Robotic sorting plant increases recycling of construction waste at RGS Nordic
16.06.2025RGS Nordic, one of the leading Danish waste management companys, has successfully implemented an advanced robotic sorting plant in collaboration with ZenRobotics® and Terex® Recycling Systems.
© Terex / ZenRobotics
Specialising in construction & demolition waste as well as soil remediation, RGS Nordic processes up to one-third of Denmark's total construction waste annually. With the new robotic sorting plant located centrally in Copenhagen, the company has improved its operations, maximising recycling rates through precise robotic sorting, ensuring materials are increasingly returned to the production cycle rather than downcycled or incinerated.
“We’ve been sorting waste for many years – it’s the bread and butter of our operations. What we saw in the ZenRobotics and Terex Recycling Systems technology, combined with their expertise, was an extension and improvement of what we already do,” said Rasmus Brødsgaard Buch, COO of RGS Nordic.
© Terex / ZenRobotics
The new facility features a comprehensive and highly automated sorting line designed for maximum efficiency and material recovery, with no hand sorting. At the front end, a TSD-280 3D screening trommel processes up to 45 t/h, separating oversize materials and eliminating the need for pre-shredding. This is followed by a ballistic screen that classifies materials into 2D, 3D, and fines smaller than 80 mm. Integrated magnets extract ferrous metals, while a dedicated feeding bunker provides consistent material flow to the robotic sorting line.
At the heart of the system are four Zen Robotics 4.1 Heavy Picker robots, capable of identifying and sorting up to 10 recyclable fractions in a single pass. These robots handle objects ranging from 80 mm to 1.2 m in size and weighing up to 40 kg. The AI-powered robots are designed to continuously improve in recognising valuable waste resources and can be adapted to sorting tasks based on customer demand and market opportunities.
© Terex / ZenRobotics
The entire operation is monitored and optimised through an advanced remote control and data system, which provides real-time insights into the composition and performance of the waste stream. In addition, the fully automated nature of the plant also enhances the safety of employees by minimising direct contact with waste.
“It just happens to be robotic and automatic,” adds Rasmus Brødsgaard Buch. “The planning, design and installation process was smooth and professional. It was clear we weren’t the first customer to go through this, and that gave us confidence. The team helped us define, scope, and execute the project from start to finish. It was an all-in solution, and that was very convenient on our side.”
© Terex / ZenRobotics
The new RGS Nordic robotic sorting plant, which is now operational, supports the company’s mission towards sustainable waste management and resource recovery. “Ultimately, our goal is to recycle or recover as much as possible. Mixed waste is largely unusable, but sorted materials can be returned to producers,” added Rasmus Brødsgaard Buch. “That’s what we aim to do – serve inbound customers with a solution for the more challenging waste materials, and outbound customers with recyclable materials to be repurposed into something new.”
Rainer Rehn, Regional Sales Manager for ZenRobotics said: “This installation reflects a growing global shift toward smarter, cleaner, and more circular waste management. As demand rises for recycled materials, facilities such as this at RGS Nordic are becoming essential. We’re proud to support RGS Nordic in setting a new benchmark for the construction waste sector, combining AI-driven robotics with proven mechanical sorting to recover valuable resources and enable producers to meet their sustainability goals.”
