consumption, allowing near carbon-free aluminium. This enables the production of its branded 'Recall' ingots, providing a competitive advantage to high-profile customers who require both high-quality materials and a low-carbon footprint.
Multi-stage sorting configuration
The key challenge for Cusiana was moving beyond simple contaminant removal to achieving the ultra-high purity and alloy-specific separation needed for high-quality re-melting. To address this, Cusiana and Tomra Recycling have developed a sophisticated, fully automated sorting line that combines multiple technologies in a three-phase process:
1. Pre-processing: The process begins with pre-shredding raw materials (mixed aluminium sheet, profiles and extrusions). The material is then run through a hammer mill, where magnets and screeners remove ferrous metals and separate the material into multiple fractions.
2. Contaminant and heavy-metal removal: This phase is divided into two sub-steps. First, two X-Tract units remove contaminants such as copper and brass. In a second step, aluminium containing heavy metals, like certain cast alloys and the 2000 and 7000 alloy series, is separated by two further X-Tract units.
3. High-purity alloy sorting: In the final, critical phase, two Autosort Pulse units perform alloy-specific sorting to further increase aluminium purity. Using Dynamic LIBS (laser-induced breakdown spectroscopy), the system precisely targets and reduces elements such as silicon (Si), iron (Fe), and manganese (Mn) to meet strict alloy specifications. The line operates at a high input rate, with a stable production throughput of seven tons per hour feeding into each Autosort Pulse unit.
In addition to this process, a Finder unit recovers valuable metal fines from the residual output of the eddy current separators, maximising overall metal yield and resource efficiency.
Planning for true circularity
For Cusiana to achieve its goal of creating specific, high-quality aluminium alloys, the final sorting step through the Autosort Pulse is critical. As traditional sorting methods cannot differentiate between subtle elemental compositions, the Autosort Pulse provides the necessary precision. This investment has transformed Cusiana’s business model by unlocking two high-value output streams.
First, they produce their branded 'Recall' ingots, offering customers a guaranteed 100% recycled content solution. Second, and most importantly, the ultra-high purity achieved by the Autosort Pulse allows Cusiana to sell premium, alloy-specific scrap directly to manufacturers without any downgrading. This enables the company to bypass the melting furnace for these streams, significantly saving on the time and high energy costs associated with ingot production.
Fabrizio Gasparin, Sales Manager Italy at Tomra Recycling, said: “Cusiana’s evolution in recent years demonstrates the vital role of multi-sensor technology in unlocking true material circularity. By combining XRT for contaminant removal and Dynamic LIBS for precision alloy separation, they are proving that high-volume recyclers can become high-value alloy producers. This transition is crucial for a less carbon-intensive aluminium supply chain. Cusiana’s plant now serves as a reference site for other TOMRA customers looking to make this shift.” (ab)
Source：INTERNATIONAL ALUMINIUM JOURNAL