Gealan: New Recycling Hall in Tanna to Increase Capacity and Process Efficiency

The symbolic groundbreaking ceremony for the start of construction of the recycling hall was attended by (from left): Ralf Hüttner (First Deputy Mayor of Tanna), Katrin Gersdorf (Honorary First Deputy of the District Administrator of the Saale-Orla district), Gealan Managing Directors Ivica Maurović and Tino Albert, Marie-Theres Wittig (Managing Director of Wittig Architecture Office), and Reinhard Schüß (Construction Manager at AS Bau). - (Image: Gealan)

Gealan is investing around €6 million in the expansion of its production and logistics site in Tanna, Thuringia. With the official groundbreaking ceremony, the manufacturer of PVC window and door profile systems has started construction of a new recycling hall, including additional silo capacity. The facility is scheduled to become operational in 2028.

The new hall will cover an area of approximately 70 by 26 meters. Most of the space will be used to shred, sort, and process PVC waste into recycled granulate. The processed material will then be fed back into profile production, reducing the use of virgin PVC and increasing the share of recycled raw materials.

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According to the company, several silos with a total capacity of several hundred tonnes of recycled material will also be installed. The initial plan includes one standard silo with a capacity of 130 tonnes and two mobile silos with capacities of 55 tonnes each. The new silo platform will also provide space for additional equipment, including a potential waste heat storage system.

Another section of the hall will be used for a movable rack storage system for extrusion tools. Consolidating the tools at one location is intended to simplify internal processes and optimize changeover procedures. In addition, social facilities will be created for cross-departmental use.

With the new building, Gealan will relocate its entire recycling process to the Tanna site. Until now, individual process steps have been split between the Tanna and Oberkotzau locations. By consolidating operations, transport between plants will be eliminated and production processes can be completed without changing sites.

In addition to site consolidation, the company is also pursuing greater automation of its recycling processes. The new equipment is expected to reduce the workload for employees while enabling higher throughput volumes. According to the company, the additional space, machinery, and silos will significantly expand capacity for the production and processing of recycled materials.

The building is scheduled for completion in 2027. Interior construction and installation of the recycling technology will then follow. The overall project is expected to be completed in 2028, when all recycling components will be moved into the new facility. The project continues the expansion of the Tanna site, where a fully automated high-bay warehouse was previously built.

More information: www.gealan.com

Gealan Formteile GmbH, Oberkotzau

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